Commodity Production Costs Report
PP Homopolymer from Propylene (UNIPOL)
Polypropylene Operating Costs & Plant Construction Costs
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.
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 is passed through fixed bed dryers for removal of water and other polar impurities. The purified propylene is then fed to the reactor, along with a recycle stream from the vent recovery system. The gas compressor circulates reaction gas upward through the reactor, providing the agitation needed for fluidization and backmixing - no mechanical stirrers or agitators are required. The overhead gas from the reactor passes through a cooler for reaction heat removal. Catalyst is continuously fed to the 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 system. 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 gas from the purge bin is compressed and chilled to condense the bulk of the hydrocarbon in the stream. The recovered hydrocarbon is fed to the vent recovery column, while lean nitrogen stream from which hydrocarbon has been condensed is recycled to the purge bin. This column separates the hydrocarbon into a monomer enriched stream and a propane rich stream. The monomer stream is returned to reaction, and the propane rich stream is returned to the monomer supply unit in order to recover propylene.
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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 (Novolen)
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.
Details: 400 kta United States-based plant | Q3 2024 | 107 pages | Issue F | From $799 USD
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