Commodity Production Costs Report
Impact PP from Propylene and Ethylene (INNOVENE)
Polypropylene Operating Costs & Plant Construction Costs
This study presents the economics of Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States. This process is similar to INEOS INNOVENE and JPP HORIZONE processes. The reaction occurs in horizontal agitated reactors connected in series.
The report provides a comprehensive study of Polypropylene production and related Polypropylene production cost, covering three key aspects: a complete description of the Polypropylene production process examined; an in-depth analysis of the related Polypropylene plant capital cost (Capex); and an evaluation of the respective Polypropylene plant operating costs (Opex).
The Polypropylene 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 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 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) Resin degassing & pelleting; and (3) Vent recovery.
Polymerization. Fresh polymer grade (PG) propylene and ethylene comonomer are passed through fixed bed dryers for removal of water and other polar impurities. Fresh propylene is then fed to a gas-liquid separation vessel along with a recycled propylene stream from the vent recovery system. Gaseous propylene from the separator is compressed and fed to the bottom of the horizontally-oriented agitated reactor, while the liquid propylene is sprayed onto the reactor to absorb the heat generated by polymerization. Liquid Catalyst is continuously fed to the reactor. Homopolymer resin containing active catalyst is transferred from the polymerization reactor to the copolymerization reactor, which is also fed with fresh ethylene and propylene. An ethylene/propylene rubber mixture intimately dispersed in the homopolymer matrix. The copolymerization reactor does not require additional catalyst feed and it is structure and operation are similar to the polymerization reactor.
Resin degassing & pelleting. Resulting granular polypropylene is removed from the reactor by the discharge tanks and sent to a purge bin where residual hydrocarbons are stripped with nitrogen from the resin and are sent to the vent recovery unit. The resin from purge bin is combined with additives and then flows to pelleting. The pellets are dried, cooled and sent to product blending and storage.
Vent recovery. The purge bin vent stream is compressed and cooled to condense the bulk of the hydrocarbons in the stream. Recovered hydrocarbons are directed to an integrated monomer supply unit for propylene purification. The lean gas stream is then directed to a membrane system that selectively separates lighter gases, such as nitrogen and hydrogen, from heavier hydrocarbons, such as ethylene, propane and propylene. The membrane system outputs two gaseous streams, a nitrogen-rich stream that is returned to the purge bin, and a hydrocarbon-rich stream that is disposed as off gas.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Polypropylene 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 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 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 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 Polypropylene Production Cost Reports
PP Homopolymer from Propylene (BORSTAR)
This study presents the economics of Polypropylene (PP) Homopolymer production from PG propylene. The process under analysis uses a hybrid (slurry/gas) polymerization process similar to the Borealis BORSTAR process. The economic analysis assumes a plant constructed in the United States.
Details: 400 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
PP Homopolymer from Propylene (Spherizone)
This report examines the costs related to Polypropylene (PP) Homopolymer production from polymer grade (PG) propylene, using a gas phase polymerization process similar to LyondellBasell Spherizone. The reaction occurs in a multi-zone circulating reactor (MZCR). The economic analysis performed assumes a plant located in the United States.
Details: 350 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
PP Homopolymer from Propylene (UNIPOL)
This study presents the economics of Polypropylene (PP) Homopolymer production from polymer grade (PG) propylene. The process examined in this report is similar to Grace UNIPOL process. In this process, gaseous propylene is polymerized to PP in fluidized-bed reactors (FBRs). The economic analysis performed assumes a plant located in the United States.
Details: 400 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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