Commodity Production Costs Report
LLDPE Production from Ethylene and 1-Butene (Similar to UNIPOL)
LLDPE Operating Costs & Plant Construction Costs
This study presents the economics of Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-butene in the United States, using a gas phase process similar to Univation UNIPOL and INEOS INNOVENE. This technology comprises a reaction loop consisting of a fluidized-bed reactor, a compressor and a heat exchanger. Residual hydrocarbons are removed from the product by a propane stream.
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): ?
The process under analysis comprises three major sections: (1) Polymerization; (2) Polymer degassing; and (3) Finishing.
Polymerization. Initially, raw materials are purified, since catalysts used in the process are sensitive to specific impurities. Such feed purification consists, mainly, in removing oxygen and water from ethylene and 1-butene, by means of purification columns and molecular sieves. After purified, the ethylene is polymerized in combination with 1-butene in a reaction loop consisting of a reactor, a compressor and a heat exchanger. The molecular weight of the polymer is controlled by hydrogen gas 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 hydrocarbons are 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 monomers are 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 LLDPE 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 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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Other LLDPE Production Cost Reports
LLDPE from Ethylene and 1-Octene (Similar to Advanced SCLAIRTECH)
This study presents the economics of Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-octene in the United States. The process examined in this report is similar to NOVA Chemicals Advanced SCLAIRTECH. This process is carried out in two CSTR operating in series.
Details: 400 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
LLDPE Production from Ethylene and 1-Hexene (Similar to MarTECH)
This report examines the costs related to Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-hexene in the United States, using a slurry process similar to Chevron Phillips MarTECH. In this technology, ethylene is polymerized in combination with 1-hexene in a slurry loop reactor.
Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
LLDPE from Ethylene and 1-Octene (Similar to DOWLEX)
This report presents the economics of Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-octene in the United States. The process examined in this report is similar to Dow DOWLEX. In this technology, the polymerization is carried out in two CSTR reactors operating in series.
Details: 300 kta United States-based plant | Q3 2024 | 107 pages | Issue D | 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.
Details: 120 kta United States-based plant | Q3 2024 | 107 pages | Issue C | 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
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.
Details: 50 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
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