Commodity Production Costs Report
Bimodal HDPE from Ethylene and 1-Hexene (Similar to Spherilene)
HDPE Operating Costs & Plant Construction Costs
This report analyses the economics of Bimodal High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene and 1-hexene in the United States, using a gas-phase process similar to LyondellBasell Spherilene. In this process, ethylene and 1-hexene are copolymerized using two fluidized-bed reactors in series.
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.
Key reference(s): ?
Product
HDPE. HDPE (a.k.a. High Density Polyethylene) is one of the three main types of polyethylene, figuring among the most used polymers worldwide. It is the most widely used polyethylene resin. HDPE may be either ethylene homopolymer or a copolymer of ethylene and alpha-olefins (1-hexene, 1-butene). Polyethylene is considered to be high density when having density greater than 0.94 g/cm³. Despite having density only marginally higher than that of low-density polyethylene (LDPE), HDPE presents larger strength-to-density ratio, due to its little branching and consequent stronger intermolecular forces. The high demand for polyethylene is in large part due to a combination of the availability of ethylene raw material, its relatively low cost and a wide variety of applications.
Raw Materials
Ethylene. Ethylene is known as a key building block for the petrochemical industry, being one of the largest-volume petrochemical produced worldwide. It is widely used as chemical intermediate in the production of several end products, including plastics, resins and fibers. Ethylene is largely produced by thermal cracking of petroleum-based feedstocks, in the presence of steam. It is stored in a liquid state under high pressure or at low temperatures. However, ethylene is, most of times, directly supplied to its consumers.
1-Hexene. Hexene is any alkene isomer with molecular formula C6H12. The most important Hexene is the 1-Hexene, which is largely employed as a comonomer in the production of polyethylene (HDPE and LLDPE). It is also used in the production of linear aldehyde heptanal. On an industrial scale, 1-Hexene is typically produced via ethylene oligomerization and on-purpose processes, such as extractive distillation from Fischer-Tropsch hydrocarbons.
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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
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Other HDPE Production Cost Reports
Bimodal HDPE from Ethylene and 1-Butene (Similar to UNIPOL)
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.
Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
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
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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-Hexene Production from Synfuels
In this report, it is approached the economics of 1-Hexene production via extractive distillation from synthetic fuels (synfuels), using an industrial process similar to the technology owned by Sasol. The economic analysis assumes a plant located in the United States.
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Details: 800 kta Germany-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
1-Hexene Production from Ethylene
This report presents the economics of an industrial process for 1-Hexene production from ethylene, assuming a trimerization process similar to the one owned by Chevron Philips. The economic analysis is based on a plant operating in the United States.
Details: 200 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
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