Commodity Production Costs Report

LLDPE from Ethylene and 1-Octene (Similar to SCLAIRTECH)

LLDPE Operating Costs & Plant Construction Costs

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

This report presents the economics of Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-octene comonomer in the United States, using a solution process similar to NOVA Chemicals SCLAIRTECH. This process uses a tubular reactor and a CSTR operating in series.

The report provides a comprehensive study of LLDPE production and related LLDPE production cost, covering three key aspects: a complete description of the LLDPE production process examined; an in-depth analysis of the related LLDPE plant capital cost (Capex); and an evaluation of the respective LLDPE plant operating costs (Opex).

The LLDPE 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 LLDPE 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 LLDPE 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): ?

LLDPE Production Cost Report Process Schematic

The process under analysis comprises four major sections: (1) Purification and catalyst preparation; (2) Reaction; (3) Distillation; and (4) Finishing.

Purification and catalyst preparation. The cyclohexane solvent, ethylene and 1-octene are sent to fixed-bed adsorption systems to remove water, oxygen and other polar impurities. The catalysts used in the process are based on mixtures of titanium and vanadium compounds in conjunction with aluminum alkyls cocatalysts.

Reaction. Ethylene, 1-octene comonomer and cyclohexane are mixed and pumped to polymerization reactor. The polymerization is carried out in a solution phase, at a temperature above the melting point of the resulting polymer. The reaction system consists of a tubular reactor and a continuous-stirred-tank reactor (CSTR). The low residence time of the reactors enables a high flexibility for grade transitions and versatility for the production of resins across a wide range of densities, melt indexes, and molecular weight distributions. The reactor output stream is fed into separator vessels where unreacted ethylene and comonomers, solvent, and any other volatile matter are separated from the PE. The polymer is sent to the finishing section while the light stream follows to the distillation system.

Distillation. The distillation step comprises five distillation columns in charge of recovering the unreacted ethylene and comonomers; recovering the solvent; purging impurities, such as oligomers (also called grease), catalyst and deactivators residues; and avoiding the buildup of inert components, such as comonomers isomers.

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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  • 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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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 LLDPE 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 LLDPE 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 LLDPE 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 LLDPE 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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