Commodity Production Costs Report
PP Random Copolymer from Propylene and Ethylene (Spheripol)
Polypropylene Operating Costs & Plant Construction Costs
This report presents the economics of Polypropylene (PP) Random Copolymer production from polymer grade (PG) propylene and ethylene. The economic analysis assumes a plant located in the United States, using a bulk phase polymerization process in loop reactors, similar to LyondellBasell Spheripol and Mitsui Hypol II.
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 Separation, Extrusion and Packaging; and (3) Monomer Recovery.
Polymerization. Fresh polymer grade propylene is sent to fixed bed dryers for removal of water and other catalyst poisons and then to the prepolymerization reactor. The catalyst and hydrogen are also fed to this reactor, forming a protective shell around the catalyst particle, in order to decrease occurrence of fouling. The reactor and dryers outlets are mixed with hydrogen and ethylene before being routed to two loop reactors in series, where the polymerization takes place. The polymerization product, containing spheres of polypropylene, unreacted monomers, catalyst and other impurities, is cooled and sent to treatment.
Polymer degassing and pelletizing. The slurry from the reactor is discharged in two pressure vessels to separate the unreacted monomer from the polymer. The polymer receives a steam treatment to deactivate the catalyst and is then dried with hot nitrogen. The product is then combined with additives and flows to the pelletizing unit. The pellets are cooled and sent to product blending and storage. The monomer stream recovered from steam treatment is sent to a steam scrubber for water removal, and then routed to the low-pressure propylene scrubber, while the condensate water is sent to drying gas scrubber. In this scrubber, nitrogen used in the nitrogen dryer is recovered, being mostly recycled, with its remainder being purged.
Monomer Recovery. The gas from the high-pressure degasser is directly sent to the propylene scrubber. The low-pressure propylene from steam scrubber is washed with an anti-fouling agent before being compressed and sent to the propylene scrubber. In the propylene scrubber, the monomer is separated from polymer residues and recycled to the reaction area. A fraction of the recycle monomer stream is sent to a propylene-propane splitter column for purification - this column is assumed to be in the purification area of a nearby propylene supplier plant and therefore out of the scope of the present analysis.
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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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