Impact PP from Propylene and Ethylene (Novolen)
Polypropylene Production Costs Report | Issue J | Q3 2024
| Report Details |
| 400 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 400 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 report examines the costs related to Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States. The process examined in this report is similar to Lummus Technology's Novolen process. This process occurs in vertical fluidized-bed reactors connected in series.
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.
Process Schematic
The process under analysis can be separated in three different areas: purification & reaction; resin degassing & pelleting; and vent recovery.
Purification & reaction. Fresh polymer grade (PG) propylene is sent to fixed bed dryers for removal of water and other polar impurities. Two reactors are operated in series for the production of impact copolymers. First, purified propylene, monomers recycle, catalysts and co-catalysts are fed to the first reactor, to produce homopolymer polypropylene. Then, polymer powder from the first reactor is fed to a second reactor, along with additional propylene and ethylene for further polymerization. Cooling is provided by flash evaporating recycle gas inside the reactors. Both reactors are mechanically stirred with a helical shaped agitator to keep the polymer bed well mixed and prevent particle agglomeration.
Resin degassing & pelleting. The outlet from the second reactor is directed to a discharge vessel where accompanying reactor gas (carrier gas) is recovered at low-pressure conditions. Polymer powder is sent to a purge vessel, while the carrier gas goes through a cyclone and a filter and is finally sent to recovery. Nitrogen is used to remove residual monomer from the polymer powder and then is also sent to recovery. The polymer powder then goes to a screw extruder, where polymer powder and additives are melted, compounded and homogenized. After being extruded, the pellets are carried to a centrifugal dryer.
Vent recovery. The carrier gas is compressed and a portion is sent back to the reactor. The remaining portion is directed to the monomer supply unit in order to recover propylene. The purge gas is separated in a membrane unit into a nitrogen stream and a propylene-rich stream. The nitrogen stream is recycled to the process, while the monomer-rich stream goes to the propylene supply unit for purification.
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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 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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