Bimodal HDPE from Ethylene and 1-Octene (Similar to Spherilene) | Economic Analysis
HDPE Production — Technology Description & Economic Analysis
High Density Polyethylene (HDPE) 1-octene copolymer production consists in the polymerization of ethylene and 1-octene, in such a way that different manufacturing routes are related to different sources of such raw materials (ethylene and 1-octene).
This article aims to present a brief process description and a condensed cost analysis of Bimodal HDPE from Ethylene and 1-Octene (Similar to Spherilene).
Process Description
The process under analysis comprises two major sections: (1) Polymerization; and (2) Finishing.
Polymerization. Initially, ethylene and 1-octene are passed through fixed-bed adsorption systems, in which potential catalyst poisons are removed before polymerization. After purification, the ethylene is polymerized in combination with 1-octene in two reaction loops connected in series. Each reaction loop comprises a gas-phase reactor, a compressor, a heat exchanger and a degassing vessel. The polymerization occurs in the gas phase at mild conditions of temperature and pressure. Propane is used as inert diluent, and hydrogen is used as molecular weight regulator. The spherical product particles of each gas-phase reactor are fed to degassing vessels, in which unreacted monomers and hydrogen are removed by a counter-current propane stream. The gaseous streams from the degassing vessels are passed through a couple of distillation columns for the recovery of unreacted monomers and diluent.
Finishing. The degassed polymer particles from the second reaction loop are transferred to a vessel where residual hydrocarbons are removed, and the catalyst is deactivated by stripping with a gaseous stream containing nitrogen and steam. The wet polymer is then dried by nitrogen before being 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, packed and finally sent to storage facilities located Outside Battery Limits (OSBL).
Cost Analysis
The economic evaluation of industrial processes is a valuable support tool for a myriad of activities and studies, such as screening and assessment of investment options, preliminary evaluation of the economic potential of emerging industrial processes, rough assessment of the economic feasibility of industrial ventures, cost estimates double-checking, preliminary budget approval, research planning, and so on.
A detailed cost analysis for the manufacturing of HDPE was developed by Intratec based on a plant constructed in 2020 Q2 in the United States with the capacity to produce 400,000 metric ton per year of HDPE. The table below presents a few economic figures related to the process “Bimodal HDPE from Ethylene and 1-Octene (Similar to Spherilene)”.
Where,
“Raw material costs” are the costs related to the raw materials directly consumed by the process to make the final product.
“Operating variable costs” are the costs directly proportional to the actual operating rate of the industrial site. Such costs include raw materials and utilities, i.e., steam, electricity, fuel, and refrigeration.
Main Reference
[1] Intratec. 2020. Bimodal HDPE from Ethylene and 1-Octene (Similar to Spherilene), Advanced Edition. Available at: www.intratec.us/analysis/hdpe-e41a
HDPE Production Processes
To learn more about processes related to HDPE production, visit: www.intratec.us/analysis/hdpe-production-cost
About Intratec Commodity Production Costs Reports
The report Bimodal HDPE from Ethylene and 1-Octene (Similar to Spherilene) is part of a series of reports prepared by Intratec approaching the production costs of commodities spanning a diverse range of industries: Oil & Energy; Fertilizers & Gases; Olefns & Derivatives; Aromatics & Derivatives; Alcohols & Organic Acids; Polymers; Inorganic Chemicals; Food & Nutrition; Metals & Mining; and Pharmaceuticals.
For information on all Intratec reports visit: www.intratec.us
