PP Homopolymer from Propane (Oleflex PDH / UNIPOL PP)

Report Abstract

This study presents the economics of Polypropylene (PP) Homopolymer production from propane. In this two-step process, first polymer grade (PG) propylene is produced via dehydrogenation of propane, carried out in a moving-bed reactor, similarly to UOP Oleflex. Gaseous PG propylene is then polymerized to PP in fluidized-bed reactors (FBRs), similarly to the Grace UNIPOL process. 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.