Commodity Production Costs Report
Homopolymer HDPE from Ethylene (Similar to UNIPOL)
HDPE Operating Costs & Plant Construction Costs
This report analyses the economics of High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene in the United States. The process examined in this report is similar to Univation UNIPOL and INEOS INNOVENE G. In this process, ethylene is polymerized 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.
Key reference(s): ?
The process under analysis comprises three major sections: (1) Polymerization; (2) Polymer degassing; and (3) Finishing.
Polymerization. Initially, ethylene monomer is purified for removal of oxygen and water, which may cause catalyst deactivation. Purification is accomplished by means of columns and molecular sieves. Ethylene is then polymerized in a reaction loop consisting of a reactor, a compressor and a heat exchanger. The molecular weight of the polymer is controlled by hydrogen addition, while the polymerization rate is controlled by the catalyst feed rate. Polyethylene granules are removed from the reactor and directed to a purge bin downstream.
Polymer degassing. In the purge bin, residual monomer is stripped with nitrogen. The purged gas is sent to vent recovery, while the polymer powder is directed to the pelletizing and finishing section downstream. In the vent recovery, unreacted monomer is condensed and pumped back to the reactor, while the uncondensed gas is purged.
Finishing. The polymer powder from the purge bin and a mix of additives are fed to a pelletizing system, where the mixture is melted, homogenized, and pelletized. Subsequently, the HDPE pellets are packed in bags before being stored in warehouses.
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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
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
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