PP Random Copolymer from Propylene and Ethylene (UNIPOL)
Polypropylene Production Costs Report | Issue Q | Q2 2024
Report Details |
400 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
This report presents a cost analysis of a 400 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
It presents the economics of Polypropylene (PP) Random Copolymer production from polymer grade (PG) propylene and ethylene in the United States. The process examined in this report is similar to Grace UNIPOL process, which uses fluidized-bed reactors (FBRs).
The report provides a comprehensive study of Polypropylene production and related Polypropylene production cost, covering three key aspects: a complete description of the Polypropylene production process examined; an in-depth analysis of the related Polypropylene plant capital cost (Capex); and an evaluation of the respective Polypropylene plant operating costs (Opex).
The Polypropylene production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Polypropylene plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Polypropylene plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Polymerization; (2) Resin degassing & pelleting; and (3) Vent recovery.
Polymerization. Fresh polymer grade (PG) propylene and ethylene comonomer are passed through fixed bed dryers for removal of water and other polar impurities. The purified monomers are then fed to the reactor, along with a recycled propylene stream from the vent recovery system. The gas compressor circulates reaction gas upward through the reactor, providing the agitation needed for fluidization and backmixing - no mechanical stirrers or agitators are required. The overhead gas from the reactor passes through a cooler for reaction heat removal. Catalyst is continuously fed to the reactor.
Resin degassing & pelleting. Resulting granular polypropylene is removed from the reactor by the discharge tanks and sent to a purge bin where residual hydrocarbons are stripped with nitrogen from the resin and are sent to the vent recovery system. The resin from purge bin is combined with additives and then flows to pelleting. The pellets are dried, cooled and sent to product blending and storage.
Vent recovery. The purge gas from the purge bin is compressed and chilled to condense the bulk of the hydrocarbon in the stream. The recovered hydrocarbon is fed to the vent recovery column, while lean nitrogen stream from which hydrocarbon has been condensed is recycled to the purge bin. This column separates the hydrocarbon into a monomer enriched stream and a propane rich stream. The monomer stream is returned to reaction, and the propane rich stream is returned to the monomer supply unit in order to recover propylene.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Polypropylene production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Polypropylene process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Polypropylene production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Polypropylene plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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Details: 350 kta United States-based plant | Q2 2024 | 107 pages | Issue X From $1,499 USD
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