04 PP Training Powerpoint PDF

POLYPROPYLENE
UNIT
About Instructor …
 Current job position:
 Working experiences:
EMERGENCY EVACUATION INSTRUCTION
Whenever you hear the building alarm or are informed of a
general building emergency:
 Leave the building immediately, in an orderly fashion;
 Do not use elevators;
 Follow quickest evacuation route from where you are;
 If the designated assembly point/area is unsafe or blocked due to
the emergency, proceed to the alternate assembly point;
 Report to your Work Area Rep at the assembly point to be checked
off as having evacuated safely;
 Specific safety requirements for TODAY.
Today: NO testing of fire alarm systems

COURSE OBJECTIVES
When you complete this module you will be able:
 To understand the feed and products characteristics; PP process
description;
 To assess the influence of operating parameters on a unit
performance through an analysis of operation case study.
 To learn about potential deficiencies and troubleshooting.
 To acquire the best practices for unit start-up, normal operation

COURSE OUTLINE
 Total duration: 2 days;
 Lecture: 2 days;
 Practice on dynamic simulator: 2 days;

COURSE ASSESSMENT
Lecture:
 The multiple-choice (knowledge based questions) section of the test
is scored based on the number of questions you answered correctly;
 Multi-choice test : 40 questions
 Passing grade: 36/ 40;
 No additional points are subtracted for questions answered
incorrectly;
 Even if you are uncertain about the answer to a question, it is better
to guess than not to respond at all.
Dynamic simulator:
 Passing grade: Implement an extract operation procedure for 10
minutes and troubleshoot successfully 2 scenarios in simulator;
OUTLINE
1. Feed Characteristics
2. Process Description
3. Start-up Preparation
4. Operation Cases Study
1. FEED CHARACTERISTICS
 Polypropylene: (PP), is a thermoplastic polymer used in a wide
variety of applications including packaging and labeling, textiles
(e.g., ropes, thermal underwear and carpets), stationery, plastic
parts and reusable containers of various types;
 An addition polymer made from the monomer propylene, it is
rugged and unusually resistant to many chemical solvents, bases
and acids
Polypropylene:
 Chemical and physical properties
 Most commercial polypropylene is isotactic and has an
intermediate level of crystallinity between that of low-density
polyethylene (LDPE) and high-density polyethylene (HDPE).
 Polypropylene is normally tough and flexible, especially when
copolymerized with ethylene. This allows polypropylene to be used
as an engineering plastic, competing with materials such as ABS.

Polypropylene:
 Polypropylene is reasonably economical, and can be made
translucent when uncolored but is not as readily made transparent
as polystyrene, acrylic, or certain other plastics.
 It is often opaque or colored using pigments. Polypropylene
has good resistance to fatigue.

Polypropylene:
 The melting point of polypropylene occurs at a range, so a
melting point is determined by finding the highest temperature of
a differential scanning calorimetry chart.
 Perfectly isotactic PP has a melting point of 171°C (340°F).

Polypropylene:
 Chemical and physical properties
 Commercial isotactic PP has a melting point that ranges from 160
to 166°C (320 to 331°F), depending on atactic material and
crystallinity.
 Syndiotactic PP with a crystallinity of 30% has a melting point of
130°C (266°F).
Polypropylene:
 The melt flow rate (MFR) or melt flow index (MFI) is a measure
of molecular weight of polypropylene.
 The measure helps to determine how easily the molten raw
material will flow during processing.

Polypropylene:
 Polypropylene with higher MFR will fill the plastic mold more
easily during the injection or blow-molding production process.
 As the melt flow increases, however, some physical properties,
like impact strength, will decrease.
 There are three general types of polypropylene: homopolymer,
random copolymer, and block copolymer.
 The comonomer is typically used with ethylene.

Polypropylene:
 Ethylene-propylene rubber or EPDM added to polypropylene
homopolymer increases its low temperature impact strength.
 Randomly polymerized ethylene monomer added to polypropylene
homopolymer decreases the polymer crystallinity and makes
the polymer more transparent

Polypropylene:
Degradation
 Polypropylene is liable to chain degradation from exposure to heat
and UV radiation such as that present in sunlight.
 Oxidation usually occurs at the tertiary carbon atom present in
every repeat unit.
 A free radical is formed here, and then reacts further with oxygen,
followed by chain scission to yield aldehydes and carboxylic acids.
 In external applications, it shows up as a network of fine cracks
and crazes that become deeper and more severe with time of
exposure.
Polypropylene:
 For external applications, UV-absorbing additives must be used.
Carbon black also provides some protection from UV attack.
 The polymer can also be oxidized at high temperatures, a
common problem during molding operations.
 Anti-oxidants are normally added to prevent polymer degradation.
 Microbial communities isolated from soil samples mixed with starch
have been shown to be capable of degrading polypropylene

Polypropylene:
Synthesis
An important concept in understanding the link between the structure of
polypropylene and its properties is tacticity. The relative orientation of each
methyl group (CH3 in the figure) relative to the methyl groups in neighboring
monomer units has a strong effect on the polymer's ability to form crystals
Isotactic
Tacticity
Syndiotactic
Tacticity
Atactic
Tacticity
Polypropylene:
Synthesis
 A Ziegler-Natta catalyst is able to restrict linking of monomer
molecules to a specific regular orientation, either isotactic, when all
methyl groups are positioned at the same side with respect to the
backbone of the polymer chain, or syndiotactic, when the
positions of the methyl groups alternate.
Polypropylene:
Synthesis
 Commercially available isotactic polypropylene is made with
two types of Ziegler-Natta catalysts.
 The first group of the catalysts encompasses solid (mostly
supported) catalysts and certain types of soluble metallocene
catalysts.
 Such isotactic macromolecules coil into a helical shape; these
helices then line up next to one another to form the crystals that
give commercial isotactic polypropylene many of its desirable
properties
Polypropylene:
Synthesis
 Modern supported Ziegler-Natta catalysts developed for the
polymerization of propylene and other 1-alkenes to isotactic
polymers usually use TiCl4 as an active ingredient and MgCl2
as a support.
 The catalysts also contain organic modifiers, either aromatic acid
esters and diesters or ethers.
 These catalysts are activated with special cocatalysts containing
an organoaluminum compound such as Al(C2H5)3 and the
second type of a modifier.
Polypropylene:
 The catalysts are differentiated depending on the procedure used
for fashioning catalyst particles from MgCl2and depending on
the type of organic modifiers employed during catalyst
preparation and use in polymerization reactions.

Polypropylene:
 Two most important technological characteristics of all the
supported catalysts are high productivity and a high fraction of the
crystalline isotactic polymer they produce at 70–80°C under
standard polymerization conditions.
 Commercial synthesis of isotactic polypropylene is usually
carried out either in the medium of liquid propylene or in gas-
phase reactors
Polypropylene:
Synthesis
 Commercial synthesis of syndiotactic polypropylene is carried
out with the use of a special class of metallocene catalysts.
 They employ bridged bis-metallocene complexes of the type
bridge-(Cp1)(Cp2)ZrCl2 where the first Cp ligand is the
cyclopentadienyl group, the second Cp ligand is the fluorenyl
group, and the bridge between the two Cp ligands is -CH2-CH2-,
>SiMe2, or >SiPh2.
Polypropylene:
Synthesis
 These complexes are converted to polymerization catalysts by
activating them with a special organoaluminum cocatalyst,
methylaluminoxane (MAO)
Feed characteristics in Dung Quat Polypropylene Plant:
 PP plant uses two raw materials, propylene and hydrogen which
are supplied from the Refinery.

Feed characteristics in Dung Quat Polypropylene Plant:
 Propylene and hydrogen from the refinery will be treated in
propylene drying/COS removal system and hydrogen purification
system to meet the following properties
No. Item Specifications

1 Hydrogen Content 95 mol% (min)
2 Methane 5 mol% max.
3 Oxygen 5 mol ppm max.
4 Water 5 mol ppm max.
5 Carbon Monoxide 5 mol ppm max.
6 Carbon Dioxide 5 mol ppm max.
7 Hydrogen Sulfide 5 mol ppm max.
Feed characteristics in Dung Quat Polypropylene Plant
1 Propylene Content 99.5 mol% (min)
2 Methane 100 mol ppm max.
3 Ethane 200 mol ppm max.
4 Ethylene 100 mol ppm max.
5 Propane 0.5 mol% max.
6 Butane & Butenes 10 mol ppm max.
7 Acetylene 5 mol ppm max.
8 Methylacetylene 5 mol ppm max.
9 Propadiene 5 mol ppm max.
10 1,3-Butadiene 5 mol ppm max.
Feed characteristics in Dung Quat Polypropylene Plant
11 Total of 7, 8, 9, 10 10 mol ppm max.
12 Oxygen 5 mol ppm max.
13 Hydrogen 5 mol ppm max.
14 Carbon Monoxide 0.1 mol ppm max.
15 Carbon Dioxide 4 mol ppm max.
16 Carbonyl Sulfide 0.05 mol ppm max.
17 Total Sulfur 1 wt ppm max.
18 Water 2 mol ppm max.
19 Oxygenated organic compounds 5 mol ppm max.
(methanol)
20 Arsine 0.03 wt ppm max.
2. PROCESS DESCRIPTION
The Mitsui “Hypol” polypropylene process has tended to make more specialty
resins, including TPO’s and very high impact copolymers. With multiple
reactors in series, the unit costs are typically higher than the larger capacity
single reactors
Feedstock and Raw Materials Preparation

 Co-catalyst (concentrated TEAL, 100% approx.) and donor-
stereomodifier are supplied in vendor containers (drums, etc.)
to feed drums with further metering to catalyst activation
section.
 Solid Ti-Mg catalyst HY-HS of the 4-generation is supplied in
drums from the chemicals store to catalyst preparation and
metering section.
 Solid Ti-Mg catalyst shall be dispersed in the blend of mineral oil
and grease (thickener) and further metered to the catalyst
activation section.
 Mineral oil shall be discharged from the drums to oil feed
drum.
 From this drum mineral oil shall be used for TEAL piping
washing and degassing and for jacketed vessel with agitator
filling.
 Mineral oil from this jacketed vessel with agitator is supplied to
the catalyst preparation and metering section.


 Grease from the drums is also discharged to jacketed vessel with
agitator with further supply to the catalyst preparation and metering
section.
 Additive for catalyst de-activation and washing oil degassing is
to be discharged to two feed drums.
 From the first drum it shall be supplied to low pressure
propylene washing tower and rich oil receiver, and from the second
drum it shall be supplied to the jacketed pipe provided for discharge
of polypropylene slurry in propylene from the reactor to high
pressure separator

 Grease from the drums is also discharged to jacketed vessel with
agitator with further supply to the catalyst preparation and metering
section.
 Additive for catalyst de-activation and washing oil degassing is
to be discharged to two feed drums.
 From the first drum it shall be supplied to low pressure
propylene washing tower and rich oil receiver, and from the second
drum it shall be supplied to the jacketed pipe provided for discharge
of polypropylene slurry in propylene from the reactor to high
pressure separator
Bulk Polymerization
 In the catalyst activation section, the catalyst suspended in oil and
grease is mixed with co-catalyst and donor and is further mixed
with small portion of liquid propylene for pre-polymerization in small
loop reactor.
 Polymerization is performed in liquid phase intwo loop reactors in
series.
Bulk Polymerization
 Reactors are of the same volume and operated under the same
conditions, as follows:
 Pressure – 4.5 MPa, approx.
 Temperature – 80oC
 Total residence time – 1.5 hours, approx.

Bulk Polymerization
 Axial pumps are installed at the bottom section of the reactor.
 Reaction blend circulation by these pumps provides a proportional
temperature profile over the whole length of the reactors.
 Heat removal in the reactors is provided via demineralized
water circulation in the reactor jackets.
 Hydrogen containing gas from the battery limits is fed to the
hydrogen recovery (up to 99.5% vol.) and compression section
with its further supply to propylene feed line upstream the
reactors.
Bulk Polymerization
 Liquid propylene from the propylene feed drum and hydrogen as
well are supplied to the both reactors.
 Some portion of propylene shall be evaporated upstream the
reactor for pressure control in the surge drum.
 This drum is provided to fill the reactors completely and to
avoid pressure swing in the reactors.

Bulk Polymerization
 Blend from the catalyst activation section is injected to the
propylene stream that is fed to the first reactor only.
 Polymer slurry from the first loop reactor feeds directly to the
second loop reactor to finalize polymerization.
 Polypropylene slurry from the second reactor is discharged via
jacketed pipe to the high-pressure separator for polymer
separation from the recycle propylene.

Polymer Degassing and Propylene Recovery
 High-pressure separator is provided to separate polymer from the
recycle propylene.
 Polymer resin from the separator is discharged to the filter for
polymer degassing.
 The resin is further supplied to the steaming section for
polymer steam-out.
 Stabilization additives shall be injected into the polymer resin prior
to steam-out.
 Filter overhead gas is fed to washing scrubber where oil washing is
provided for fines removal in recycle gas.
 Specific additive shall be added to the oil for TEAL traces
removal.
 Upon saturation with polymer rich washing oil shall be replaced
with fresh one. Rich oil is pumped out to recovery.
 Scrubber off-gas is compressed, mixed with high-pressure
separator off-gas and supplied to the propylene recovery tower.
 Tower overhead vapors are condensed and recycled to the
tower as a reflux.
 Balanced recovered propylene is collected in the receiver
where fresh purified propylene is to be fed.
 Propylene from the receiver is fed to the polymerization reactors.
 Propylene recovery tower bottoms are supplied to the polymer filter
inlet via jacketed pipe.

Polymer Steaming and Drying
 Downstream the filter polymer resin by gravity flow is supplied
to the polymer steaming section where catalyst reminder is
deactivated and entrained hydrocarbons are steamed out by
direct steam.
 Vapor and gas mixture from the steaming section is supplied to
water scrubber for steaming and water washing.
 Water condensate and steamed hydrocarbonsare fed to the
separator from scrubber draw-off tray.

 Liquid from the separator is recycled to the scrubber and vapor
and gas phase is to be combined with scrubber overhead
monomers and to be supplied to water cycle compressor.
 Cooled downstream water cycle compressor vapor and gas
phase shall be either routed to the flare system or recycled to
the process after drying.

 Organic liquid separated in the water cycle compressor (oligomers)
shall be discharged into drums after separation.
 Wet polymer from the steaming section is conveyed to dryingby
circulating nitrogen.
 Dried polymer is supplied by closed nitrogen transportation system
to the surge silo.

 Wet nitrogen from the polymer drying section shall bewashed
and cooled in the scrubber.
 Then it is recycled to the drying section by blower via preheater.
 Water is supplied to the scrubber for nitrogen washing.
 Water condensate with polymer traces is discharged from the
scrubber bottom to the waste water sump.

Emergency Discharge System
 Emergency discharge from the reactor safety valves is routed to
steam jacketed high pressure emergency blow-down drum.
 Discharges from the reactors shall be routed to low-pressure drum
when shutdown is required.
 Polymer powder collected in the high-pressure drum is transferred
to the low pressure drum by steam and nitrogen mixture.

Emergency Discharge System
 After polymer powder de-activation by circulating steam and
nitrogen mixture, the powder shall be discharged to containers.
 Gas vents from both drums are discharged to the Refinery flare
system via cyclone.

Refrigeration Unit
 Chilled water (diethyleneglycol solution indemineralized water)
is prepared at the package supplied refrigeration unit where
propylene is used as a cooling agent.
 Then chilled water is collected in the receiver under nitrogen
blanket (to prevent corrosion) and pumped out to consumers.

Condensate Return
 All steam condensate from the PP Plant is collected incondensate
receiver and further pumped out to the battery limits.
 Some portion of condensate is cooled and supplied for expansion
vapors condensing.
Washing Oil Recovery
 This section is under intermittent operation.
 Mineral oil contaminated with TEAL is collected in the recovery
vessel, liquid additive for TEAL neutralization is supplied to this
vessel as well.
 Recovered oil is routed to incineration.

Feedstock Preparation
 Polymer grade propylene (99.6% wt.) is pumped from the
intermediate storage to the feed preparation section.
 In this section propylene is dried at molecular sieves for water
removal and treated by catalyst for COS traces removal.
 These treatments are required, as polymerization catalyst is very
sensitive to certain impurities in the feedstock.

Silos, Extrusion, Pelletizing, Homogenization and Storage
 Polymer from the surge silo is metered to blender. Solid and liquid
additives are also metered to the blender continuously.
 Polypropylene with additives from the blender is fed to the
extruder.
 Fusible additives can be added to the extruder as well, if required.
 In the extruder polymer and additives are homogenized, gelled and
filtrated.
 Pelletizing is performed in subaqueous pelletizer.
 Pellets are supplied by circulating water (demin water) to
separator and further to air dryer.
 Dry pellets are fed by gravity to the classifier.

 On-spec polymer pellets are supplied to the feed drum with
further air
 conveying to the homogenization and storage silos.
 Off-spec pellets are collected in the container.
 Water separated from the polymeris collected in the drum with
further recycle to the pelletizer via cooler.

 Polymer homogenization and storage silos are provided to get
homogeneous polymer batches.
 They serve as a buffer between production sections and bagging
lines. Storage capacity enables to store the product within 5 days
maximum.
Bagging and Palletization Section
 Commercial polypropylene is bagged automatically into 25 kg PE
bags.
 The bags are automatically palletized and wrapped by PE
shrink film and transported to the warehouse by a forklift.
 The PP Plant comprises facilities for PE bags and shrink film
production.
Local Effluent Treatment
 Condensate and industrial and rainwater effluents, as well as floor
washing effluents are collected in the waste water sump.
 Water from the sump after oil and polymer powder removal is
to be pumped out to the Refinery treatment facilities.

Effluents Disposal
 Effluents disposal section covered by the PP Plant is provided
for effluents incineration.
 Spent oil from the PP Plant and non-diluted laboratory wastes
(acetone, xylene, etc.) are to be combusted in the incinerator
on intermittent base.
 Effluents are to be delivered to the incinerator in bottles by trucks.
 Flue gas filtration at the bag filter is provided for environmental
protection purpose prior to flue gas discharge to incinerator
stack.
3. START-UP PREPARATION
Outlines
 Each equipment at the plant is run for trial prior to the start-up of the
plant.
 When the construction of the plant progresses to such a stage that
various pieces of equipment can undergo trial run, it is necessary to
first introduce utilities into the plant so as to facilitate the
preparations for this trial run.
 The trial run is the best opportunity for plant operators to become
familiar with pieces of equipment and their operation
procedures.
 For this reason, it is desirable that the operators make
preparations in person for plant start-up.
Outlines
The following are the precautions required for the preparations:
 Inspections to be made at the time of completion of plant
construction.
 The above inspections should be carried out in line with P &
ID and construction drawings before conducting the cleaning and
airtight test of pieces of equipment.

Outlines
 These inspections are to ascertain whether or not:
a) The pipings are installed exactly as specified in P & ID
b) There is any problem as to the operability of equipment
c) The materials and parts of pipings are proper
d) The heat insulation of pieces of equipment, etc. has been properly
provided
e) Measuring instruments have been installed exactly as specified in
P & ID.
Cleaning
 The following are the items to which attention should be paid during
cleaning:
a) Pieces of equipment and pipings are cleaned in such a manner
that scrapings and the like can be collected in drums. For
this reason, inspect the drum interiors after the cleaning to see
whether or not there are any scrapings or the like left there.
b) In cleaning the seal oil line, skip the mechanical seals of
pieces of rotary equipment which use seal oil.
c) In order to prevent control valves from being fouled with
dirt during the cleaning, temporarily remove these valves or
insert a blind plate into their flanges.
Cleaning
The following are the items to which attention should be paid during
cleaning:
d) Do not use water for cleaning catalyst-measuring instruments,
pieces of equipment and lines from which it is difficult to completely
remove water. If water should be used for cleaning any equipment
or line, completely remove the water from it.
e) Thoroughly clean the Catalyst Preparation Section and any
section where product polymer is handled.
f) In cleaning the heat exchangers, pay attention to the smudges on
both shell and tube sides.
Cleaning
g) It is necessary to surely clean the lines mentioned here.
i) Seal oil lines
ii) Propylene flushing lines
iii) Connection lines for process gas chromatographs and moisture
analyzers
iv) Connection lines for pieces of equipment which handle AT-CAT
v) Suction lines for pumps and blowers
Airtight test
The following are the items which demand attention particularly at the
time an airtight test.
a) Confirmation of the design pressures of equipment and piping
prior to an airtight test
b) Sure insertion of a blind plate at a portion where two lines of
different design pressures join

Airtight test
Never carry out an airtight test with equipment isolated with valves
only. Also, open the vent and drain valves of lower-pressure
equipment connected to the portion which is to be subjected to an
airtight test.
This is because if the compressed air for airtight test should leak into
any lower-pressure equipment, such air can be released into the
atmosphere to prevent the equipment from being over-pressurized.

Airtight test
c) When an airtight test is conducted on any rotary equipment, the
seal oil system should be put in service when possible, and the
test be implemented after seal oil is supplied to the rotary
equipment, with a view to preventing its mechanical seal from
being damaged.
d) How to raise pressure
The pressures of equipment and piping should be raised by stages.
e) First, raise the pressure to the 50% level of the pressure designed
for airtight test to see whether or not there is any leakage.

Airtight test
f) When there is no leakage, raise the pressure by stages by 10% of
the air tight test pressure at a time.
g) Every time the pressure is raised to a given level, apply soapy
water or the like to the equipment and piping to see whether or not
they have any leakage, and then raise the pressure to their
specified target pressure to confirm that they have no leakage.

Confirmation of performance of rotary equipment

The performance of rotary equipment should be confirmed prior to
plant startup. The following are the items which require attention at
the time of this confirmation.
a) Confirm that all pieces of rotary equipment have been
installed precisely in line with the instructions given by their
respective vendors.
b) Install temporary strainers to remove weld scraps, foreign matters
and the like from rotary equipment for the purpose of damage
prevention.
Confirmation of performance of rotary equipment
c) Confirm beforehand the differences in shaft horsepower,
pressure rise and temperature rise which stem from the difference
in physical property of fluid.
d) In order to accurately grasp the performance of pumps,
compressors and blowers, obtain the necessary information
and guidance from the respective vendors beforehand.

Instrumentation and electricity
 Regarding the instrumental and electrical installations, put
necessary sequence control systems in service, and confirm
their performance during the simulation of normal operation.
 Prior to starting an airtight test and also to performance
confirmation test of rotary equipment, put both measuring and
controlling instruments in service, and test use these instruments
to ascertain whether or not they function properly.

Instrumentation and electricity
 Put alarms and interlock systems in service to closely ascertain
whether or not they function properly at their respectively
specified set points.

Safety system
a) Prior to their installation, ascertain by the use of a testing device
whether or not safety valves function properly.
b) Confirm that all XVs open and close normally.
c) Conduct a test on alarms to see whether or not they function
normally.
d) Conduct a test on flammable gas detectors and fire-fighting
facilities to see whether or not these detectors and facilities
function normally.
Safety system
e) Prepare documents which graphically show the following
information to communicate such information to those who
concern for the sake of the safety at the plant. Meanwhile, it is
desirable to train operators and personnel concerned in plant
safety when possible.

Safety system
f) Block diagram of Emergency Shut Down (ESD) procedures
g) The locations of fire extinguishers, fire hydrants and ESD valves
h) Locations of emergency lights
i) Comprehensive table of safety valves and rupture disks
j) Distribution diagram of power supply
k) Lists of measuring instruments and alarms
l) Distribution diagrams of instrumental- and back-up power supplies
m) Diagram of waste-water system

Introduction of utilities
The utilities referred to here include:
a) Fire-fighting water
b) Cooling Water (CW)
c) Steam
d) Demineralized Water (DW)
e) Nitrogen
f) Instrument Air (IA)
g) Electricity
Plan for plant start-up preparations
The following should be taken into consideration in planning
plant start-up preparations.
a) Introduction of utilities should be begun with IA, CW, nitrogen and

steam in this order.
b) When utilities are introduced in the course of plant

construction, safety measures inclusive of the following should be
taken.
i) Make necessary isolation with blind plates.

ii) Never close nor open any valve.
Plan for plant start-up preparations
The following should be taken into consideration in planning
plant start-up preparations.
c) Cleaning of the CWS, CWR and DW lines should be

conducted before the trial run of rotary equipment.
d) Since seal oil is required for the trial run of rotary equipment, it is
desirable to operate the seal oil system if possible before such
equipment is put to test.
Nitrogen purge
Precautions required for nitrogen purge
a) In order to properly conduct nitrogen purge, it is important to
decide from where nitrogen should be introduced, where nitrogen
purge be conducted and whether relevant valves be closed or
opened, in accordance with the shape of equipment.
b) Nitrogen purge procedures vary with the analytical value of
oxygen concentration at the place where this purge is intended.

Nitrogen purge
c) Supply of refrigerated water to equipment which is being purged with
nitrogen causes the equipment to be dewed internally, thus possibly
hindering nitrogen purge. Hence, refrigerated water should be
supplied after completion of nitrogen purge.
d) Nitrogen purge should be conducted in such a manner that oxygen,
water or the like will not be left in the pocketed areas of equipment
and drain valves on its associated lines.

Nitrogen purge
e) While conducting nitrogen purge, drain and vent valves should be
closed or opened so that equipment, lines, valves, etc. will not
be left unpurged with nitrogen.

Nitrogen purge
Completion of nitrogen purge
a) Nitrogen purge is deemed completed when as a result of oxygen
concentration analysis, this concentration in equipment is
ascertained to have become lower than the lower explosive limit,
by making reference to the material relative to the explosive
ranges of multiple-component systems
b) Measure oxygen concentrations and dew points at given locations.
When the values so measured meet the respective specified
values, close the valves at the places where nitrogen purge has
been performed. Thus the nitrogen purge is concluded.
Nitrogen purge
Completion of nitrogen purge
c) The following are the criteria by which to judge the
completion of nitrogen purge.
Item Criterion
Dew point in equipment -40°C or lower
Oxygen conc. in equipment 0.2 vol% or lower
Note: Unless otherwise mentioned.
For gas analysis, take sample gas at three or more spots of the place
where nitrogen purge has been conducted.
Nitrogen purge
d) Measures to be taken after completion of nitrogen purge. When
nitrogen purge is completed, blanket pieces of equipment with
nitrogen with their pressures kept at 0.2 to 1 Kg/cm2g so that
oxygen, water, etc. will not enter them.
Note: Nitrogen purge procedures and a rough diagram for nitrogen
purge are shown as an example in the ensuing page; however,
these diagram and procedures should be established by taking into
consideration the actual plant at the time of its completion.
 Blowdown and Flare system
 When a safety device is actuated due to abnormality occurring to
any equipment at the time during the start-up, normal operation or
shutdown of the plant, the blowdown and flare system serve to
release the flammable gases discharged from the safety devices.

 Therefore, the aforesaid system is first put in service prior to
introducing flammable gases into B/L. When the airtight test and
nitrogen purge of the blowdown and flare lines are completed and
the flare system commissioned and ready for use, connect the flare
line to the outside-B/L flare line and immediately start to use these
lines
 Cooling water (CWS and CWR)
 Cooling water is used for removing the heat of polymerization
reaction and for cooling pieces of equipment. CWS is introduced
from outside B/L and CWR is discharged back to B/L.
 After an airtight test is conducted on CWS and CWR lines
and CWS supply valve for each CWS user is closed, the CWS
receipt B/L valve is opened to introduce CWS into B/L.

 After the gas in the CWS header line is discharged, the B/L valve
for CWR is opened to discharge CWR. CWS is supplied to each
CWS user to discharge gas in its CWS line. The specified set
points of PT-0121A LL, PT-0121B LL and FQI-0121 L are set on
them respectively.
 Demineralized water (DW)
 After mechanical completion and cleaning of DW line, the DW
supply valve for each DW user is closed. Then, the B/L valve for
DW is opened to introduce DW into B/L.
 DW so introduced is supplied to its users in order one by one to
discharge the gas in their DW lines. The leak test is performed by
DW when DW is introduced inside B/L.

 Low pressure steam (SL)
 Low pressure steam (SL) is supplied from outside B/L. Steam
condensate (CL) of SL generated by SL users are collected into
the steam condensate drum (D-606) and transferred to the CL
users inside B/L and/or outside B/L.
a) Preparations for SL introduction
b) Introduction of SL
c) Put steam condensate system in service

Nitrogen (HN, MN and LN)
Nitrogen is produced inside B/L also to meet the requirement and
back-up. HN is also produced with nitrogen generation PKG.
a) Preparations and confirmation
b) Nitrogen Purge
c) Open and close the nitrogen supply valves of each equipment
to which a nitrogen supply line is connected to conduct nitrogen
purge on this nitrogen supply line.
d) Completion of nitrogen purge

 Instrument air (IA)
 IA is supplied from outside B/L and used for various
instruments.
 After the airtight test of the IA line is completed, IA is introduced into
B/L as occasion demands

 Plant air (PA)
 PA is supplied from outside B/L as Instrument air (IA) and
used for various equipments.
 After the airtight test of the PA line is completed, PA is introduced
into B/L as occasion demands

Propylene circulation operation
 Start-up sequence of the units with propylene
 Upon completion of the preliminary operations, the plant units shall
be arranged for the start-up. The units shall be started-up in the
following sequence.
a) Blowdown
b) Reactor feed
c) Degassing and monomer recovery
d) Reactors
e) Steaming and drying
f) Catalyst and cocatalyst storage and metering

 Propylene circulation operation is performed in preparation for start-
up.
 This mode is also used during the time of temporary catalyst
outages and for a short period before plant shutdown.
 Fresh and recycle propylene is supplied to the loop reactors
from the propylene feed drum (D-302) and circulated with the
loop reactor pumps (P-201/P-202).
 The pressure of loop reactors is maintained with the reactors
surge drum (D-202). The loop reactors are operated liquid full at all
times
 The propylene from the loop reactors is sent to the transfer line
dryer (E-307). Here the liquid propylene is heated and vaporized
before it enters the flash drum (D-301).
 A small portion of vapor is directly to the recycle gas filter (F-301),
while the main flow goes overhead from D-301 to the recycle
propylene scrubber (T-301) for recovery.
 Vapor propylene exits the top of F-301 and enters the low pressure
propylene scrubber (T-302).

 The propylene gas from the top of T-302 is compressed with the
recycle gas compressor (PK-301) and transferred to the T-301.
 Liquid propylene for scrubbing of T-301 comes from the boot
of the propylene condenser (E-301) and enter the top of T-301.
 Liquid propylene from the bottom of T-301 is discharged to F-301
passing through double tube vaporizers.
 Vapor propylene leaves the top of T-301, is condensed and
pumped back to D-302 for recycle back through the system.

4. OPERATION CASES STUDY
The following refers to some troubleshooting cases in Dung Quat
Polypropylene Plant sections
1. AT-CAT Storage and Feeding
2. OF-CAT Storage and Feeding
3. Catalyst Dispersion Preparation and Metering
4. Prepolymerization and Polymerization

4. OPERATION CASES STUDY
The following refers to some troubleshooting cases in Dung Quat
Polypropylene Plant sections
5. Degassing and Monomer Recovery
6. Low Pressure Flash and Monomer Compression
7. Reactor Feed System
8. Polymer finishing
THANK YOU
www.pvmtc.com.vn

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POLYPROPYLENE

 Current job position:

Today: NO testing of fire alarm systems

When you complete this module you will be able:

 To understand the feed and products characteristics; PP process

 To assess the influence of operating parameters on a unit

performance through an analysis of operation case study.

 To learn about potential deficiencies and troubleshooting.

 To acquire the best practices for unit start-up, normal operation

 Total duration: 2 days;

 Practice on dynamic simulator: 2 days;

 Polypropylene: (PP), is a thermoplastic polymer used in a wide

variety of applications including packaging and labeling, textiles

(e.g., ropes, thermal underwear and carpets), stationery, plastic

parts and reusable containers of various types;

 An addition polymer made from the monomer propylene, it is

rugged and unusually resistant to many chemical solvents, bases

 Chemical and physical properties

 Most commercial polypropylene is isotactic and has an

intermediate level of crystallinity between that of low-density

polyethylene (LDPE) and high-density polyethylene (HDPE).

 Polypropylene is normally tough and flexible, especially when

copolymerized with ethylene. This allows polypropylene to be used

as an engineering plastic, competing with materials such as ABS.

 Polypropylene is reasonably economical, and can be made

translucent when uncolored but is not as readily made transparent

as polystyrene, acrylic, or certain other plastics.

 It is often opaque or colored using pigments. Polypropylene

has good resistance to fatigue.

 The melting point of polypropylene occurs at a range, so a

melting point is determined by finding the highest temperature of

a differential scanning calorimetry chart.

 Perfectly isotactic PP has a melting point of 171°C (340°F).

 Chemical and physical properties

 Commercial isotactic PP has a melting point that ranges from 160

to 166°C (320 to 331°F), depending on atactic material and

 Syndiotactic PP with a crystallinity of 30% has a melting point of

of molecular weight of polypropylene.

 The measure helps to determine how easily the molten raw

material will flow during processing.

easily during the injection or blow-molding production process.

 As the melt flow increases, however, some physical properties,

like impact strength, will decrease.

 There are three general types of polypropylene: homopolymer,

random copolymer, and block copolymer.

 The comonomer is typically used with ethylene.

 Ethylene-propylene rubber or EPDM added to polypropylene

homopolymer increases its low temperature impact strength.

 Randomly polymerized ethylene monomer added to polypropylene

homopolymer decreases the polymer crystallinity and makes

the polymer more transparent

 For external applications, UV-absorbing additives must be used.

Carbon black also provides some protection from UV attack.

 The polymer can also be oxidized at high temperatures, a

common problem during molding operations.

 Anti-oxidants are normally added to prevent polymer degradation.

 Microbial communities isolated from soil samples mixed with starch

have been shown to be capable of degrading polypropylene

 The catalysts are differentiated depending on the procedure used

for fashioning catalyst particles from MgCl2and depending on

the type of organic modifiers employed during catalyst

preparation and use in polymerization reactions.

 Two most important technological characteristics of all the