Commodity Production Costs Report

Homopolymer HDPE from Ethylene (Similar to MarTECH Loop Slurry)

HDPE Operating Costs & Plant Construction Costs

450 kta United States-based plant | 107 Pages | Issue F | Q3 2024
Starting at $799 USD | See Report Editions Prices

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.

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): ?

HDPE Production Cost Report Process Schematic

The process under analysis comprises four major sections: (1) Feed Preparation; (2) Polymerization; and (3) Separation; and (4) Finishing.

Feed Preparation. This area comprises a catalyst activation system (fluidized-bed activator) and fixed bed treaters for purification of ethylene monomer and isobutane, used as diluent in the polymerization.

Polymerization. In a loop reactor, the monomers and the catalyst suspension are mixed and circulated - as the polymer particles precipitate, they do not dissolve in the slurry. Cooling water in reactor jacket removes reaction heat. The slurry is continuously discharged to a flash chamber, for removing residual monomers.

Separation. The flashed stream passes through a bag filter for polymer fines removal. The fines are sent to the purge column. In the purge column, the residual hydrocarbons are stripped from the polymer product with heated nitrogen. The separated gaseous hydrocarbon streams from flash chamber and purge column are sent to purification in order to recover monomers and diluent, reused in the process.

Finishing. The polymer powder from the purge column, additives and antiblocks are fed to a pelletizing system, where the mixture is melted, homogenized, and pelletized. The pellets are homogenized in blending silos and stored.

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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 Images

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Updated with Q3 2024 Data

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
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 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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Table of Contents


Features
  • 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
  • Costs in Different Countries Add-on
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
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  • Updated with Q3 2024 Data
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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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Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD

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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

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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.

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Isobutane Production

This report examines the costs incurring from producing Isobutane via catalytic isomerization of n-butane. n-Butane is dehydrogenated to 1-butene, which is then rearranged to isobutylene. Finally, isobutylene is hydrogenated producing isobutane. The economic analysis provided assumes a plant located in the United States.

Details: 850 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $999 USD

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