Technology Economics Polypropylene Via Gas Phase Process

Polypropylene
via Gas Phase

Process
#TEC004B
Technology Economics
Polypropylene Production via Gas Phase Process
2013
Abstract
Polypropylene is a thermoplastic polymer with low specific gravity, high stiffness, relatively high temperature resistance and good
resistance to chemicals and fatigue. These exceptional properties, combined with this materials versatility have made it one of the
most widely used polymers, second only to polyethylene in terms of global demand. The global market for polypropylene was
over 50 million metric tons in 2011 as it was utilized in a broad and diverse range of end-uses from injection molding applications
to film and sheet, raffia and fiber, among others.
Growth in polyolefin consumption will be largely driven by the rapid economic development of numerous transition countries in
the Asia Pacific region, Central Europe, the Middle East and South America. On the supply side, the shift in global steam cracker
production toward lighter, natural gas-based feedstock is increasingly limiting by-product propylene output. The resulting tight
supply of propylene has led to higher propylene and polypropylene prices, which are encouraging investments in alternate
propylene sources, as the on-purpose technologies. High propylene feedstock prices also rendered the construction of standalone polypropylene plants infeasible, making upstream integration indispensable for most of the new polypropylene projects.
Gas phase polypropylene production technology is the fastest growing route for producing polypropylene homopolymers and
random copolymers. In this report, the production of polypropylene through the polymerization of propylene via a gas phase
process is reviewed. Included in the analysis is an overview of the technology and economics of a method similar to the Dow
UNIPOL TM process. Both the capital investment and the operating costs for plants erected on the US Gulf Coast are presented.
The economic analysis presented in this study is based on a 400 kta polypropylene plant. Two scenarios are analyzed: a standalone unit, obtaining feedstock at market prices and a plant integrated upstream with a propylene source, acquiring feedstock at a
transfer price, below market average. The economic feasibility of both scenarios is presented and the actual market conditions for
polypropylene production are discussed.
Propylene elevated market prices in the USA make it unprofitable to operate a stand-alone PP unit in that country. However, when
Copyrights 2013 by Intratec Solutions LLC. All rights reserved. Printed in the United States of America.
This Publication Was Not a Publication

It was actually an advisory
service ordered by one of our
clients, now disclosed to our
readership with his consent.
It results from the innovative
concept, designed by Intratec for
leading companies in the chemical and allied
sectors who have asked for more affordable
and reliable studies to plan their investments.
Intratecs strategy works by charging clients
lower-than-market fees to conduct a
technology advisory service with the
understanding that such studies may be
released, after an agreed upon period of time,
as publications.
Available through well-known sales channels
such as Amazon, Google Books and HP
MagCloud, our publications can be purchased
by any interested reader.
In short, our clients receive

traditionally expensive studies
for a fraction of the cost, and
our readers get unprecedented
access to real professional
publications at steep discounts.
How Readers Benefit?

From academics to industry executives, our
readers benefit by gaining access to real
consulting cases, released for the first time to
the market as one-of-a-kind publications at
affordable prices.
Through our university discount policy,
students and faculty members will be able to
become familiar with challenges faced by
industry for a price similar to a usual textbook.
How Clients Benefit?

While traditional consulting firms charge their
clients hundreds of thousands of dollars,
Intratec offers, from the convenience of a web
browser, a much better advisory experience
for a price 80% lower than market.
What is Technology
Economics?
Advisory services targeting investments on
new chemical units, answering:
What is the process? What equipment is
necessary?
What are the raw materials and utilities
consumptions?
What are the operating and capital
expenses?
In which locations is this technology more
profitable?
Each new assignment comprises of a study
structured like this publication, valuable
spreadsheets and broad support.
ii
Consulting as Publications at a Glance

Reshaping the Advisory Industry
1) Our publications are accessed and attested to by a huge audience . . .
2) . . . including potential clients who like the publication structure . . .
3) . . . and order advisory services based on the same format.
4) If our clients agree, their advisory services are disclosed as publications.
Everyone Benefits from Cost Sharing & Online Experience

1) Readers purchase our publications at steep discounts online . . .
4) . . . because they were actually consulting cases . . .
3) . . . requested online by the initial client . . .
2) . . . who shared the costs with the readers.
For a better understanding of our innovative concept, please visit www.intratec.us.

iii
Terms & Conditions

Information, analyses and/or models herein presented
are prepared on the basis of publicly available
information and non-confidential information disclosed
by third parties. Third parties, including, but not limited
to technology licensors, trade associations or
marketplace participants, may have provided some of
the information on which the analyses or data are based.
Intratec Solutions LLC (known as Intratec) does not
believe that such information will contain any
confidential information but cannot provide any
assurance that any third party may, from time to time,
claim a confidential obligation to such information.
The aforesaid information, analyses and models are
developed independently by Intratec and, as such, are
the opinion of Intratec and do not represent the point of
view of any third parties nor imply in any way that they
have been approved or otherwise authorized by third
parties that are mentioned in this publication.
The application of the solutions presented in this
publication without license from the owners infringes on
the intellectual property rights of the owners, including
patent rights, trademark rights, and rights to trade
secrets and proprietary information.
Intratec conducts analyses and prepares publications
and models for readers in conformance with generally
accepted professional standards. Although the
statements in this publication are derived from or based
on several sources that Intratec believe to be reliable,
Intratec does not guarantee their accuracy, reliability, or
quality; any such information, or resulting analyses, may
be incomplete, inaccurate or condensed. All estimates
included in this publication are subject to change
without notice. This publication is for informational
purposes only and is not intended as any
recommendation of investment.
Reader agrees it will not, without prior written consent of
Intratec, represent, directly or indirectly, that its products
have been approved or endorsed by the other parties.
In no event shall Intratec, its employees, representatives,

resellers or distributors be liable to readers or any other
person or entity for any direct, indirect, special,
exemplary, punitive, or consequential damages,
including lost profits, based on breach of warranty,
contract, negligence, strict liability or otherwise, arising
from the use of this publication, whether or not they or it
had any knowledge, actual or constructive, that such
damages might be incurred.
Reader shall indemnify and hold harmless Intratec and its
resellers, representatives, distributors, and information
providers against any claim, damages, loss, liability or
expense arising out of readers use of the publication in
any way contrary to the present terms and conditions.
Intratec publications are the product of extensive work
and original research and are protected by international
copyright law.
Products supplied as printed reports or books should not
be copied but can be included in schools, universities or
corporate libraries and circulated to colleagues to the
extended permitted by copyright law.
Products supplied digitally are licensed, not sold. The
purchaser is responsible for ensuring that license terms
are adhered to at all times. PDF documents may be
supplied watermarked with the customers name, email
and/or company. Digital documents are supplied with
an enterprise license and can be shared by all employees
and on-site contractors of a single organization.
Members of the organization may make such copies as
are necessary to facilitate this distribution. An enterprise
license does not permit sharing with external
organizations.
Reader agrees that Intratec retains all rights, title and
interest, including copyright and other proprietary rights,
in this publication and all material, including but not
limited to text, images, and other multimedia data,
provided or made available as part of this publication.
Contents
About this Study .............................................................................................................................................................. 8
Object of Study.............................................................................................................................................................................................................................8
Analysis Performed ....................................................................................................................................................................................................................8
Construction Scenarios ..............................................................................................................................................................................................................8
Location Basis ...................................................................................................................................................................................................................................8
Design Conditions......................................................................................................................................................................................................................9
Study Background ........................................................................................................................................................ 10

About Polypropylene............................................................................................................................................................................................................10
Types of Polypropylene Resins ...........................................................................................................................................................................................10
Applications.................................................................................................................................................................................................................................... 11
Polypropylene Manufacturing........................................................................................................................................................................................11
Types of Process........................................................................................................................................................................................................................... 11
The Role of Catalyst in Process ...........................................................................................................................................................................................12
Licensor & Historical Aspects ...........................................................................................................................................................................................13
Technical Analysis......................................................................................................................................................... 14
Chemistry.......................................................................................................................................................................................................................................14
Raw Material ................................................................................................................................................................................................................................14
Technology Overview...........................................................................................................................................................................................................15
Detailed Process Description & Conceptual Flow Diagram.......................................................................................................................16
Area 100: Purification & Reaction.....................................................................................................................................................................................16
Area 200: Resin Degassing & Pelleting .........................................................................................................................................................................17
Area 300: Vent Recovery........................................................................................................................................................................................................ 17
Key Consumptions ..................................................................................................................................................................................................................... 18
Technical Assumptions ........................................................................................................................................................................................................... 18
Labor Requirements.................................................................................................................................................................................................................. 18
ISBL Major Equipment List.................................................................................................................................................................................................23

OSBL Major Equipment List ..............................................................................................................................................................................................26
Other Process Remarks ........................................................................................................................................................................................................27
Improvements in Fluidized-Bed Polymerization Technology ........................................................................................................................27
Propylene-Polypropylene Integration Alternatives...............................................................................................................................................28
Economic Analysis ........................................................................................................................................................ 29

2
General Assumptions............................................................................................................................................................................................................29
Project Implementation Schedule...............................................................................................................................................................................30
Capital Expenditures..............................................................................................................................................................................................................30
Fixed Investment......................................................................................................................................................................................................................... 30
Working Capital............................................................................................................................................................................................................................ 32
Other Capital Expenses ...........................................................................................................................................................................................................32
Total Capital Expenses ............................................................................................................................................................................................................. 33
Operational Expenditures ..................................................................................................................................................................................................34

Manufacturing Costs................................................................................................................................................................................................................. 34
Historical Analysis........................................................................................................................................................................................................................ 34
Economic Datasheet .............................................................................................................................................................................................................34
Regional Comparison & Economic Discussion.................................................................................................... 37

Regional Comparison............................................................................................................................................................................................................37
Capital Expenses.......................................................................................................................................................................................................................... 37
Operational Expenditures......................................................................................................................................................................................................37
Economic Datasheet................................................................................................................................................................................................................. 37
Economic Discussion ............................................................................................................................................................................................................38
References....................................................................................................................................................................... 40
Acronyms, Legends & Observations....................................................................................................................... 41
Technology Economics Methodology................................................................................................................... 42
Introduction.................................................................................................................................................................................................................................42
Workflow........................................................................................................................................................................................................................................42
Capital & Operating Cost Estimates ............................................................................................................................................................................44
ISBL Investment............................................................................................................................................................................................................................ 44
OSBL Investment ......................................................................................................................................................................................................................... 44
Working Capital............................................................................................................................................................................................................................ 45
Start-up Expenses ....................................................................................................................................................................................................................... 45
Manufacturing Costs................................................................................................................................................................................................................. 46
Contingencies ............................................................................................................................................................................................................................46
Accuracy of Economic Estimates..................................................................................................................................................................................47
Location Factor..........................................................................................................................................................................................................................47
Appendix A. Mass Balance & Streams Properties............................................................................................... 49

Appendix B. Utilities Consumption Breakdown ................................................................................................. 54
3
Appendix C. Process Carbon Footprint ................................................................................................................. 55

Appendix D. Equipment Detailed List & Sizing................................................................................................... 56
Appendix E. Detailed Capital Expenses................................................................................................................. 62
Direct Costs Breakdown ......................................................................................................................................................................................................62
Indirect Costs Breakdown ..................................................................................................................................................................................................63
Appendix F. Economic Assumptions...................................................................................................................... 64

Capital Expenditures..............................................................................................................................................................................................................64
Construction Location Factors ...........................................................................................................................................................................................64
Working Capital............................................................................................................................................................................................................................ 64
Operational Expenses ...........................................................................................................................................................................................................65

Fixed Costs ...................................................................................................................................................................................................................................... 65
Depreciation................................................................................................................................................................................................................................... 65
Appendix G. Latest & Upcoming Reports ............................................................................................................. 66

Appendix H. Technology Economics Form Submitted by Client ................................................................. 67
List of Tables
Table 1 Construction Scenarios Assumptions (Based on Degree of Integration) ......................................................................................9
Table 2 Locations & Pricing Basis ..................................................................................................................................................................................................9
Table 3 General Design Assumptions .......................................................................................................................................................................................9
Table 4 Polypropylene End-uses................................................................................................................................................................................................11
Table 5 Catalyst Advances..............................................................................................................................................................................................................12
Table 6 - Raw Materials & Utilities Consumption (per ton of product)................................................................................................................18
Table 7 Design & Simulation Assumptions.........................................................................................................................................................................18
Table 8 Labor Requirements for a Typical Plant..............................................................................................................................................................18
Table 9 Main Streams Operating Conditions and Composition..........................................................................................................................23
Table 10 Inside Battery Limits Major Equipment List...................................................................................................................................................23
Table 11 - Outside Battery Limits Major Equipment List ...............................................................................................................................................26
Table 12 Base Case General Assumptions...........................................................................................................................................................................29
Table 13 - Bare Equipment Cost per Area (USD Thousands)......................................................................................................................................30
Table 14 Total Fixed Investment Breakdown (USD Thousands) ..........................................................................................................................30
Table 15 Working Capital (USD Million) ................................................................................................................................................................................32
Table 16 Other Capital Expenses (USD Million) ...............................................................................................................................................................33
Table 17 CAPEX (USD Million)......................................................................................................................................................................................................33
Table 18 Manufacturing Fixed Cost (USD/ton) ................................................................................................................................................................34
Table 19 Manufacturing Variable Cost (USD/ton)..........................................................................................................................................................34
Table 20 OPEX (USD/ton)................................................................................................................................................................................................................34
Table 21 Technology Economics Datasheet: Polypropylene via Gas Phase Process on the US Gulf Coast.........................36
Table 22 Technology Economics Datasheet: Polypropylene via Gas Phase Process in Client-Defined Location ...........39
Table 23 Project Contingency......................................................................................................................................................................................................46
Table 24 Criteria Description.........................................................................................................................................................................................................46
Table 25 Accuracy of Economic Estimates .........................................................................................................................................................................47
Table 26 Detailed Material Balance & Stream Properties..........................................................................................................................................49
Table 27 Utilities Consumption Breakdown ......................................................................................................................................................................54
Table 28 Assumptions for CO2e Emissions Calculation.............................................................................................................................................55
Table 29 CO2e Emissions (ton/ton prod.)............................................................................................................................................................................55
Table 30 Compressors .......................................................................................................................................................................................................................56
Table 31 Heat Exchangers ..............................................................................................................................................................................................................56
Table 32 Pumps......................................................................................................................................................................................................................................57
5
Table 33 Separation Equipment.................................................................................................................................................................................................58

Table 34 Special Equipment .........................................................................................................................................................................................................58
Table 35 Utilities Supply...................................................................................................................................................................................................................58
Table 36 Reactor....................................................................................................................................................................................................................................59
Table 37 Columns.................................................................................................................................................................................................................................59
Table 38 Vessels & Tanks..................................................................................................................................................................................................................59
Table 39 Indirect Costs Breakdown for the Base Case (USD Thousands) ......................................................................................................63
Table 40 Detailed Construction Location Factor............................................................................................................................................................64
Table 41 Working Capital Assumptions (Base Case) ....................................................................................................................................................64
Table 42 Other Capital Expenses Assumptions (Base Case) ...................................................................................................................................64
Table 43 Other Fixed Cost Assumptions ..............................................................................................................................................................................65
Table 44 Depreciation Value & Assumptions ....................................................................................................................................................................65
List of Figures
Figure 1 OSBL Construction Scenarios .....................................................................................................................................................................................8
Figure 2 Polypropylene from Multiple Sources...............................................................................................................................................................13
Figure 3 Process Block Flow Diagram.....................................................................................................................................................................................15
Figure 4 Inside Battery Limits Conceptual Process Flow Diagram.....................................................................................................................19
Figure 5 Project Implementation Schedule.......................................................................................................................................................................29
Figure 6 Total Direct Cost of Different Integration Scenarios (USD Thousands) ......................................................................................31
Figure 7 Total Fixed Investment of Different Integration Scenarios (USD Thousands) .......................................................................32
Figure 8 Total Fixed Investment Validation (USD Million)........................................................................................................................................33
Figure 9 OPEX and Product Sales History (USD/ton) ...................................................................................................................................................35
Figure 10 EBITDA Margin & IP Indicators History Comparison..............................................................................................................................35
Figure 11 CAPEX per Location (USD Million).....................................................................................................................................................................37
Figure 12 Operating Costs Breakdown per Location (USD/ton) .........................................................................................................................38
Figure 14 Methodology Flowchart...........................................................................................................................................................................................43
Figure 15 Location Factor Composition...............................................................................................................................................................................47
Figure 16 ISBL Direct Costs Breakdown by Equipment Type (Base Case).....................................................................................................62
Figure 17 OSBL Direct Costs by Equipment Type (Base Case) ..............................................................................................................................62
About this Study

This study follows the same pattern as all Technology
Economics studies developed by Intratec and is based on
the same rigorous methodology and well-defined structure
(chapters, type of tables and charts, flow sheets, etc.).
This chapter summarizes the set of information that served
as input to develop the current technology evaluation. All
required data were provided through the filling of the
Technology Economics Form available at Intratecs website.
Figure 1 OSBL Construction Scenarios
Non-Integrated
Partially Integrated
Products Storage
Products Storage
ISBL Unit
ISBL Unit
Raw Materials
Storage
Raw Materials
Provider
You may check the original form in the Appendix H.

Technology Economics Form Submitted by Client.
Object of Study
This assignment assesses the economic feasibility of an
industrial unit for homopolymer polypropylene (PP)
production via gas phase process, implementing
technology similar to the Dow UNIPOL process.
The current assessment is based on economic data
gathered on Q3 2011 and a chemical plants nominal
capacity of 400 kta (thousand metric tons per year).
Source: Intratec www.intratec.us
Analysis Performed
Location Basis
Construction Scenarios
Intratec | About this Study
The economic analysis is based on the construction of a

plant partially integrated to a petrochemical complex. A
nearby unit continuously provides polymer-grade (PG)
propylene. Thus, no storage for propylene is required.
However, since there are no polypropylene consumers in
the complex, the product must be stored in warehouses
and silos. Facilities for supplying the required utilities are
also included in the analysis.
Petrochemical Complex
Since the Outside Battery Limits (OSBL) requirements

storage and utilities supply facilities significantly impact
the capital cost estimates for a new venture, they may play a
decisive role in the decision as to whether or not to invest.
Thus, in this study two distinct OSBL configurations are
compared. Those scenarios are summarized in Figure 1 and
Table 1.
The regional comparison analysis is performed for two

similar units operating on the US Gulf Coast. The main
difference between the two units is the price assumption
for PG propylene.
While the base case considers a stand-alone polypropylene
plant, obtaining PG propylene at average market prices,
available at Intratec database, the alternative scenario
defined by the client (referred as Client-Defined)
approaches a unit, which is integrated to an upstream
propylene plant, obtaining feedstock at a transfer price,
provided by the client, lower than market price.
The remaining prices are assumed to be the same. The
assumptions that distinguish the two scenarios analyzed in
this study are provided in Table 2.
Table 1 Construction Scenarios Assumptions (Based on Degree of Integration)
Storage Capacity (Area 700)

Feedstock & Chemicals
20 days of operation
Not included
End-products & By-products
All required
All required
Utility Facilities Included (Area 800)

Support & Auxiliary Facilities
(Area 900)
Control room, labs, gate house,

maintenance shops, warehouses, offices,
change house, cafeteria, parking lot
Control room, labs, maintenance shops,

warehouses
Design Conditions
Table 2 Locations & Pricing Basis
The process analysis is based on rigorous simulation models
developed on Aspentech Aspen Plus and Hysys, which
support the design of the chemical process, equipment and
OSBL facilities.
The design assumptions employed are depicted in Table 3.
Table 3 General Design Assumptions

Cooling water temperature
24 C
Cooling water range
11 C
Steam (Low Pressure)
7 bar abs
Wet Bulb Air Temperature
25 C

USD/manhour
Supervisor
USD/man-
Salaries
hour
Intratec | About this Study
Study Background
About Polypropylene
Polypropylene (PP) is a thermoplastic material formed by
the reaction of polymerization of propylene, resulting in a
macromolecule that contains from 10,000 to 20,000
monomer units. As a thermoplastic, PP is capable of
melting and flowing (in a reversible physical transformation)
when subjected to increases in temperature and pressure,
assuming a specified form when those conditions cease.
Based on its exceptional mechanical and thermal
properties, it is suitable for applications in fibers, injection
molding, thermoforming, film and blow molding.
In a qualitative approach, PP is a colorless, translucent to
transparent solid with a glossy surface, with very good
resistance to chemicals (except for hydrocarbons and
chloride compounds), greater scratch resistance than other
polyolefins, good environmental stress cracking resistance,
good processability via injection molding and extrusion,
and a low moisture absorption rate.
Polypropylene annual consumption worldwide exceeds 50
million tons, with an expanding market in its core
applications as well as in inter-material substitution. The
use of polypropylene has increased at rates slightly faster
than one of its main competitor materials, polyethylene;
while linear low and high density polyethylene are growing
faster than polypropylene, low density polyethylene drags
down overall polyethylene growth.
Intratec | Study Background
The discovery of polypropylene homopolymer is generally

credited to the independent work of Karl Ziegler and Giulio
Natta, in 1954. The organometallic catalyst system used
became known as Ziegler-Natta catalysts, still one of the
most remarkable components of PP production. Natta was
able to synthesize polypropylene and, additionally,
associate the resulting polymer high melting point with the
distribution of methyl groups along the carbon chain.
10
Phillips Petroleum was developing the polypropylene

technology concurrently with Nattas work and Phillips was
awarded the composition of matter patent in the US in
1983. Polypropylene producers around the world
celebrated on March 1, 2000 the day the Phillips patent
expired.
Unlike the symmetrical ethylene molecule, for example, the

way each propylene monomer unit links to the other
generates polymers with distinct characteristics. Those
structural chains can be summarized as follow:
Atactic. The pendant methyl groups are attached in a
random manner on the polymer backbone chain. At
room temperature, atactic polypropylene is a waxy and
tacky solid.
Isotactic. All the methyl groups are on the same side
of the winding spiral chain molecule. Since it is
difficult to completely control the polymerization
reaction, isotactic polypropylene always presents
atactic content. It is important to keep such content to
a minimum, to provide a higher stiffness and a wider
spectrum of applications.
Syndiotactic. The pendant methyl groups are
attached in an alternating pattern on the polymer
backbone chain. It is soft and clear, in addition to
having a good gloss, but its production costs are high
when compared to the other existing structural chains.
Only isotactic polypropylene has the requisite properties of
a useful commodity plastic material. Compared with HDPE
or LDPE, its higher stiffness at lower density and superior
working temperature when not subjected to mechanical
stress are key factors to isotactic polypropylenes
preferential use in certain applications. However, recently,
technological improvements in the catalyst system allowed
the synthesis of crystalline syndiotactic polymer.
Commercially, this kind of polypropylene is produced with a
metallocene catalyst system. Companies involved in
syndiotactic PP production claim that it has enhanced
properties, but a more detailed evaluation is yet to be made
for a proper comparison with isotactic PP. This kind of
information will be fundamental to determining the real
competitiveness of such material, through the balance of
better properties and its higher cost. Until now, the low
molecular mass atactic PP had only a few commercial
outlets for adhesives and roofing materials.
Types of Polypropylene Resins

Polypropylene production advances in both the
manufacturing process and catalyst allowed the creation of
three major types of resins: homopolymers, random

copolymers and impact (or block) copolymers. All PP
processes are capable of producing homopolymer and
random copolymer PP, and all require one or more
additional reactors to produce impact copolymer.
Homopolymers. Produced through polymerization of
propylene in the presence of a stereospecific catalyst,
homopolymers have an isotactic index in the range of
92-99%. As stiffness and resistance to impact are
directly dependent on the equilibrium between the
atactic and isotactic fractions, they are more rigid and
have better resistance to high temperatures than
copolymers, but with inferior impact strength below
0C. Thus, this kind of polymer is indicated for high
temperature applications such as hair dryer, sterilizers,
irons, coffee makers and toasters. Woven bags, fine
denier fibers, windshield washer tanks and shrouds for
fans toasters can also use homopolymers.
Random copolymers. Random copolymers are
obtained by copolymerization of propylene with
ethylene or higher olefins (e.g. butene-1), which
represents from 1.5 to 6 wt% of the product. Those
molecules are randomly dispersed along the carbon
chain by their addition during the reaction; the
resulting product offers improved impact strength and
clarity, as well as a softer feel. Typical applications of
random copolymer are films, injection-molding and
blow-molding. Typical applications are battery cases,
blow-molded bottles, bumper filler supports, interior
trim, glove boxes, package trays and window
moldings, video cassette boxes, office furniture,
disposable containers, boxes and appliance housings.
Applications
This combination of physical, chemical, mechanical, thermal
and electrical properties explains polypropylenes
immediate industrial application and continuous growth. In
terms of current global representativeness, polypropylene is
the second largest consumed plastic material after
polyethylene (PE) and before polyvinyl chloride (PVC).
Furthermore, PP processes are able to improve polymer
properties through orientation, i.e., the previously
mentioned methyl groups distribution. This unique aspect
is only found in a limited number of the other major plastics
(e.g. PET), and contributes to expanding the range of
polypropylene applications.
Table 4 lists polypropylene end-uses, as well as respective
examples, considering all the spectrum of grades that can
be produced varying methyl groups distribution,
copolymers and additives employed.
Table 4 Polypropylene End-uses
Film and sheet
Food packaging
Injection molding
Automotive components
Fibre
Medical garment and carpets
Blow molding
Bottles
Extrusion and piping
Civil piping
Raffia
Sports fabrics and bags
Polypropylene Manufacturing
Types of Process
In order to properly explain the technology involved in PP
manufacturing it is useful to define some concepts about
the forms in which propylene polymerization is conducted.
Traditionally, the following are the most representative:
Hydrocarbon Slurry or Suspension. Consists of using
a liquid inert hydrocarbon diluent in the reactor to
facilitate transfer of propylene to the catalyst, the
removal of heat from the system, the
deactivation/removal of the catalyst as well as
Impact copolymers. Similar to random copolymers,

impact copolymers use olefins other than propylene
for polymerization. The main difference is that
polymerization of those olefins occurs in another
reactor, forming a dispersed phase within the PP
matrix. Copolymers content in this kind of material
ranges from 5-25% and its large rubber content serves
to improve impact strength. This characteristic suits
impact copolymer for use in automotive and appliance
parts, industrial products and as compounds
blendstocks. Its used by automakers for door panels,
quarter-panel trim, lower trim, doors, seat shields,
pillars, headers, rib cartridges, head impact and air
bags.
11
dissolving the atactic polymer. The range of grades

that could be produced was very limited. (The
technology had fallen into disuse).
Bulk (or Bulk Slurry). Uses liquid propylene instead of
liquid inert hydrocarbon diluent. The polymer does
not dissolve into a diluent, but rather rides on the
liquid propylene. The formed polymer is withdrawn
and any unreacted monomer is flashed off.
Gas Phase. Uses gaseous propylene in contact with
the solid catalyst, resulting in a fluidized-bed medium.
Hybrid. Uses a slurry loop reactor followed by a gas
phase reactor, combining the bulk slurry and gas
phase processes.
The Role of Catalyst in Process

Technology for polypropylene manufacturing has kept pace
with the catalysts evolution. Traditionally, because of the
technical breakthrough that each one represented,
polypropylene catalysts are divided into generations. Table
5 depicts those advances, although this division may vary,
since the recognition of a breakthrough is, to some extent,
subjective. The plants built in the 1960s and 1970s using
hydrocarbon slurry process (based on the first generation
catalyst) were very cost-intensive because of the large
amount of equipment required for handling the solvent
related steps, the large space and complicated plot plans.
Also, labor requirements, energy inefficiency and catalyst

poor activity (1kg of polypropylene produced per gram of
catalyst) made production costs very high. In addition, PP
produced had very narrow range of applications due to its
poor properties.
Despite such high production costs, hydrocarbon slurry
process remained economically feasible in the following
years due to the advances in catalyst (second generation).
However, the introduction of the third generation enabled
the production of polypropylene via bulk slurry and via gas
phase in the late 1970`s.
Both processes presented much lower capital and
operating costs, since the steps related to hydrocarbon
solvent became unnecessary, simplifying plot plans and
significantly reducing space required. Third generation
catalyst provided yields of 12-15 kg of polypropylene per
gram of catalyst.
The fourth generation took polypropylene production to
the level of about 30kg of PP produced per gram of catalyst
employed. Such catalysts are currently the most popular in
the industry and have already achieved mileages as high as
120 kg of PP per gram of catalyst. The fifth and sixth
generations of catalysts are not still fully developed and
considerable effort is being to enable them to be fully
commercialized. Meanwhile, fourth generation catalysts are
still the most widely used in polypropylene production
Table 5 Catalyst Advances
1st (1957-1970)
3TiCl3AlCl3/AlEt2Cl
0.81.2
8891
2nd (1970-1978)
TiCl3/AlEt2Cl
35
95
3rd (1978-1980)
TiCl4/Ester/MgCl2 + AlEt3/Ester
515
98
2060
99
50120
99
59 x 103 (on Zr)
9099
59 x 103 (on Zr)
9099
TiCl4/Diester/MgCl2 + AlEt3/silane three

th
dimensional catalyst granule architecture
4 (1980) RGT
TiCl4/Diether/MgCl2 + AlEt3 three dimensional
catalyst granule architecture
12
Metallocenes
Zirconocene + MAO
Multicatalyst RGT (Reactor
Mixed catalysis: ZN + radical initiators, ZN +
Granule Technology)
single site (catalysts)
Figure 2 Polypropylene from Multiple Sources
Propylene
Polypropylene
(PP)
Bulk Phase Processes

LyondellBasell
Spheripol
Mitsui HYPOL II
ExxonMobil PP
Process
Gas Phase Process:
Fluidized Bed Reactor
Dow Unipol
Gas Phase Process:
Stirred Bed Reactor
Lummus
Novolen
INEOS Innovene
JPP Horizone
Gas Phase Process:
Multi-zone Circulation
Reactor
LyondellBasell
Spherizone
Hybrid Process
Borealis Borstar
Olefin polymerization in gas phase fluidized-bed reactors

has been recognized as being among the most economical
methods of manufacturing commodity polymers, including
polyethylene (PE), polypropylene (PP) and ethylenepropylene rubber (EPR). In the 1960s, BASF developed a gas
phase, mechanically stirred polymerization process for
making PP. In that process, the particle bed in the reactor
was either not fluidized or not fully fluidized.
In 1968, the first gas phase fluidized-bed polymerization

process, i.e., the UNIPOL Process, was commercialized by
Union Carbide to produce polyethylene. This process was
quickly licensed to other manufacturers. In the mid-1980s, it
was further extended to produce polypropylene.
The features of the fluidized-bed process, including its
simplicity and superior product quality, made it widely
accepted all over the world. As of today, the fluidized-bed
process is the dominant means of producing PE (especially
LLDPE), as is one of the two most widely used technologies
for producing PP.
Licensor & Historical Aspects
13
Technical Analysis
Chemistry
The main reaction that occurs in the polymerization of
propylene to polypropylene is shown in the following.
Propylene
Polypropylene
A Ziegler-Natta catalyst is utilized to achieve this. The

original catalyst for propylene polymerization was
aluminum alkyl and titanium trichloride, but much work has
been done to find better catalysts. The main objective is to
enable a controlled polymerization reaction with a narrow
molecular weight distribution of the product and enhanced
properties, as well as an increase in the catalyst productivity
(or mileage), defined as the kilograms of PP produced per
gram of catalyst.
The continuous back-mixed reactor operates at about 33
35 bara and contains a fluidized bed of granular
polypropylene with a trace of catalyst. Temperature is mild
(65 80C) and is controlled by adjusting the temperature
of the cycle gas returned to the reactor. An overall yield of
about 99+ wt% of propylene is expected.
Intratec | Technical Analysis
Raw Material
14
In terms of raw materials, polypropylene is the largest

downstream derivative made from propylene. Typically, PP
manufacturers use polymer grade (PG) propylene, with 99.5
wt% purity, as feedstock. Due to the high cost related to
transport of highly pressurized or refrigerated liquids,
propylene produced or purchased from local steam
crackers, FCC units or even on-purpose plants tends to be
most cost-effective. In some cases, propylene is refined to
achieve a purity compatible with the sensitivity of the
catalyst system and/or to avoid the accumulation of inert
substances.
The major PG propylene feed impurity is propane. Similar
to other inert components such as methane, nitrogen,
ethane and other higher alkanes, propane works as a
diluent to reduce polymerization rate, not having any other
adverse effect. Thus, the use of the propylene feed as

polymerization monomer is more impacted by the levels of
trace impurities, which affect the activity and
stereospecificity of propylene polymerization catalysts,
rather than specifically by the propane content.
The polymerization catalysts are sensitive to certain
impurities, including the oxygen, carbon monoxide, carbon
dioxide, water, and alcohols potentially present in the
various feed streams.
Based on the typical purity of raw materials available on the
US Gulf Coast, the following topics summarize the raw
materials and respective purification facilities required to
protect the catalyst against the effects of impurities.
Ethylene, Nitrogen, and Hydrogen: Filtration
Propylene: Two fixed bed dryers, one operating, one
on standby, for removal of water and other polar
impurities.
The purification steps included in the process are primarily
considered to be guard beds for spike protection. Bed life
between regenerations is relatively long (measured in
months, not days).
Technology Overview
The process is separated into three different areas:
purification & reaction; resin degassing & pelleting; and vent
recovery.
Fresh propylene and the other raw materials fed to the unit
are passed through the purification facilities, in which trace
quantities of impurities are removed. The purified raw
materials are then fed to the reaction system.
Only one reaction system, consisting of a fluidized bed
reactor, a cycle gas compressor and cooler, and product
discharge tanks, is required to produce homopolymer and
random copolymer. The raw materials and a recycle stream
from the vent recovery system are fed continuously to the
reactor. The cycle gas compressor circulates reaction gas
upward through the reactor, providing the agitation
required for fluidization, backmixing, and heat removal. No
mechanical stirrers or agitators are needed in the process
reactors. The cycle gas leaving overhead from the reactor
passes through the cooler that removes the heat of
reaction. Catalyst is continuously fed to the reactor.
Resulting granular polypropylene is removed from the

reactor by the discharge tanks and sent to a purge bin
where residual hydrocarbons are stripped with nitrogen
from the resin and are sent to the vent recovery system.
The purged resin is sent to the pelleting system.
The vent gas is processed to separate hydrocarbons and
nitrogen purge gas, which is returned to the process. The
condensed components are separated into a propylene
stream, which is returned to the reaction system, and a
propane stream.
Solid additives are metered and sent to the pelleting
system. The resin and the additives are mixed, melted and
pelleted in the pelleting system. The pellets are dried,
cooled and sent to product blending and storage.
Figure 3 Process Block Flow Diagram
Recovered Propylene
Recycled Nitrogen
PG Propylene
Area 100
Purification &
Reaction
Area 200
Resin Degassing &
Pelleting
Unreacted
Monomer
Area 300
Vent Recovery
Fresh Nitrogen
Polypropylene
Catalyst &
Chemicals
15
16
17
Key Consumptions
Table 6 - Raw Materials & Utilities Consumption (per ton

of product)
Table 7 Design & Simulation Assumptions

Labor Requirements
Table 8 Labor Requirements for a Typical Plant
Non-Integrated Plant
Partially Integrated Plant
18
Figure 4 Inside Battery Limits Conceptual Process Flow Diagram
19
Figure 3 Inside Battery Limits Conceptual Process Flow Diagram (Cont.)
20
P-303A/B
21
22
Information regarding utilities flow rates is provided in

Appendix B. Utilities Consumption Breakdown. For further
details on greenhouse gas emissions caused by this process,
see Appendix C. Process Carbon Footprint.
ISBL Major Equipment List

Table 10 shows the equipment list by area. It also presents
a brief description and the construction materials used.
Find main specifications for each piece of equipment in
Appendix D. Equipment Detailed List & Sizing.
Table 9 presents the main streams composition and

operating conditions. For a more complete material
balance, see the Appendix A. Mass Balance & Streams
Properties.
23
24
25
OSBL Major Equipment List
The OSBL is divided into three main areas: storage (Area

700), energy and water facilities (Area 800), and support &
auxiliary facilities (Area 900).
26
Table 11 shows the list of tanks located in the storage area

and the energy facilities considered in the construction of a
non-integrated unit.
27
28
Economic Analysis
General Assumptions
The general assumptions for the base case of this analysis
are outlined below.
Table 12 Base Case General Assumptions
In Table 12, the IC Index stands for Intratec chemical plant

Construction Index, an indicator, published monthly by
Intratec, to scale capital costs from one time period to
another.
This index reconciles prices trends of fundamental
components of a chemical plant construction such as labor,
material and energy, providing meaningful historical and
forecast data for our readers and clients.
The assumed operating hours per year indicated do not
represent any technology limitation; rather, it is an
assumption based on common industrial operating rates.
Additionally, Table 12 discloses assumptions regarding the
project complexity, technology maturity and data reliability,
which are of major importance for attributing reasonable
contingencies for the investment and for evaluating the
overall accuracy of estimates. Definitions and figures for
both contingencies and accuracy of economic estimates
can be found in this publication in the chapter Technology
Economics Methodology.
Figure 5 Project Implementation Schedule
Basic Engineering
Detailed Engineering
Procurement
Construction
Start-up
Intratec | Economic Analysis
Total EPC Phase
29
Project Implementation
Schedule
The main objective of knowing upfront the project
implementation schedule is to enhance the estimates for
both capital initial expenses and return on investment.
The implementation phase embraces the period from the
decision to invest to the start of commercial production.
This phase can be divided into five major stages: (1) Basic
Engineering, (2) Detailed Engineering, (3) Procurement, (4)
Construction, and (5) Plant Start-up.
The duration of each phase is detailed in Figure 5.
installation bulks). The total direct cost represents the total

bare equipment installed cost.
Table 14 shows the breakdown of the total fixed investment
(TFI) per item (direct & indirect costs and process
contingencies).
Appendix E. Detailed Capital Expenses provides a detailed
breakdown for the direct expenses, outlining the share of
each type of equipment in total.
Table 14 Total Fixed Investment Breakdown (USD

Thousands)
Capital Expenditures
Fixed Investment
Table 13 shows the bare equipment cost associated with
each area of the project.
Table 13 - Bare Equipment Cost per Area (USD

Thousands)
30
Table 14 presents the breakdown of the total fixed

investment (TFI) per item (direct & indirect costs and
process contingencies). For further information about the
components of the TFI please see the chapter Technology
Economics Methodology.
Fundamentally, the direct costs are the total direct material
and labor costs associated with the equipment (including
After defining the total direct cost, the TFI is established by

adding field indirects, engineering costs, overhead, contract
fees and contingencies.
It is important to emphasize that capital expenditures for

the propylene plant are not included in the present study.
Indirect costs are defined by the American Association of
Cost Engineers (AACE) Standard Terminology as those
"costs which do not become a final part of the installation
but which are required for the orderly completion of the
installation."
For example, if there are nearby facilities consuming a units

final product or supplying a units feedstock, the need for
storage facilities significantly decreases, along with the total
fixed investment required. This is also true for support
facilities that can serve more than one plant in the same
complex, such as a parking lot, gate house, etc.
This study analyzes the total fixed investment for two
distinct scenarios regarding OSBL facilities:
The indirect project expenses are further detailed in

Appendix E. Detailed Capital Expenses.
Non Integrated Plant
Alternative OSBL Configurations
Plant Partially Integrated
The total fixed investment for the construction of a new

chemical plant is greatly impacted by how well it will be
able to take advantage of the infrastructure already installed
in that location.
The detailed definition, as well as the assumptions used for

each scenario is presented in the chapter About this
Study.
The influence of the OSBL facilities on the capital
investment is depicted in Figure 6 and in Figure 7.
Figure 6 Total Direct Cost of Different Integration Scenarios (USD Thousands)
31
Figure 7 Total Fixed Investment of Different Integration Scenarios (USD Thousands)
Table 15 Working Capital (USD Million)
Other Capital Expenses
32
Start-up costs should also be considered when determining

the total capital expenses. During this period, expenses are
incurred for employee training, initial commercialization
costs, manufacturing inefficiencies and unscheduled plant
modifications (adjustment of equipment, piping,
instruments, etc.).
Figure 8 Total Fixed Investment Validation (USD Million)
Initial costs are not addressed in most studies on estimating

but can become a significant expenditure. For instance, the
initial catalyst load in reactors may be a significant cost and,
in that case, should also be included in the capital
estimates.
The purchase of technology through paid-up royalties or
licenses is considered to be part of the capital investment.
Other capital expenses frequently neglected are land

acquisition and site development. Although these are small
parts of the total capital expenses, they should be included.
A summary of other capital expenses is presented in Table
16. Assumptions used to calculate them are provided in
Appendix F. Economic Assumptions.
Total Capital Expenses

Table 16 Other Capital Expenses (USD Million)
Table 17 presents a summary of the total Capital

Expenditures (CAPEX) detailed in previous sections.

Table 17 CAPEX (USD Million)
33
Operational Expenditures
Table 18 Manufacturing Fixed Cost (USD/ton)
Manufacturing Costs
The manufacturing costs, also called Operational
Expenditures (OPEX), are composed of two elements: a fixed
cost and a variable cost. All figures regarding operational
costs are presented in USD per ton of product.
Table 18 shows the manufacturing fixed cost, while Table 19
details the manufacturing variable cost breakdown.
To learn more about the assumptions for manufacturing

fixed costs, see the Appendix F. Economic Assumptions.
Table 20 shows the OPEX of the presented technology.
Table 19 Manufacturing Variable Cost (USD/ton)

Table 20 OPEX (USD/ton)
Historical Analysis
Figure 9 depicts Sales and OPEX historic data. Figure 10

compares the project EBITDA trends with Intratec
Profitability Indicators (IP Indicators). The Basic Chemicals IP
Indicator represents basic chemicals sector profitability,
based on the weighted average EBITDA margins of major
global basic chemicals producers. Alternately, the Chemical
Sector IP Indicator reveals the overall chemical sector
profitability, through a weighted average of the IP Indicators
calculated for three major chemical industry niches: basic,
specialties and diversified chemicals.
Economic Datasheet
34
The Technology Economic Datasheet, presented in Table

21, is an overall evaluation of the technology's production
costs in a US Gulf Coast based plant.
The expected revenues in products sales and initial
economic indicators are presented for a short-term
assessment of its economic competitiveness.
Figure 9 OPEX and Product Sales History (USD/ton)
Figure 10 EBITDA Margin & IP Indicators History Comparison
35
36
Regional Comparison & Economic Discussion

Regional Comparison
Capital Expenses
Variations in productivity, labor costs, local steel prices,
equipment imports needs, freight, taxes and duties on
imports, regional business environments and local
availability of sparing equipment were considered when
comparing capital expenses for the different regions under
consideration in this report.
Capital costs are adjusted from the base case (a plant
constructed on the US Gulf Coast) to locations of interest by
using location factors calculated according to the items
aforementioned. For further information about location
factor calculation, please examine the chapter Technology
Economics Methodology. In addition, the location factors
for the regions analyzed are further detailed in Appendix F.
Economic Assumptions.
Figure 11 summarizes the total Capital Expenditures

(CAPEX) for the locations under analysis.
Operational Expenditures
Specific regional conditions influence prices for raw
materials, utilities and products. Such differences are thus
reflected in the operating costs. An OPEX breakdown
structure for the different locations approached in this study
is presented in Figure 12.
Economic Datasheet
The Technology Economic Datasheet, presented in Table
22, is an overall evaluation of the technology's capital
investment and production costs in the alternative location
analyzed in this study.
Intratec | Regional Comparison & Economic Discussion
Figure 11 CAPEX per Location (USD Million)
37
Figure 12 Operating Costs Breakdown per Location (USD/ton)
38
39
Intratec | References
References
40
Acronyms, Legends & Observations

AACE: American Association of Cost Engineers
LLDPE: Linear Low Density Polyethylene
C: Distillation, stripper, scrubber columns (e.g., C-101 would

denote a column tag)
OPEX: Operational Expenditures

OSBL: Outside battery limits
C2, C3, ... Cn: Hydrocarbons with "n" number of carbon

atoms
P: Pumps (e.g., P-101 would denote a pump tag)
CAPEX: Capital expenditures
PDH: Propane dehydrogenation
CC: Distillation column condenser
PE: Polyethylene
CP: Distillation column reflux pump
PG: Polymer grade
CR: Distillation column reboiler
PP: Polypropylene
CT: Cooling tower
PSA: Pressure swing adsorption
CV: Distillation column accumulator drum
PVC: Polyvinyl chloride
E: Heat exchangers, heaters, coolers, condensers, reboilers

(e.g., E-101 would denote a heat exchanger tag)
R: Reactors, treaters (e.g., R-101 would denote a reactor tag)

ROCE: Return on the capital employed
EBIT: Earnings before Interest and Taxes

SB: Steam boiler
EBITDA: Earnings before Interests, Taxes, Depreciation and
Amortization
T: Tanks (e.g., T-101 would denote a tank tag)
EPR: Ethylene-propylene rubber
TFI: Total Fixed Investment
F: Filter(e.g., F-101 would denote a filter tag)
TPC: Total process capital
FCC: Fluid catalytic cracking
V: Horizontal or vertical drums, vessels (e.g., V-101 would

denote a vessel tag)
HDPE: High Density Polyethylene

IC Index: Intratec Chemical Plant Construction Index
WD: Demineralized water
IP Indicator: Intratec Chemical Sector Profitability Indicator
ISBL: Inside battery limits
X: Special equipment (e.g., X-101 would denote a special

equipment tag)
K: Compressors, blowers, fans (e.g., K-101 would denote a

compressor tag)
Obs.: 1 ton = 1 metric ton = 1,000 kg
kta: thousands metric tons per year
LDPE: Low Density Polyethylene
Intratec | Acronyms, Legends & Observations
VOC: Volatile organic compounds
41
Technology Economics Methodology

Intratec Technology Economics methodology
ensures a holistic, coherent and consistent
techno-economic evaluation, ensuring a clear
understanding of a specific mature chemical
process technology.
Introduction
The same general approach is used in the development of
all Technology Economics assignments. To know more
about Intratecs methodology, see Figure 14.
While based on the same methodology, all Technology
Economics studies present uniform analyses with identical
structures, containing the same chapters and similar tables
and charts. This provides confidence to everyone interested
in Intratecs services since they will know upfront what they
will get.
Workflow
Once the scope of the study is fully defined and
understood, Intratec conducts a comprehensive
bibliographical research in order to understand technical
aspects involved with the process analyzed.
Intratec | Technology Economics Methodology
Subsequently, the Intratec team simultaneously develops

the process description and the conceptual process flow
diagram based on:
42
a.
Patent and technical literature research
b.
Non-confidential information provided by technology

licensors
c.
Intratec's in-house database
d.
Process design skills
Next, all the data collected are used to build a rigorous

steady state process simulation model in Aspen Hysys
and/or Aspen Plus, leading commercial process
flowsheeting software tools.
From this simulation, material balance calculations are

performed around the process, key process indicators are
identified and main equipment listed.
Equipment sizing specifications are defined based on
Intratec's equipment design capabilities and an extensive
use of AspenONE Engineering Software Suite that enables
the integration between the process simulation developed
and equipment design tools. Both equipment sizing and
process design are prepared in conformance with generally
accepted engineering standards.
Then, a cost analysis is performed targeting ISBL & OSBL
fixed capital costs, manufacturing costs, and overall working
capital associated with the examined process technology.
Equipment costs are primarily estimated using Aspen
Process Economic Analyzer (formerly Aspen Icarus)
customized models and Intratec's in-house database.
Cost correlations and, occasionally, vendor quotes of unique
and specialized equipment may also be employed. One of
the overall objectives is to establish Class 3 cost estimates 1
with a minimum design engineering effort.
Next, capital and operating costs are assembled in Microsoft
Excel spreadsheets, and an economic analysis of such
technology is performed.
Finally, two analyses are completed, examining:
a.
The total fixed investment in different construction

scenarios, based on the level of integration of the plant
with nearby facilities
b.
The capital and operating costs for a second different

plant location
These are estimates that form the basis for budget authorization,
appropriation, and/or funding. Accuracy ranges for this class of
estimates are + 10% to + 30% on the high side, and - 10 % to - 20 %
on the low side.
Figure 13 Methodology Flowchart
Study Understanding Validation of Project Inputs

Patent and Technical
Literature Databases
Non-Confidential
Information from
Technology Licensors or
Suppliers
Bibliographical Research
Technical Validation
Process Description &
Flow Diagram
Vendor Quotes
Material & Energy Balances, Key

Process Indicators, List of
Equipment & Equipment Sizing
Pricing Data Gathering: Raw

Materials, Chemicals,
Utilities and Products
Capital Cost (CAPEX)

& Operational Cost (OPEX)
Estimation
Construction Location
Factor
(http://base.intratec.us)
Economic Analysis
Analyses of
Different Construction
Scenarios and Plant Location
Project Development Phases

Information Gathering / Tools
Final Review &

Adjustments
Aspen Plus, Aspen Hysys

Aspen Exchanger Design &
Rating, KG Tower, Sulcol
and Aspen Energy Analyzer
Aspen Process Economic

Analyzer, Aspen Capital
Cost Estimator, Aspen InPlant Cost Estimator &
Intratec In-House Database
Intratec Internal Database
43
Capital & Operating Cost

Estimates
Process equipment (e.g., reactors and vessels, heat

exchangers, pumps, compressors, etc.)
Process equipment spares
The cost estimate presented in the current study considers

a process technology based on a standardized design
practice, typical of a major chemical company. The specific
design standards employed can have a significant impact
on capital costs.
The basis for the capital cost estimate is that the plant is
considered to be built in a clear field with a typical large
single-line capacity. In comparing the cost estimate hereby
presented with an actual project cost or contractor's
estimate, the following must be considered:
Minor differences or details (many times, unnoticed)
between similar processes can affect cost noticeably.
The omission of process areas in the design considered
may invalidate comparisons with the estimated cost
presented.
Industrial plants may be overdesigned for particular
objectives and situations.
Rapid fluctuation of equipment or construction costs
may invalidate cost estimate.
Equipment vendors or engineering companies may
provide goods or services below profit margins during
economic downturns.
Specific locations may impose higher taxes and fees,
which can impact costs considerably.
Housing for process units

Pipes and supports within the main process units
Instruments, control systems, electrical wires and other
hardware
Foundations, structures and platforms
Insulation, paint and corrosion protection
In addition to the direct material and labor costs, the ISBL
addresses indirect costs, such as construction overheads,
including: payroll burdens, field supervision, equipment
rentals, tools, field office expenses, temporary facilities, etc.
OSBL Investment
The OSBL investment accounts for auxiliary items necessary
to the functioning of the production unit (ISBL), but which
perform a supporting and non-plant-specific role. OSBL
items considered may vary from process to process. The
OSBL investment could include the installed cost of the
following items:
Storage and packaging (storage, bagging and a
warehouse) for products, feedstocks and by-products
Steam units, cooling water and refrigeration systems
Process water treating systems and supply pumps
44
In addition, no matter how much time and effort are

devoted to accurately estimating costs, errors may occur
due to the aforementioned factors, as well as cost and labor
changes, construction problems, weather-related issues,
strikes, or other unforeseen situations. This is partially
considered in the project contingency. Finally, it must
always be remembered that an estimated project cost is not
an exact number, but rather is a projection of the probable
cost.
ISBL Investment
The ISBL investment includes the fixed capital cost of the
main processing units of the plant necessary to the
manufacturing of products. The ISBL investment includes
the installed cost of the following items:
Boiler feed water and supply pumps

Electrical supply, transformers, and switchgear
Auxiliary buildings, including all services and
equipment of: maintenance, stores warehouse,
laboratory, garages, fire station, change house,
cafeteria, medical/safety, administration, etc.
General utilities including plant air, instrument air, inert
gas, stand-by electrical generator, fire water pumps,
etc.
Pollution control, organic waste disposal, aqueous
waste treating, incinerator and flare systems
For the purposes of this study, 2 working capital is defined as

the funds, in addition to the fixed investment, that a
company must contribute to a project. Those funds must
be adequate to get the plant in operation and to meet
subsequent obligations.
The initial amount of working capital is regarded as an
investment item. This study uses the following
items/assumptions for working capital estimation:
Accounts receivable. Products and by-products
shipped but not paid by the customer; it represents
the extended credit given to customers (estimated as a
certain period in days of manufacturing expenses
plus depreciation).
Accounts payable. A credit for accounts payable such
as feedstock, catalysts, chemicals, and packaging
materials received but not paid to suppliers (estimated
as a certain period in days of manufacturing
expenses).
Product inventory. Products and by-products (if
applicable) in storage tanks. The total amount depends
on sales flow for each plant, which is directly related to
plant conditions of integration to the manufacturing of
products derivatives (estimated as a certain period in
days of manufacturing expenses plus depreciation,
defined by plant integration circumstances).
Cash on hand. An adequate amount of cash on hand

to give plant management the necessary flexibility to
cover unexpected expenses (estimated as a certain
period in days of manufacturing expenses).
Start-up Expenses
When a process is brought on stream, there are certain onetime expenses related to this activity. From a time
standpoint, a variable undefined period exists between the
nominal end of construction and the production of quality
product in the quantity required. This period is commonly
referred to as start-up.
During the start-up period expenses are incurred for
operator and maintenance employee training, temporary
construction, auxiliary services, testing and adjustment of
equipment, piping, and instruments, etc. Our method of
estimating start-up expenses consists of four components:
Labor component. Represents costs of plant crew
training for plant start-up, estimated as a certain
number of days of total plant labor costs (operators,
supervisors, maintenance personnel and laboratory
labor).
Commercialization cost. Depends on raw materials
and products negotiation, on how integrated the plant
is with feedstock suppliers and consumer facilities, and
on the maturity of the technology. It ranges from 0.5%
to 5% of annual manufacturing expenses.
Raw material inventory. Raw materials in storage

tanks. The total amount depends on raw material
availability, which is directly related to plant conditions
of integration to raw material manufacturing
(estimated as a certain period in days of raw
material delivered costs, defined by plant integration
circumstances).
Start-up inefficiency. Takes into account those

operating runs when production cannot be
maintained or there are false starts. The start-up
inefficiency varies according to the process maturity:
5% for new and unproven processes, 2% for new and
proven processes, and 1% for existing licensed
processes, based on annual manufacturing expenses.
In-process inventory. Material contained in pipelines

and vessels, except for the material inside the storage
tanks (assumed to be 1 day of manufacturing
expenses).
Unscheduled plant modifications. A key fault that

can happen during the start-up of the plant is the risk
that the product(s) may not meet specifications
required by the market. As a result, equipment
modifications or additions may be required.
Supplies and stores. Parts inventory and minor spare

equipment (estimated as a percentage of total
maintenance materials costs for both ISBL and OSBL).
2
The accounting definition of working capital (total current assets
minus total current liabilities) is applied when considering the
entire company.
Working Capital
45
Other Capital Expenses

Prepaid Royalties. Royalty charges on portions of the
plant are usually levied for proprietary processes. A
value ranging from 0.5 to 1% of the total fixed
investment (TFI) is generally used.
Site Development. Land acquisition and site
preparation, including roads and walkways, parking,
railroad sidings, lighting, fencing, sanitary and storm
sewers, and communications.
Manufacturing Costs
Manufacturing costs do not include post-plant costs, which
are very company specific. These consist of sales, general
and administrative expenses, packaging, research and
development costs, and shipping, etc.
Operating labor and maintenance requirements have been
estimated subjectively on the basis of the number of major
equipment items and similar processes, as noted in the
literature.
Plant overhead includes all other non-maintenance (labor
and materials) and non-operating site labor costs for
services associated with the manufacture of the product.
Such overheads do not include costs to develop or market
the product.
G & A expenses represent general and administrative costs
incurred during production such as: administrative
salaries/expenses, research & development, product
distribution and sales costs.
Contingencies
46
Contingency constitutes an addition to capital cost

estimations, implemented based on previously available
data or experience to encompass uncertainties that may
incur, to some degree, cost increases. According to
recommended practice, two kinds of contingencies are
assumed and applied to TPC: process contingency and
project contingency.
Process contingency is utilized in an effort to lessen the
impact of absent technical information or the uncertainty of
that which is obtained. In that manner, the reliability of the
information gathered, its amount and the inherent
complexity of the process are decisive for its evaluation.
Errors that occur may be related to:
Uncertainty in process parameters, such as severity of

operating conditions and quantity of recycles
Addition and integration of new process steps
Estimation of costs through scaling factors
Off-the-shelf equipment
Hence, process contingency is also a function of the
maturity of the technology, and is usually a value between
5% and 25% of the direct costs.
The project contingency is largely dependent on the plant
complexity and reflects how far the conducted estimation is
from the definitive project, which includes, from the
engineering point of view, site data, drawings and sketches,
suppliers quotations and other specifications. In addition,
during construction some constraints are verified, such as:
Project errors or incomplete specifications
Strike, labor costs changes and problems caused by
weather
Table 23 Project Contingency

Plant Complexity
Complex
Typical
Simple
Project Contingency
25%
20%
15%
Intratecs definitions in relation to complexity and maturity

are the following:
Table 24 Criteria Description
Simple
Complexity
Typical
Somewhat simple, widely known

processes
Regular process
Several unit operations, extreme
Complex
temperature or pressure, more

instrumentation
New &
Maturity
Proven
Licensed
From 1 to 2 commercial plants

3 or more commercial plants
Accuracy of Economic Estimates

The accuracy of estimates gives the realized range of plant
cost. The reliability of the technical information available is
of major importance.
Table 25 Accuracy of Economic Estimates
Reliability
Accuracy
Very
Low
Moderate
High
+ 30%
+ 22%
+ 18%
+ 10%
- 20%
- 18%
- 14%
- 10%
High
The non-uniform spread of accuracy ranges (+30 to 20 %,

rather than 25%, e.g.) is justified by the fact that the
unavailability of complete technical information usually
results in under estimating rather than over estimating
project costs.
Location Factor
A properly estimated location factor is a powerful tool, both

for comparing available investment data and evaluating
which region may provide greater economic attractiveness
for a new industrial venture. Considering this, Intratec has
developed a well-structured methodology for calculating
Location Factors, and the results are presented for specific
regions capital costs comparison.
Intratecs Location Factor takes into consideration the
differences in productivity, labor costs, local steel prices,
equipment imports needs, freight, taxes and duties on
imported and domestic materials, regional business
environments and local availability of sparing equipment.
For such analyses, all data were taken from international
statistical organizations and from Intratecs database.
Calculations are performed in a comparative manner, taking
a US Gulf Coast-based plant as the reference location. The
final Location Factor is determined by four major indexes:
Business Environment, Infrastructure, Labor, and Material.
The Business Environment Factor and the Infrastructure
Factor measure the ease of new plant installation in
different countries, taking into consideration the readiness
of bureaucratic procedures and the availability and quality
of ports or roads.
A location factor is an instantaneous, total cost factor used

for converting a base project cost from one geographic
location to another.
Relative Steel Prices

Labor Index
Taxes and Freight
Rates
Spares
Taxes and Freight
Rates
Spares
Relative Salary
Productivity
Ports, Roads, Airports

and Rails (Availability
and Quality)
Communication
Technologies
Warehouse
Infrastructure
Border Clearance
Local Incentives
Readiness of
Bureaucratic
Procedures
Legal Protection of
Investors
Taxes
Figure 14 Location Factor Composition
47
Labor and material, in turn, are the fundamental

components for the construction of a plant and, for this
reason, are intrinsically related to the plant costs. This
concept is the basis for the methodology, which aims to
represent the local discrepancies in labor and material.
Productivity of workers and their hourly compensation are
important for the project but, also, the qualification of
workers is significant to estimating the need for foreign
labor.
On the other hand, local steel prices are similarly important,
since they are largely representative of the costs of
structures, piping, equipment, etc. Considering the
contribution of labor in these components, workers
qualifications are also indicative of the amount that needs
to be imported. For both domestic and imported materials,
a Spare Factor is considered, aiming to represent the need
for spare rotors, seals and parts of rotating equipment.
The sum of the corrected TFI distribution reflects the relative
cost of the plant, this sum is multiplied by the Infrastructure
and the Business Environment Factors, yielding the Location
Factor.
For the purpose of illustrating the conducted methodology,

a block flow diagram is presented in Figure 15 in which the
four major indexes are presented, along with some of their
components.
48
(kJ/kg K)
Liquid Thermal
Conductivity (W/m K)
Liquid Heat Capacity
(kJ/kg K)
Intratec | Appendix A. Mass Balance & Streams Properties
Gas Heat Capacity
49
50
51
52
53
54
Intratec | Appendix B. Utilities Consumption Breakdown
Appendix C. Process Carbon Footprint

The process carbon footprint can be defined as the total
amount of greenhouse gas (GHG) emissions caused by the
process operation.
Although it is difficult to precisely account for the total
emissions generated by a process, it is possible to estimate
the major emissions, which can be divided into:
The assumptions for the process carbon footprint

calculation are presented in Table 28 and the results are
provided in Table 29.
Table 29 CO2e Emissions (ton/ton prod.)
Direct emissions. Emissions caused by process waste

streams combusted in flares.
Indirect emissions. The ones caused by utilities
generation or consumption, such as the emissions due
to using fuel in furnaces for heating process streams.
Fuel used in steam boilers, electricity generation, and
any other emissions in activities to support process
operation are also considered indirect emissions.
In order to estimate the direct emissions, it is necessary to
know the composition of the streams, as well as the
oxidation factor.
Estimation of indirect emissions requires specific data,
which depends on the plant location, such as the local
electric power generation profile, and on the plant
resources, such as the type of fuel used.
Equivalent carbon dioxide (CO2e) is a measure that

describes the amount of CO2 that would have the same
global warming potential of a given greenhouse gas, when
measured over a specified timescale.
All values and assumptions used in calculations are based
on data provided by the Environment Protection Agency
(EPA) Climate Leaders Program.
Intratec | Appendix C. Process Carbon Footprint
Table 28 Assumptions for CO2e Emissions Calculation
55
56
Intratec | Appendix D. Equipment Detailed List & Sizing
57
58
59
Table 39 Vessels & Tanks (Cont.)
60
61
Appendix E. Detailed Capital Expenses

Direct Costs Breakdown
Figure 15 ISBL Direct Costs Breakdown by Equipment Type (Base Case)
Intratec | Appendix E. Detailed Capital Expenses
Figure 16 OSBL Direct Costs by Equipment Type (Base Case)
62
63
Intratec | Appendix E. Detailed Capital Expenses
Appendix F. Economic Assumptions

Capital Expenditures
Working Capital
For a better description of working capital and other capital

expenses components, as well as the location factors
methodology, see the chapter Technology Economics
Methodology.
Table 41 Working Capital Assumptions (Base Case)
Construction Location Factors
Table 40 Detailed Construction Location Factor
Table 42 Other Capital Expenses Assumptions (Base

Case)
days of all labor
Intratec | Appendix F. Economic Assumptions
costs
64

Operational Expenses
Fixed Costs
Fixed costs are estimated based on the specific
characteristics of the process. The fixed costs, like operating
charges and plant overhead, are typically calculated as a
percentage of the industrial labor costs, and G & A expenses
are added as a percentage of the operating costs.
Table 43 Other Fixed Cost Assumptions
Intratec | Appendix F. Economic Assumptions
Table 44 Depreciation Value & Assumptions
65
Appendix G. Latest & Upcoming Reports

The list below is intended to be an easy and quick way to
identify Intratec reports of interest. For a more complete
and up-to-date list, please visit the Publications section on
our website, www.intratec.us.
TECHNOLOGY ECONOMICS
Propylene Production via Metathesis: Propylene
production via metathesis from ethylene and butenes,
in a process similar to Lummus OCT.
Propylene Production via Propane
Dehydrogenation: Propane dehydrogenation (PDH)
process conducted in moving bed reactors, in a
process similar to UOP OLEFLEX.
Propylene Production from Methanol: Propylene
production from methanol, in a process is similar to
Lurgi MTP.
Polypropylene Production via Gas Phase Process: A
gas phase type process similar to the Dow UNIPOL PP
process to produce both polypropylene homopolymer
and random copolymer.
Polypropylene Production via Gas Phase Process,
Part 2: A gas phase type process similar to Lummus
NOVOLEN for production of both homopolymer and
random copolymer.
Intratec | Appendix G. Latest & Upcoming Reports

Dehydrogenation, Part II: Propane dehydrogenation
(PDH) in fixed bed reactors, in a process is similar to
Lummus CATOFIN.
66
Sodium Hypochlorite Chemical Production: Sodium

hypochlorite (bleach) production, in a widely used
industrial process, similar to that employed by Solvay
Chemicals, for example.
Dehydrogenation, Part III: Propane dehydrogenation
(PDH) by applying oxydehydrogenation, in a process
similar to the STAR PROCESS licensed by Uhde.
CONCEPTUAL DESIGN
Membranes on Polyolefins Plants Vent Recovery:
The Report evaluates membrane units for the
separation of monomers and nitrogen in PP plants,
similar to the VaporSep system commercialized by
MTR.
Use of Propylene Splitter to Improve Polypropylene
Business: The report assesses the opportunity of
purchasing the less valued RG propylene to produce
the PG propylene raw material used in a PP plant.
Appendix H.
Technology Economics Form
Submitted by Client
Chemical Produced by the Technology to be Studied

Define the main chemical product of your interest. Possible choices are presented below.
Choose a Chemical
Acetic Acid
Acetone
Acrylic Acid
Acrylonitrile
Adipic Acid
Aniline
Benzene
Butadiene
n-Butanol
Isobutylene
Caprolactam
Chlorine
Cumene
Dimethyl Ether (DME)
Ethanol
Ethylene
Bio-Ethylene
Ethylene Glycol
Ethylene Oxide
Formaldehyde
HDPE
Isoprene
LDPE
LLDPE
MDI
Methanol
Methyl Methacrylate
Phenol
Polypropylene (PP)
Polybutylene Terephthalate
Polystyrene (PS)
Polyurethanes (PU)
Polyvinyl Chloride (PVC)
Propylene
Propylene Glycol
Propylene Oxide (PO)
Terephthalic Acid
Vinyl Chloride (VCM)
If the main chemical product of your target technology is not found above, please check the "Technology Economic Form - Specialties".
Chemical Process Technology to be Studied

Identify the mature chemical process technology you would like us to assess. Intratec considers mature technologies the ones already used on
a commercial scale plant.
Technology Description
Gas phase technology - similar to Dow UNIPOL

E. g. technology for propylene production from methanol - similar to Lurgi MTP
Commercial Scale Unit. Inform the exact location of one commercial scale plant under operation.
Plant Location:
I don't know
I know the location of a commercial plant:
New Jersey, USA
If there is no commercial scale plant based on the technology of your interest, you are referred to Intratec's Research Potential advisory service
at www.intratec.us/advisory/research-potential/overview
Industrial Unit Description

Plant Nominal Capacity
Operating Hours
Inform the plant capacity to be considered in the study. Provide

the main product capacity in kta (thousands of metric tons per
year of main chemical product).
Plant Capacity
150 kta
Operating Hours
300 kta
Other (kta)
Inform the assumption for the number of hours the plant

operates in a year.
8,000 h/year
Other (h/year)
400
Analysis Date
Define the date (quarter and year) that will be considered in the analysis. Our databases can provide consolidated values from the year 2000
up to the last closed quarter, quarter-to-date values are estimated.
Quarter
Year
Q3
2011
Storage Facilities
Define the assumptions employed for the storage facilities design.
Products
20 days
By-Products
20 days
Other
Other
Raw Materials
20 days
Other
Utilities Supply Facilities

The construction of supply facilities for the utilities required (e.g. cooling tower, boiler unit, refrigeration unit) impacts the capital investment
for the construction of the unit.
Consider construction of supply facilities ?
Yes
No
General Design Conditions

General utilities and environmental conditions that may be relevant to the process simulation are presented below. Provide other assumptions if
you deem necessary.
Specification
Unit
Default Value
User-specified value
Cooling water temperature
24
DSPEC1
Cooling water range
11
DSPEC2
bar abs
DSPEC3
Steam (Medium Pressure)
bar abs
11
DSPEC4
Steam (High Pressure)
bar abs
28
DSPEC5
Refrigerant (Ethylene)
-100
DSPEC6
Refrigerant (Propane)
-40
DSPEC7
Refrigerant (Propylene)
-45
DSPEC8
Dry Bulb Air Temperature
38
DSPEC9
Wet Bulb Air Temperature
25
DS10
Industrial Unit Location

The location of an industrial unit influences in prices for both construction and operation of the unit. In this study, the economic
performances of TWO similar units erected in different locations are compared.
The first plant is located in the United States (US Gulf Coast) and the second location is defined by YOU.
Plant Location
I would like to keep the plant location confidential.

Country (or region) to be considered.
United States
E.g. Louisiana (USA), China or Saudi Arabia. Please define only one location.
Plant Location Data
Provider
I will use Intratec's Internal Database containing standard chemical prices and location factors
(only for Germany, Japan, China or Brazil).
I will provide location specific data. Please fill the Custom Location topic below.
Custom Location Description. Describe both capital investment and prices at your custom location.
A) Capital Investment. Provide the relative capital cost at your custom location in comparison to the United States (U.S. Gulf Coast)
Custom Location Relative Cost (%)
130% means that the capital costs in the custom location are 30% higher than the costs in the United States.
B) Raw Materials Prices. Describe the raw material prices to be considered in the custom location.
Item Description
Raw1
Polymer grade Propylene
Price Unit
RU1
USD/metric ton
Price
RP1
Raw2
RU2
RP2
Raw3
RU3
RP3
E.g.
Propane
USD/metric ton
420
C) Product Prices. Describe the products prices to be considered in the custom location.
Item Description
Price Unit
Price
Prod1
PU1
PP1
Prod2
PU2
PP2
Prod3
PU3
PP3
E.g.
Polypropylene
USD/metric ton
1700
D) Utilities Prices. Describe the utilities prices to be considered in the custom location.
Item Description
Price Unit
Price
Electricity
UP1
UP2
Steam (High Pressure)
UP3
Fuel
UP4
Clarified Water
UP5
Util6
UU6
YP6
Util7
UU7
UP7
Util8
UU8
UP8
E) Labor Prices. Describe the labor prices to be considered in the custom location.
Item Description
Price Unit
Price
Operating Labor
USD/operator/hour
LP1
Supervision Labor
USD/supervisor/hour
LP1
F) Others. Describe any other price you deem necessary to be considered in the custom location.
Item Description
Price Unit
Price
Other1
OU1
OP1
Other2
OU2
OP2
Other3
OU3
OP3
E.g.
Catalyst
USD/metric ton
5000
Other Remarks
If you have any other comments, feel free to write them below:
Co
m
m
en
ts:
I have filled just the propylene price field, because a propylene source already exists and may provide propylene at prices below
market average. Regarding the reamining prices, please use the same of your internal database for the US Gulf.
Complementary Files
Along with this form, you may also upload any other chemical document deemed relevant for the description of the project, such as
articles, brochures, book sections, patents, etc. Multiple files may be uploaded.
If you are filling this form offline please upload this form and any complementary files at www.intratec.us/advisory/technology-economics/
order-commodities
Non-Disclosure Period & Pricing

You can keep your study confidential or get discounts, by allowing Intratec to disclose it to the market as a publication, after an
agreed non-disclosure period, starting at the date you place your order.
Choose an Option
6 months
24 months
36 months
Never Disclosed
Non-Disclosure Period
Price
6 months
$8,000 (9 x $899)
Save 84%
24 months
$28,000 (9 x $3,111)
Save 44%
automatically, in equal and pre-defined installments
36 months
$40,000 (11 x $3,636)
Save 20%
- Every 15 days, an installment will be charged to your
Never Disclosed
$50,000 (13 x $3,846)
- Payment of our advisory service is conducted
credit card or PayPal account.
Pay Less! Benefit From a 5% Discount

Inform us the email address of the Intratec Agent that introduced you to our advisory services you will benefit from a 5% discount on the total
price of your service. To know more about Intratec New Business Development Agents, please visit www.intratec.us/be-our-agent.
Intratec Agent Email
Evaluate our Intratec Agent. Your opinion will be kept confidential.

Unsatisfied
Knowledge about Intratec
offerings and presentation skills
Kindness and Helpfulness
DOWNLOAD EXAMPLES OF FILLED FORMS HERE.

DOWNLOAD A PDF VERSION OF THIS FORM HERE.
NEED ASSISTANCE ? SEND AN EMAIL TO sales@intratec.us.
v.1-mar-13
Neutral
Satisfied
Technology Economics
Standardized advisory services developed
under Intratecs Consulting as
Publications pioneer approach.
Technology Economics studies answer
main questions surrounding process
technologies:
- How is the technology? What are the
main pieces of equipment required?
- What are the raw materials and utilities
consumption rates?
- What are the capital and operating
expenses breakdown?
- What are the economic
indicators?
- In which regions is this
technology more
profitable?

Technology Economics Polypropylene Via Gas Phase Process

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Technology Economics Polypropylene Via Gas Phase Process

Hochgeladen von

Copyright:

Verfügbare Formate

Polypropylene

via Gas Phase

This Publication Was Not a Publication

In short, our clients receive

How Readers Benefit?

How Clients Benefit?

Consulting as Publications at a Glance

Everyone Benefits from Cost Sharing & Online Experience

For a better understanding of our innovative concept, please visit www.intratec.us.

Terms & Conditions

In no event shall Intratec, its employees, representatives,

Study Background ........................................................................................................................................................ 10

Licensor & Historical Aspects ...........................................................................................................................................................................................13

ISBL Major Equipment List.................................................................................................................................................................................................23

Economic Analysis ........................................................................................................................................................ 29

Operational Expenditures ..................................................................................................................................................................................................34

Economic Datasheet .............................................................................................................................................................................................................34

Regional Comparison & Economic Discussion.................................................................................................... 37

Economic Discussion ............................................................................................................................................................................................................38

Appendix A. Mass Balance & Streams Properties............................................................................................... 49

Appendix C. Process Carbon Footprint ................................................................................................................. 55

Appendix F. Economic Assumptions...................................................................................................................... 64

Operational Expenses ...........................................................................................................................................................................................................65

Appendix G. Latest & Upcoming Reports ............................................................................................................. 66

Table 33 Separation Equipment.................................................................................................................................................................................................58

About this Study

Figure 1 OSBL Construction Scenarios

You may check the original form in the Appendix H.

Source: Intratec www.intratec.us

Intratec | About this Study

The economic analysis is based on the construction of a

Since the Outside Battery Limits (OSBL) requirements

The regional comparison analysis is performed for two

Table 1 Construction Scenarios Assumptions (Based on Degree of Integration)

Storage Capacity (Area 700)

End-products & By-products

Utility Facilities Included (Area 800)

Control room, labs, gate house,

Control room, labs, maintenance shops,

Source: Intratec www.intratec.us

Table 3 General Design Assumptions

Cooling water range

Steam (Low Pressure)

Wet Bulb Air Temperature

Source: Intratec www.intratec.us

Intratec | About this Study

Source: Intratec www.intratec.us

Intratec | Study Background

The discovery of polypropylene homopolymer is generally

Phillips Petroleum was developing the polypropylene

Unlike the symmetrical ethylene molecule, for example, the

Types of Polypropylene Resins

three major types of resins: homopolymers, random

Table 4 Polypropylene End-uses

Film and sheet

Medical garment and carpets

Extrusion and piping

Sports fabrics and bags

Source: Intratec www.intratec.us

Intratec | Study Background

Impact copolymers. Similar to random copolymers,

dissolving the atactic polymer. The range of grades

The Role of Catalyst in Process