LLDPE Production from Ethylene and 1-Hexene (Similar to UNIPOL)
LLDPE Production Costs Report | Issue E | Q4 2024
| Report Details |
| 450 kta United States-based plant | Q4 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
It presents the economics of Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-hexene in the United States. This report examines a gas phase process similar to Univation UNIPOL and INEOS INNOVENE. The system comprises a fluidized-bed reactor, compressor and heat exchanger.
The report provides a comprehensive study of LLDPE production and related LLDPE production cost, covering three key aspects: a complete description of the LLDPE production process examined; an in-depth analysis of the related LLDPE plant capital cost (Capex); and an evaluation of the respective LLDPE plant operating costs (Opex).
The LLDPE 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 LLDPE 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 LLDPE 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 four major sections: (1) Polymerization; (2) Degassing; and (3) Finishing.
Polymerization. Since the catalysts used in the process are sensitive to some impurities in the raw materials feed, the monomers are purified before being fed to the bottom of the reactor, where ethylene is polymerized in combination with 1-hexene 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 with trace of metallocene catalyst. 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 low pressures of (15 - 35) bar.
Degassing. 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 Costs Datasheet
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Production Process Information
Process Consumptions
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Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
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 LLDPE 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 LLDPE 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 LLDPE 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 LLDPE 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 study presents the economics of Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-butene in the United States, using a gas phase process similar to Univation UNIPOL and INEOS INNOVENE. This technology comprises a reaction loop consisting of a fluidized-bed reactor, a compressor and a heat exchanger. Residual hydrocarbons are removed from the product by a propane stream.
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LLDPE from Ethylene and 1-Butene (Similar to Spherilene)
This report presents the economics of Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-butene in the United States. The process examined in this report is similar to LyondellBasell Spherilene S. It comprises a small loop reactor for catalyst activation before the main reaction loop with fluid-bed reactor. Residual hydrocarbons are stripped from the product by nitrogen.
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