Commodity Production Costs Report
PP Homopolymer from Propylene (Spherizone)
Polypropylene Operating Costs & Plant Construction Costs
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.
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) Product Treatment and Storage; and (3) Monomer Recovery.
Polymerization. Propylene and catalyst are fed into the Multi-Zone Circulation (MZC) Reactor, a closed loop circulating system, composed of two sections: the riser and the downcomer. In the riser, the polymer particles are entrained upwards by the monomer flow in a fast fluidization regime, being separated from the gas and directed to the downcomer section, where the polymerization takes place. From the bottom of the downcomer, polymer particles are partly recirculated into the riser, with the remainder being sent to the Medium Pressure (MP) Degasser.
Product Treatment and Storage. In the MP Degasser, unreacted propylene is separated from polymer and sent to the Propylene Scrubber. The polymer product is routed to the Low Pressure (LP) Degasser to remove remaining monomer, which is sent to the Propylene Recycle Compressor I. The Polymer is fed to a Steamer to deactivate the catalyst and remove residual monomer. These impurities are sent to the Steam Scrubber, while the polymer is dried in a fluid bed dryer with hot nitrogen, pelletized, homogenized, and sent to storage.
Monomer Recovery. The gas product from the steamer is fed to the Steam Scrubber, that generates a gaseous stream rich in propylene, sent to the Propylene Recycle Compressor I, and a high-water content waste stream, which is routed to the hot nitrogen dryer. Gaseous streams from the Steam Scrubber and the LP Degasser are compressed in the Recycle Compressor I and fed to the Propylene Scrubber to recover propylene. A portion of this recovered monomer is compressed and recycled to the MZC Reactor, with the remainder being sent to a nearby plant to purify propylene and avoid propane build-up.
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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
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Details: 400 kta United States-based plant | Q3 2024 | 107 pages | Issue F | From $799 USD
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