Commodity Production Costs Report
Bimodal HDPE from Ethylene and 1-Butene (Similar to UNIPOL)
HDPE Operating Costs & Plant Construction Costs
This analysis presents the economics of Bimodal High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene and 1-butene in the United States. The process examined is similar to Univation UNIPOL process. In this process, ethylene is polymerized in combination with 1-butene in the gas-phase in a reaction loop consisting of a fluidized-bed reactor, a compressor and a heat exchanger.
The report provides a comprehensive study of HDPE production and related HDPE production cost, covering three key aspects: a complete description of the HDPE production process examined; an in-depth analysis of the related HDPE plant capital cost (Capex); and an evaluation of the respective HDPE plant operating costs (Opex).
The HDPE 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 HDPE 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 HDPE plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
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The process under analysis comprises three major sections: (1) Reaction; (2) Purification; and (3) Finishing.
Reaction. The catalysts used in the process are sensitive to specific impurities in the raw materials feed. Therefore, ethylene and 1-butene are treated to remove water, oxygen and other polar impurities. The monomers are fed to the bottom of the reactor, where ethylene is polymerized in combination with 1-butene in a reaction loop consisting of a reactor, a compressor and a heat exchanger. The copolymerization reaction is conducted in gas-phase fluidized beds of granular polyethylene resin. While the compressor circulates the reaction gas and provides the required agitation, the external cooler removes reaction heat from the circulating gas. The reaction is carried out at low temperatures (80 - 110 °C) and somewhat low pressures of (15 - 35) bar.
Purification. The granular PE powder from the reactor is conveyed to a Purge Bin. In the Purge Bin, residual hydrocarbons are stripped with a nitrogen purge, and the catalyst is deactivated with steam. The purged gas is cooled and fed to two separators, in which condensed reactants are recovered and directly pumped back to the reactor, while uncondensed gas taken is purged.
Finishing. The resulting polymer stream is further fed into an extruder, which is used to incorporate the required additives, as well as to pelletize the polymer. The product is then sent to product blending and storage.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the HDPE 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 HDPE 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 HDPE 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 HDPE 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
Other HDPE Production Cost Reports

Bimodal HDPE from Ethylene and 1-Butene (Similar to BORSTAR)
This report presents the economics of Bimodal High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene and 1-butene in the United States. The process examined in this report uses a slurry loop process similar to Borealis BORSTAR. The reaction system consists of a slurry loop and a gas phase reactor.
Details: 350 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD

Bimodal HDPE from Ethylene and 1-Hexene (Similar to MarTECH ADL)
This report analyses the economics of Bimodal High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene and 1-hexene in the United States. The process examined in this report uses two slurry loop reactors, similar to Chevron Phillips’ MarTECH Advanced Dual Loop (ADL) and INEOS INNOVENE S.
Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD

Homopolymer HDPE from Ethylene (Similar to MarTECH Loop Slurry)
This report presents the economics of High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene in the United States, using a slurry loop process similar to Chevron Phillips MarTECH and INEOS INNOVENE S. In this process, the monomers are polymerized in a single loop reactor.
Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue F | From $799 USD
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Other Related Production Cost Reports

Ethylene Production from Ethane
This report presents the economics of Polymer Grade (PG) Ethylene production from ethane in the United States. In the process under analysis, ethane is thermally cracked in pyrolysis furnaces through the use of steam, yielding Ethylene. A hydrogen-rich gas is generated as by-product.
Details: 1200 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD

1-Butene from Raffinate-2 (Extractive Distillation)
In this report, the economic analysis concerns a plant located in the United States, producing 1-Butene using a conventional industrial approach for extractive distillation of raffinate-2, which also generates raffinate-3 as by-product.
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Ethylene Production from Naphtha (Low Severity Steam Cracking)
This report presents the economics of a naphtha-based steam cracker, equipped with an electricity cogeneration unit. In this process, naphtha is thermally cracked at low severity conditions, maximizing propylene to Ethylene ratio. The analysis is based on a plant located in Germany.
Details: 800 kta Germany-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD

1-Butene Production from Ethylene
This study presents the costs associated with the construction of an industrial plant producing 1-Butene from ethylene in the United States. This study analyzes a process similar to the Axens/SABIC AlphaButol technology. In the process under analysis, ethylene is dimerized into butenes with high selectivity for 1-Butene. Gasoline (C6+ stream) is generated as by-product.
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