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Plant Overview
Polypropylene-IV
Contents
Plant Overview
Process Capabilities
Process flow Diagrams
Process Description
Offsite & Utilities
Power & Utilities Requirements
Catalyst Loading & Unloading Procedures
Drain, Blow down, Vent & safety relief
Department
Plant Overview
Department
Plant Overview
Commissioned
September,1996
Technology
Basell
Designed capacity
75000 MTA
Present Capacity
1,25000 MTA
Catalyst
ZN118(stereo-specific catalyst)
Co-catalyst
TEAL,C-Donor
Monomer
Propylene, Ethylene
Terminator
Hydrogen
Grades
MFI range
0.3 to 400
Additives
Product name
REPOL
Reaction Killer
CO
Department
Polypropylene Applications:
Sr.
No
Product
Applications
AS030N
3.0
AS160N
16.0
AM120N
12.0
AM650N
65.0
AER003N
0.3
AMI400N
40
AS4000N
400
Department
Production Trend
140000
130000
120000
110000
100000
90000
80000
70000
2002-03
2003-04
2004-05
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
2011-12
Actual
96090
106190
118150
121550
119101
125165
116000
126565
121010
126140
Budget
100051
107404
114950
123818
126543
125151
127945
128355
127884
128429
Department
Process Capabilities
Department
Department
Capabilities :
Department
Department
10
Proplyene
from GOP
Prepoly Reactor
DONOR
Sulfur
Removal
Tower
CW
T EAL
Propylene
Feed
Tank
Waste water
CAT ALYST
M
RW
PROPYLENE
RW
1000 Kg/h r
INLINE
MIXER
Water
Collection
RW
RW
RW
RW
CW
COS
Removal
Tower
Hydrogen
PROPYLENE
Recycle
Propylene
Propylene Drying T owers
M
Wet
Powder
From
Steamer
CW
CW
Flash
drum
Recycle gas
compressor
CW
Dryer Scrubber
Compressor
KO Drum
Atmer
+
Oil
Recycle Filter
LS
DRYER
CW
Liquid
Additives
LP Proylene
Scrubbing
CW
LS
Solid
Additives
FINES
CW
Off Gas
compression
Package
Steamer
SC
LS
CW
Steamer
Scrubber
Beads Cooling
Screening
Cooling
Storage
Silos
Department
11
Process Areas:
Department
12
Polymerization Reaction :
CH3 H
|
|
C C
|
|
H
H
catalyst.
propylene
CH3 H
|
|
C C
|
|
H
H
n
polypropylene
Department
13
Process Description
Department
14
Propylene Purification:
FRESH
PROPYLENE
Sulphur
Removal
CO &
lighters
removal
Moisture
Removal
COS
Removal
RECYCLE
PROPYLENE
PROPYLENE FOR
POLYMERISATION
Department
15
Propylene Specifications:
Department
16
Catalyst System:
CATALYST :
ZN118
Department
17
Precontacting Pot:
RPM ~ 350
C-DONOR
TEAL
INLINE
MIXER
CATALYST
ZN118 PASTE
PROPYLENE
@ 1 TPH
10 C
PCP
13 Deg C
Volume 3 Lit.
RESIDENCE TIME 20 MINUTES
Department
TO
PREPOLY
REACTOR
18
Precontacting Pot:
The catalyst suspension in the oil / grease mixture, the donor and the
aluminum alkyl are precontacted in the precontacting pot at 13 deg c.
The reactive centers of the catalyst are activated for the subsequent contacts
with the monomers.
The feeds are sent in from top through dip tubes and the mixture is made to
overflow to prevent gas pockets.
Department
19
PREPOLY REACTOR
RWR
34.5-37 Kg/cm2,
17-20 Deg C
Volume 680 Liters
Res. Time 20 minutes
From
INLINE
MIXER
RWS
Flow 250 M3/hr.
Head 4 meter
To Loop Reactor
20
Pre Polymerisation:
The purpose of prepolymerisation is to slowly encapsulate or form a shell of
polypropylene around the catalyst particle.
This shell protects the catalyst when it enters the loop reactor.
If the catalyst was fed directly to the loop reactor without encapsulation, the
catalyst particles would be sticky and they could also explode, resulting in
excessive fines.
Department
21
Loop Reactor:
HEAT OF RXN - 470 KCAL/KG PP
Surge
Drum
DMW
Hydrogen
From
Prepoly
Reactor
Head 21 M
Ethylene
in RCP
LS
Propylene for
seal flushing
SC
Flash Line
Department
Length 137.7 M
Polymer
slurry to
Flash
Drum
22
Polymerisation:
The precontacting pot, prepolymerizer and loop reactor are all operated continuously
and in series.
They are all operated under high working pressure, thus allowing the loop reactor to
be operated with liquid propylene.
From the prepolymerizer, propylene, catalyst, donor and teal are fed to the loop
reactor. Fresh propylene is fed to the loop also.
The slurry concentration (50 % by wt) of the loop is controlled by regulating the
propylene feed to the reactor.
Polymer slurry from the loop reactor is continuously fed to the polymer degassing
section through the flash line..
Department
23
Recovered
Propylene
BAG FILTER
To Feed
tank
FLASH
DRUM
18 Kg/cm2
70 Deg C
5.2 m3
0.7 Kg/cm2
70 Deg C
RECYLE GAS
COMPRESSOR
To
GPR
in
ICP
run
From GPR
in ICPDepartment
run
To
STEAMER
24
Polymer is discharged from the loop reactor suspended in liquid propylene. This
excess of propylene vaporized in steam jacketed flash pipe is seperated from the
polymer in a flash drum to permit recovery of propylene.
Polymer with a small amount of monomer is fed to the bag filter where further
separation of monomer from polymer takes place.
Monomer gas is sent to recovery area after compression by recycle gas compressor
to the propylene recovery .
Department
25
DMW
80 Deg C
Res. Time 30 min.
DMW
C3 + H2
Volume 35.6 M3
C2
26
Department
27
OFF
GAS
M
V 9.1 M3
RT 9.5 Min.
0.2 Kg/cm2
108 Deg C
DRYER
0.1 Kg/cm2
STEAMER
80 Deg C
RT- 9 Min.
V 8.5 M3
Nitrogen
110 Deg C
Steam : 1MT
7 MT/hr.
To Intermediate
silos
Department
28
Drying:
Polymer is fed from the steamer to a fluid bed dryer by gravity. In the
steamer, moisture is condensed on the polymer. Hot nitrogen circulates
continuously through the dryer to remove water from the polymer. (
From ~ 3 wt to less than 0.02 wt%)
Department
29
Intermediate Silos:
FROM DRYER
Cap.
50 M3
Cap. 200 M3
Cap. 200 M3
TO ADDITIVATION
AREA
Department
30
Polymer Additivation
Polymer
from silo
VOLUME 4.4 M3
Loss in Weight Feeder
RT 5.6 Min.
Liquid Additive Blender
SOLID
ADDITIVE
LIQUID
ADDITIVE
M
To Beads
Cooler
Solid Additive Blender
Department
31
Polymer Additivation
The Additivation of the product is done for the topical adhesion of the
stabilizers and additives to reactor polymers without melting the polymer.
Liquid additives are fed ,in a proportioned quantity to the polymer / liquid
additive horizontal continuous mixer, to help their distribution and to promote
their adhesion to each particle of polymer.
Department
32
Polymer Additivation
Liquid additives
1.
Irganox 1076
32 %
2.
Irganox 1010
45 %
3.
Irgaphos PEPQ
13.5 %
4.
Irgaphos 168
9.5 %
Solid additive
CALCIUM STEARATE
200 ppm
Department
33
BEADS
COOLER
45 deg C
Nitrogen
SCREEN
REGULAR
PRODUCT
FINES < 1 .4 mm
Department
34
PRODUCT
SILO
PRODUCT
SILO
PRODUCT
SILO
PRODUCT
SILO
PRODUCT
SILO
HOMO
SILO
To
Bagging
Silos
Department
35
Bagging
From
HOMO Silo
Fines from
Plant &
Screen
undersize
Bagging
Silo
Fines
Silo
250 m3
100 m3
Bagging
Silo
250 m3
2 nos.
P5
Fines Bagging
Machine
P 10
Department
P 15
36
Department
37
Type:
Air Liquefaction
Capacity:
Purity:
Nitrogen: 99.99%(Vol.)
Oxygen: 99.5%(Vol.)
Department
38
Clean Air
1600 M3/Hr
5.5 Kg/cm2
Cooling Tower
Supplier:
Flow rate:
Paharpur
2200 CMH/Cell
Department
39
Department
40
Specific
Consumption
Parameters
Source
Pressure
Temperature
Cooling Water
0.099 KM3/MT PP
5.0 Kg/cm2
30 Deg C
O & U, BBP
0.358 MT/MT PP
3.0 Kg/cm2
145 Deg C
IOP
Plant Air
5.59 NM3/MT PP
5.0 Kg/cm2
Atm.
O & U, BBP
Instrument Air
36.37 NM3/MT PP
5.0 Kg/cm2
Atm.
O & U, BBP
Raw Water
0.324 M3/MT PP
5.0 Kg/cm2
Atm.
O & U, BBP
DM Water
0.002 M3/MT PP
5.0 Kg/cm2
Atm.
O & U, BBP
Nitrogen
63 NM3/MT PP
4.0 Kg/cm2
Atm.
UBII
OR
O & U, BBP
Power
121 KWH/MT PP
NA
NA
GTPP
Department
41
Department
42
Catalyst System:
CATALYST :
ZN118
Department
43
Department
44
Department
45
Department
46
Department
47
Department
48
Department
49
Department
50
Department
51
Department
52