Commodity Production Costs Report
PP Homopolymer from Propylene (Novolen)
Polypropylene Operating Costs & Plant Construction Costs
This study presents the economics of Polypropylene (PP) Homopolymer production from polymer grade (PG) propylene in the United States. In this process, gaseous PG propylene is polymerized in vertical stirred-bed reactors. The process examined in this report is similar to Lummus Technology's Novolen.
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 can be separated in three different areas: purification & reaction; resin degassing & pelleting; and vent recovery.
Purification & reaction. Fresh polymer grade (PG) propylene is treated in fixed bed dryers for removal of water and other polar impurities before being mixed with a recycle stream from the vent recovery system are then continuously fed to a mechanically stirred reactor that uses a helically shaped agitator to keep the polymer bed well mixed and prevent particle agglomeration. Cooling is provided by flash evaporating recycle gas inside the reactors.
Resin degassing & pelleting. The outlet reactor stream is directed to a discharge vessel where accompanying reactor gas (carrier gas) is recovered at low-pressure conditions. Polymer powder is sent to a purge vessel, while the carrier gas goes through a cyclone and a filter and is finally sent to recovery. Nitrogen is used to remove residual monomer from the polymer powder and then is also sent to recovery. The polymer powder then goes to a screw extruder, where polymer powder and additives are melted, compounded and homogenized. After being extruded, the pellets are carried to a centrifugal dryer.
Vent recovery. The carrier gas is compressed and a portion is sent back to the reactor. The remaining portion is directed to the monomer supply unit in order to recover propylene. The purge gas is separated in a membrane unit into a nitrogen stream and a propylene-rich stream. The nitrogen stream is recycled to the process, while the monomer-rich stream goes to the propylene supply unit for purification.
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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 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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