Commodity Production Costs Report
Polypropylene Carbonate Production
Polypropylene Carbonate Operating Costs & Plant Construction Costs
This report provides the economics of Polypropylene Carbonate (PPC) production from propylene oxide and carbon dioxide in the United States using a process based on patents issued to SK Energy. In this process, the polymerization occurs in full-liquid phase and under pressure.
The report provides a comprehensive study of Polypropylene Carbonate production and related Polypropylene Carbonate production cost, covering three key aspects: a complete description of the Polypropylene Carbonate production process examined; an in-depth analysis of the related Polypropylene Carbonate plant capital cost (Capex); and an evaluation of the respective Polypropylene Carbonate plant operating costs (Opex).
The Polypropylene Carbonate 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 Polypropylene Carbonate 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 Polypropylene Carbonate 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 four major sections: (1) Polymerization; (2) Phase Separation; (3) Monomers Separation; and (4) Pelletizing & Finishing.
Polymerization. Fresh carbon dioxide (CO2) feed is mixed with recycled CO2 from Monomers Separation. Propylene oxide feed is also mixed with a recovered stream. Both reactants are treated for moisture removal. Part of the propylene oxide treated feed is fed to the polymerization reactor outlet to dissolve the polymer solution obtained. The remainder is mixed with catalyst and CO2 feed, forming a liquid solution that is transferred to the prepolymerization reactor. The prepolymerization reaction effluent is fed to the polymerization reactor, where the polymer solution is obtained.
Phase Separation. The polymer solution is contacted with a material that binds to the catalyst and allows its removal via filtration. The catalyst-free solution is subjected to gradual pressure decrease, so that unreacted monomers can be released. Once the monomers are removed, the polymer melt is transferred to the Pelletizing & Finishing. Released monomers are routed to the Monomers Separation.
Monomers Separation. Unreacted monomers are fed to two consecutive distillation columns, from which three streams are obtained. A high-purity propylene oxide stream is recycled to the Feed Preparation and mixed with fresh feed. A carbon dioxide-rich stream (also containing propylene oxide) is also recycled to the feed preparation. Another stream, comprising heavy ends generated as side-products, is discharged from the process.
Pelletizing & Finishing. The polymer melt is fed to a pelletizing system, where it is homogenized and pelletized. Subsequently, the 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 Polypropylene Carbonate 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 Polypropylene Carbonate 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 Polypropylene Carbonate 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 Polypropylene Carbonate 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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