Bimodal HDPE from Ethylene and 1-Butene (Similar to UNIPOL)
HDPE Production Costs Report | Issue C | Q3 2024
| Report Details |
| 450 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 450 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This analysis presents the economics of Bimodal High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene and 1-butene in the United States. The process examined is similar to Univation UNIPOL process. In this process, ethylene is polymerized in combination with 1-butene in the gas-phase in a reaction loop consisting of a fluidized-bed reactor, a compressor and a heat exchanger.
The report provides a comprehensive study of HDPE production and related HDPE production cost, covering three key aspects: a complete description of the HDPE production process examined; an in-depth analysis of the related HDPE plant capital cost (Capex); and an evaluation of the respective HDPE plant operating costs (Opex).
The HDPE 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 HDPE 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 HDPE plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Reaction; (2) Purification; and (3) Finishing.
Reaction. The catalysts used in the process are sensitive to specific impurities in the raw materials feed. Therefore, ethylene and 1-butene are treated to remove water, oxygen and other polar impurities. The monomers are fed to the bottom of the reactor, where ethylene is polymerized in combination with 1-butene in a reaction loop consisting of a reactor, a compressor and a heat exchanger. The copolymerization reaction is conducted in gas-phase fluidized beds of granular polyethylene resin. While the compressor circulates the reaction gas and provides the required agitation, the external cooler removes reaction heat from the circulating gas. The reaction is carried out at low temperatures (80 - 110 °C) and somewhat low pressures of (15 - 35) bar.
Purification. The granular PE powder from the reactor is conveyed to a Purge Bin. In the Purge Bin, residual hydrocarbons are stripped with a nitrogen purge, and the catalyst is deactivated with steam. The purged gas is cooled and fed to two separators, in which condensed reactants are recovered and directly pumped back to the reactor, while uncondensed gas taken is purged.
Finishing. The resulting polymer stream is further fed into an extruder, which is used to incorporate the required additives, as well as to pelletize the polymer. The product is then sent to product blending and storage.
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Production Process Information
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the HDPE 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 HDPE 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 HDPE 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 HDPE 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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This report analyses the economics of High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene and 1-butene in the United States. The process examined in this report uses a gas-phase polymerization in a single reactor similar to LyondellBasell Spherilene S.
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