Commodity Production Costs Report
PP Homopolymer from Propane (Oleflex PDH / Spheripol PP)
Polypropylene Operating Costs & Plant Construction Costs
This study presents the economics of Polypropylene production from propane. In this two-step process, first polymer grade (PG) propylene is produced via dehydrogenation of propane, carried out in a moving-bed reactor, similarly to UOP Oleflex. PG propylene is then polymerized using a bulk phase polymerization process similar to LyondellBasell Spheripol. The economic analysis performed assumes a plant located in the United States.
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 four major sections: (1) Propane Dehydrogenation; (2) Propylene Purification; (3) Polymerization; and (4) Polymer Degassing and Pelletizing.
Propane Dehydrogenation. Fresh and recycled propane are fed to a depropanizer column for heavy impurities removal and then heated to the reaction temperature in a charge heater. The dehydrogenation reaction takes place on moving bed reactors across multiple stages, which operate in a continuous mode. In this process, a continuous catalyst regenerator (CCR) unit is used to purge the coke accumulated on the surface of the platinum-based catalyst during the reaction.
Propylene Purification. The reactor effluent is compressed, dried and sent to a low-temperature separation system (cold box) for the removal of a hydrogen-rich stream. Subsequenty. light hydrocarbons and hydrogen traces are removed in a deethanizer column and PG propylene is obtained in a propane-propylene (P–P) splitter.
Polymerization. PG propylene is sent to fixed bed dryers for removal of water and other catalyst poisons, and to the prepolymerization reactor. The catalyst and hydrogen are also fed to this reactor. The reactor and dryers outlets are mixed with hydrogen and routed to two loop reactors in series, where the polymerization takes place.
Polymer Degassing and Pelletizing. The slurry from the reactor containing spheres of polypropylene, unreacted monomer, catalyst and other impurities is discharged in a degassing system to separate the unreacted monomer from the polymer. The gas from the degassing sent to a monomer recovery area before being recycled to the reaction area. A fraction of the recycle monomer stream is sent to a propylene-propane splitter column for purification. The degassed polymer is combined with additives and then flows to the pelletizing unit before being sent to product blending and storage.
Report in PDF Format
Download & Explore Anytime
Access in Various Devices
Print & Read Comfortably
Share With Co-workers
Up-to-date Report
Professional report based on Q3 2024 economic data, ensuring timely evaluations.
Multiple Use Cases
Ideal for investment screening, feasibility studies, cost estimates, and research planning.
Proven Methodology
Developed using a consistent methodology honed over a decade, ensuring reliable cost analyses.
Report Editions
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
Preview our Production Cost Reports
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
Could Not Find the Report You Need?
Obtain a Bespoke Report
Get a report targeting the process in which you are interested
See Offer Details
Understand Bespoke Reports and how you can easily order them
Check Editions & Pricing
Complete a brief form and see a quotation for your Bespoke Report
Other Related Production Cost Reports
Polypropylene Nonwoven Production
This report presents the economics of Nonwoven production from polypropylene via spunbond technology. The economic analysis performed assumes a plant located in the United States.
Details: 10 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $1,999 USD
+800 Reports Developed, Targeting +250 Commodities
Vast Report Library
858 independent and up-to-date reports examining embryonic and established production processes.
Free Sample Reports
Quickly understand the structure and depth of content of our professional reports.