1.

0 CHAPTER ONE
1.1 INTRODUCTION

1.1.1 INTRODUCTION TO SIWES

The Students Industrial Work Experience Scheme (SIWES) was established by the Industrial
Training Fund (ITF) in 1973. It was designed to enable Nigerian students in tertiary
institutions to gain experience that would supplement their theoretical learning. In the earlier
stages of science and technology education in Nigeria, students were graduating from their
respective institutions without any technical knowledge or working experience in their
respective course of study. It was for this reason that students undergoing science and
technology related courses were mandated for SIWES in different institutions to enable them
to have a technical knowledge and working experience before graduating from their various
institutions. Participation in SIWES has become a necessary pre-condition for the award of
Diploma and Degree certificates in specific disciplines in most institutions of higher learning
in the country, in accordance with the educational policy of the government.

PHILOSOPHY OF SIWES

SIWES was established to facilitate the full realization and mandatory skills acquisition and
proper training programmes designed to expose students to the industrial workplace
environment in their respective disciplines during their course of study. The students are
expected to develop occupational competence that would facilitate their fitting into the world
of the working class after graduation.

1.2 AIMS AND OBJECTIVES OF SIWES

The following are some of the objectives of SIWES:

 To provide students with an opportunity to apply their theoretical knowledge in real

work situations, thereby bridging the gap between theory and practice.

 To prepare students for the work situation they are likely to meet after graduation.
 To expose students to work methods and techniques in handling equipment and
machineries that may not be available in their universities.

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1.3 HISTORY OF NNPC
The Nigerian National Petroleum Corporation (NNPC) is the state oil corporation which was
established on April 1, 1977. In addition to its exploration activities, the Corporation was given
powers and operational interests in refining, petrochemicals and products transportation as well
as marketing. Between 1978 and 1989, NNPC constructed refineries in Warri, Kaduna and Port
Harcourt and took over the 35,000-barrel Shell Refinery established in Port Harcourt in 1965.

In 1988, the NNPC was commercialised into 12 strategic business units, covering the entire
spectrum of oil industry operations: exploration and production, gas development, refining,
distribution, petrochemicals, engineering, and commercial investments. Currently, the
subsidiary companies include:

 Nigerian Petroleum Development Company (NPDC)

 The Nigerian Gas Company (NGC)
 The Products and Pipelines Marketing Company (PPMC)
 Integrated Data Services Limited (IDSL)
 National Engineering and Technical Company Limited (NETCO)
 Hydrocarbon Services Nigeria Limited (HYSON)
 WARRI REFINERY AND PETROCHEMICAL CO. LIMITED (WRPC)
 Kaduna Refinery and Petrochemical Co. Limited (KRPC)
 Port Harcourt Refining Co. Limited (PHRC)
 NNPC Retail

1.3.1 MISSION/VISION OF NNPC

MISSION
NNPC is an integrated Oil and Gas Company, engaged in adding value to the nation’s
hydrocarbon resources for the benefit of all Nigerians and other stakeholders.

VISION

NNPC will be a world-class oil and gas company driven by shared commitment to excellence.

1.3.2 INTRODUCTION TO WRPC

Warri Refining and Petrochemicals Company Limited, is a subsidiary of Nigerian National

Petroleum Corporation (NNPC) established for the purpose of processing crude oil into different

2
petroleum and petrochemicals products for both domestic and industrial uses. The Fuel plant section
(Refinery) was built and commissioned in 1978 while the Petrochemicals section was commissioned
in 1988. The fuels plant has the capacity to process 125000 Barrels of crude oil per day the
petrochemicals plants produce 35000 metric tons of Polypropylene (PP) pellets and 18000 metric
tons of carbon black (CB) per annum respectively.

Some of the processed Petrochemical and Petroleum products produced by WRPC are:

 Liquefied Petroleum Gas (LPG).

 Premium Motor Spirit (PMS).
 Dual Purpose Kerosene (DPK).
 Automotive Gas Oil (AGO).
 Fuel Oil.
 Liquid Nitrogen.
 Carbon Black (CB).
 Polypropylene (PP).

1.3.3 MISSION/VISION OF WRPC

MISSION

To efficiently and profitably process crude oil into petroleum products, manufacture, and
market petrochemicals products; through effective resource utilization, while exploiting new
business opportunities.

VISION
To be a leader in the petroleum processing business in Africa.

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 ORGANISATION STRUCTURE

Figure 1: WRPC Organisation Structure.

4
2.0 CHAPTER TWO
2.1 INTRODUCTION
Polypropylene is a thermoplastic polymer obtained by linking together many molecules of a
substance (propylene) called ‘’monomer’’. One of the main advantage of Polypropylene is that
it can be easily transformed into any object, sheet, or filament by simply melting it and then
moulding, injecting, extruding, or blowing by means of special machines. Even complicated
forms can be made quickly and economically. The resulting objects are resistant to shocks, are
rustproof, and can be made in one piece. The starting material is usually in the form of chips,
pellets, or powder and incorporates stabilizers and dyes. The articles obtained with
Polypropylene, because of their general and specific properties, are of interest to practically all
branches of industry. The purpose of this module is to explain how the Polypropylene is made.

The production process, i.e. all operations necessary to obtain the Polypropylene are briefly
described and explained. It is not the purpose of the module to describe the production plant.

2.1.1 SAFETY IN POLYPROPYLENE OPERATIONS

Warri Refining and Petrochemical Company is highly committed to employees’ general safety.
The life of this company depends on the production and sale of its products. Interruption of this
cycle by injury to employees, equipment or material can slow its growth, sometimes beyond
repair.

- Ensure the use proper PPE

- The plant is equipped with modern protective devices such as over pressure controllers
(PSVs), failed-safe interlocks, automatic fire fighting equipment, etc.

- Follows approved practices and procedures.

- Develop and exercise good work habits, positive safety attitudes and proper housekeeping
practices.

- Identify any unusual noise with running equipment.

- Identify any leakages of hydrocarbon in the plant.

- Means of handling potentially hazardous chemicals/materials such as propylene, TIBAL,

Hydrogen, etc.

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2.2 PROPYLENE

We have seen the Polypropylene is obtained by linking together many molecules of propylene
(monomer). The main properties of propylene are listed in Table 1. Propylene is a flammable,
gaseous, unsaturated hydrocarbon which can be formed as a by-product of the fluid catalytic
cracking of heavy gas oils.

Table 1 – properties of propylene monomer

________________________________________________________________

• Boiling point, oC -47.7

• Critical temperature, oC 91.9
• Critical pressure, atm 45.4
• Explosion range when mixed with air, % by vol. 2.0-11.1

________________________________________________________________

The process by which the propylene molecules are linked together is called ‘’polymerization’’ and
can be chemically represented as follows:

CH3 CH3 CH3

I I I

nCH3 – CH=CH2 (CH-CH2-CH-CH2-CH-CH2-) n/3

Where (n) is the number of propylene molecules in the polymer; this number can reach the
value of some hundreds. Commercial polypropylene has the regular isotactic structure; the
random atactic polypropylene has practically no commercial applications being soft and plastic
like wax. Three structures are possible for polypropylene, namely isotactic, with the same
configuration throughout a long portion of the chain; syndiotactic, with configurations in
regular alternation; and atactic, with random distribution. Actual commercial polypropylene has
the isotactic structure; depending on the polymerization conditions, minor amount of other
forms may be present (fig. 1).

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ISOTACTIC (commercial polypropylene)

-CH2 -CH2 -CH2 -CH2 -CH2 -CH2 -CH2 -CH2 -CH2 –

I I I I

CH3 CH3 CH3 CH3

SYNDIOTACTIC

CH3 CH3

I I

-CH2 -CH - CH2 – CH -CH2 –CH - CH2 -CH - CH2 –

I I

CH3 CH3

ATACTIC (Random configuration)

CH3 CH3

I I

-CH2 -CH - CH2 – CH -CH2 –CH - CH2 -CH - CH2 –

I I

CH3 CH3

C = Carbon Atoms

H = Hydrogen Atoms

Fig. 3 – Chemical configuration of Polypropylene

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Table 2 – typical properties of some polypropylene grade
________________________________________________________________

Property Pipe and Films Injection

Sheet moulding

________________________________________________________________

Density, g/m3 0.900-9.905 0.900-9.905 0.900-9.905

Crystallinity, % 58-59 59-60 61-62

Crystallization, oC 103-105 104-106 104-107

Melt flow rate, g/10 min 0.25-0.35 1.5-2.0 5-7

Isotactic index (ISO) > 96.0 >96.0 >95.0

Water absorption (24 h),% 0.03 0.03 0.03

Linear mould shrinkage,% < 1.9 < 1.9 < 1.9

Tensile yield elongation,% 10 – 12 10 -12 8 -10

Tensile yield strength, % MPa* 29 – 31 32-34 33-35

________________________________________________________________

Isotactic polypropylene can be easily melted, but at room temperature it is sufficiently hard and does
not show brittleness; it has good mechanical and chemical resistance. Table 2 gives the properties of
various polymer grades. The properties of moulded articles depend heavily on orientation and
stresses introduced during moulding. Polypropylene is more rigid and has a higher softening point
than polypropylene. The main advantage of a thermoplastic polymer such as polypropylene is that it
can be easily transformed into any object, sheet, or filament by simply melting it and then moulding,
injecting, extruding, or blowing by means of special machines.

2.3 POLYPROPYLENE PRODUCTION

Isotactic polypropylene is obtained by stereo regular polymerization of propylene based on the
use of Ziegler-Natta catalysts. A catalyst is a substance which increase the rate of a chemical
reaction and which is itself unchanged at the end. Although scientific and patent literature
reports a large number of catalytic combinations yielding isotactic polypropylene, in
commercial practice titanium chloride is generally used in combination with aluminium
diethylmonochloride;

8
 C1 C1

T1 C1 A1 C2H5

C1 C2H5

The process for polypropylene production can be divided into two main groups:

- processes utilizing a “low yield” catalyst

- process utilizing a “high yield” catalyst

The choice of the process is principally determined by the performance of the catalyst. The
highly specific catalysts developed in recent years (containing also magnesium) make it
possible to leave catalyst residues and atactic (i.e. waxy) polymer in the product because they
are in small quantities. By using low yield catalysts (the previous type of catalyst) a certain
amount of amorphous (not stereospecific) polymer is obtained, which must be eliminated.

Moreover, the catalyst residues must be deactivated, solubilized and removed by extraction. The
resulting plant is much more complex than the plant which uses a high yield catalyst. A simple
representation of the process utilizing a high yield catalyst is shown in Fig. 2

PROPYLENE

POLYMERIZATION
POLYPROPYLENE

CATALYST
Fig. 4 – Simple representation of a process utilizing a high yield catalyst

The polymer made only by propylene molecules is called “homopolymer” or polypropylene.

Another monomer, usually ethylene, can be added to obtain a product with slightly different

characteristics, called “co-polymer” (Fig. 3)

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n CH3 - CH = CH2 CH2 – CH – CH2 - CH – CH2 – CH - CH2

I I I

CH3 CH3 CH3

Propylene Polypropylene (homopolymer)

n CH3–CH=CH2 + m CH2=CH2 CH2-CH–CH2–CH–CH2-CH2-CH = CH2

I I

CH3 CH3

Propylene Ethylene Ethylene-Propylene copolymer

Fig. 3 – homopolymer and copolymer

In an industrial plant for the production both of polypropylene homopolymer and of

ethylenepropylene copolymer, the main steps of the process are:

- propylene purification
- catalyst preparation
- polymer powder production(polymerization reaction)
- ethylene (copolymer) addition
- polymer additives and blending
- extrusion and pelletizing - homogenization and storage - bagging and
storing.

The second step (i.e. catalyst preparation) may or may not be accomplished in the plant because the
catalyst can be purchased ready made from the licensor of process.

The polymerization reaction is carried out in a liquid phase: modern processes use liquid propylene
as the diluent.

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3.0 CHAPTER THREE

3.1 THE EL PASO PROCESS (POLYMERIZATION OF PROPYLENE)

The EL PASO polypropylene process is a process for the polymerization of propylene in a
liquid pool of monomer by using high-efficiency Ziegler-Natta supported catalyst. High yields
of stereo regular polymer provided by the new catalyst eliminate the need for removal of
catalyst residue and atactic material from reactor product. The liquid phase consists of liquid
propylene.

Fig 5:Block diagram of polypropylene production; each block represents a section of the plant
identified by a set of numbers.

A simplified flow diagram of the EL PASO process is shown in fig. 6.

The propylene required for the polymerization process must be very pure. There finery-grade
propylene (raw propylene) usually requires further treatment to remove propane and other
impurities. A polymergrade propylene is obtained by distillation in a propylene-concentration
unit. The distillation is carried out at low temperature owing to the low boiling point of propane
and propylene, which are -42oC and -47.7oC, respectively. The purified liquid propylene
together which the catalyst produced in another section of plat, and hydrogen (used for
molecular weight control) is introduced into an agitated reactor already containing liquid
propylene. The polymerization reaction takes place at 54-82oC and 28-41 atm. Propylene
polymer forms as particles (powder), and this product leaves the reactor in slurry with unreacted
liquid propylene. The slurry enters a flash vessel where the monomer is separated and recycled
to be mixed with the feed. Ethylene - propylene random copolymers are also produced in this

11
process by introducing ethylene as a comonomer in the polymerization vessel. Additionally,
ethylene – propylene block copolymers are made by reacting the homopolymer, still containing
active catalyst, with ethylene in an auxiliary reactor.

Fig 6: simplified flow diagram of the propylene production

With the new high-efficiency catalyst, polymer yields in the order of 5000-7000 Kg/Kg of solid

catalyst are obtained. Also, the polymer produced with this catalyst contains 94-95%

stereospecific (heptane-insoluble) material; therefore, the removal of both catalyst residues and

atactic polymer is no longer necessary. In fact, the amount of catalyst left in the polymer is

negligible. After drying to eliminate residual monomer the polymer powder is compounded

with anti-oxidants and processing aids. The pellets are tested to ensure that their characteristics

conform to the specifications are them sent to the bagging machine where they are bagged, and

stored.

3.2 DESCRIPTION OF THE PRODUCTION SECTIONS

The production plant is subdivided into a number of sections (or “areas”) each one defined by

asset of numbers (Fig. 5). In every section of definite number of homogeneous and subsequent

12
operations are carried out. Each item of equipment is identified by a letter and a number. For

example, the reactor of the polymer powder production section (200) is identified by R-201.

Where R is the symbol of the reactor; 200 is the identifying number of the section;1 is the

number of the reactor (there could be more than one reactor).

3.2.1 SECTION 000 - RAW PROPYLENE STORAGE

Propylene is a flammable gas which becomes liquid at -47.7 oc. By increasing the pressure to

maintain propylene at higher temperature in a liquid state. The storage of the raw propylene

produced in the catalytic cracking unit (FCC) of the Refinery includes three cylindrical pressure

vessels of 350 m3 capacity (D-002 A / B /C) each to receive the liquid raw propylene from the

Refinery, and one sphere (D-001) of 2200m3 capacity (Fig. 7). Two pumps, one as sphere, to

feed the propylene purification unit, and one recycle pump to send the eventual off-spec. raw

propylene back to the Refinery, are provided. The Three cylindrical vessels are each sized to

receive one day’s production of the Refinery FCC plant. The production of the FCC plant has

been based on the test run capacity which is 5785 kg/hr. The sphere is sized so as to allow seven

days autonomy to the polypropylene (P.P) plant in the case of FCC shut-down.

The resulting configuration of the raw propylene storage tanks is as follows:

- The sphere is normally full, in order to face any possible shut-down of the FCC plant;

- one cylindrical vessel receives the raw propylene from the FCC plant;

- one vessel is in analysis;

- one vessel feeds the propylene purification unit.

3.2.2 SECTION 100 – PROPYLENE PURIFICATION

The refinery-grade propylene (raw propylene) contains about 70-75% propylene by volume,
and requires further treatment to remove propane, the other main constituent of the gas, and
other impurities. Polymer-grade propylene must contain at least 94% propylene and 6% propane
max. The propylene purification section is designed to purify the raw propylene coming from

13
the refinery FCC plant and the unreacted propylene recycled from homopolymer and copolymer
reactors. The designed capacity of the section is 10,747 kg/hr of polymer grade propylene (as
100%) with a min. purity of 94% in order to provide the required quantity of polymer grade
propylene for 35,000 tons/yr of homopolymer and copolymer (stream efficiency 8,000 hr/yr).

The polypropylene purification section is represented in Fig. 4 which shows the flow-sheet of
the whole P.P production process. Raw propylene from storage enters the hydrolysis unit in
which the compound COS, present as an impurity in the propylene, is removed by reacting it
with water vapor in the reactor R-101 at temperatures in the range of 350°C.

COS +H2O COS2 + H2 S

Carbon dioxide (CO2) and hydrogen sulphide ( H2S ) are removed after propylene condensation,

as they are gaseous products. The propylene from the COS removal unit is condensed together

with the unreacted propylene recycle from the polymerization section Condensation is obtained

through refrigeration and compression ( P - 101 A/B). From the condensate receiver D-103 the

propylene is sent to the “LIGHTS” separation columns C-101 A/B where the gas (such as CO2

and H2S) and lighter components are separated and sent to flare as overhead product. The

refrigeration fluid for the condensers is provided by a refrigeration unit (Y-102 ) not shown in

Fig. 4.

The propylene from the bottom of the column C-101 A is sent to the propane/propylene splitter

columns ( C-102 A/B ) where it is split into propane steam ( bottom ) and pure propylene (

overhead product ), owing to the higher boiling point of the propane. The propane is sent back

to the Refinery.

The propylene is partially used as a reflux for the column C-102 B and sent to the cylindrical
pressure storage tanks D-111 A/B/C after having passed through the molecular sieve unit Y101
for water removal.

The polymer grade propane storage is based on three cylindrical vessels working as follows:

14
 - one is full on-spec. polymer grade propylene

- one is crossed and feeds the polymerization section;

- one is empty to receive eventual off-grade propylene.

The volume of each vessel is sized in order to have an autonomy of about 7hrs in case of propylene

purification troubles.

The storage of the propane by – product coming from the splitter column has been fixed

considering the large volume of the Refinery sphere to which the propane has to be sent and the

fact that the normal composition characteristics correspond to a commercial propane grade.

The storage capacity is fixed at one vessel of about 1.7 day’s autonomy (22 m3).

3.2.3 SECTION 150 -CATALYST PREPARATION

Section 150 of the P.P. plant is composed of the following parts:

1 - Catalyst Preparation

2 – Hydrogen Purification and Storage

3 – Xylene Wash System

4 – Heptane and Isopropyl Alcohol Storage

5 – Nitrogen Storage

1. Catalyst preparation

The catalytic system for the P.P. reactor is composed of (fig.8):

- FT 1 catalyst
- TEAL co-catalyst ( 50% and 7.5%
- MPT catalyst
FT 1 Catalyst, received in drums, is weighed and slurried with treated Mineral oil and treated
petroleum in D – 156 agitated vessel and then Continuously fed, from the agitated surge drum
15
D–157 to the homopolymer reactor by means of the progressive cavity metering Pumps G 154 /
R. Mineral oil and petrolatum received in drums are treated under vacuum in the agitated
vessels D – 151 and D – 162. Intermediate storage tanks D – 152 and D – 163 and metering
tanks D-153 and D – 164 are provided for mineral oil and petrolatum. (D – 164 is not shown)

TEAL co-catalyst is weighed and directly fed from portable shipping containers to the
polymerization reactor by means of metering pumps (G – 151 / R to feed the homopolymer
reactor with TEAL 50% Concentration; G – 159 / R to feed the copolymer reactor with TEAL
7.5% Concentration). The TEAL 50% and 7.5% concentration storage is based on 6 months
Consumption using 1980 gallon portable tanks.

MPT co-catalyst, received in commercial drums, is dissolved with heptane in the agitated vessel D-
158, dried through BE-152 molecular sieves bed and then continuously fed, from the surge drum D-
159, to the primary homopolymer reactor by means of metering pumps G-156/R.

2. Hydrogen Purification and storage

The raw hydrogen, coming from Warri Refinery, is purified and dried in the purification unit Y-151
having a capacity of 40 Nm3 / hr. (Fig. 9.). The purified hydrogen is compressed by P-151
compressor up to 200 kg/cm and stored in ten pressure storage tanks (D-166 A - J). The purified
hydrogen storage is designed to have a storage capacity of 8 days based on the average consumption
of the polymerization, which is 10 Nm3/h.

3. Xylene Wash System

Xylene is used for washing the equipment used in polymerization area. The Xylene wash system

consists of storage tank for fresh, intermediate and fouled xylene (Fig.10): D-169 (150 m3), D-

170 (80 m3), D-171(80m3) and of flash drum D-168 with relevant overhead condenser E-152.

The storage of fresh xylene is seized to have about 2 year’s autonomy on the base of the

consumption of about 21,000 kg every six months.

4. Isopropyl alcohol and heptane storage

16
Isopropyl alcohol (IPA) is used as catalysts deactivator, is stored in the D-172 tank (80m3) and

fed to the polymerization section by G-162 pump (Fig.11). Heptane is used in catalyst

preparation, is stored in the D-160 tank (50m3) and fed to catalysts preparation by G-158 pump

through BE-151 molecular sieves drier and D-161 metering tank. The storage is sized to have

about 6 month’s autonomy on the base of the average consumption.

5. Nitrogen Compressor and Storage

Low pressure nitrogen (N2) is compressed by P-752 compressor and storage in the pressure tanks D-

752 A/B. The H.P. nitrogen is filtered and sent to the users (Fig.12).

3.2.4 SECTION 200 -POLYMER POWDER PRODUCTION

The polymer powder production section has a design capacity of 4375kg/hr homopolymer or

copolymer has final pallets product. A flow sheet of the polymer production section is shown in

Fig.5 (flow-sheet of the whole plant).

Depending on the type of polymer produced, propylene or propylene and ethylene are fed to the

reactor together with the MPT co-catalyst solution. The vapours coming from the reactor are

compressed by the compressor P-201R and mixed with the ethylene feed.

The polymer powder discharged from the reactor is conveyed to the homopolmer bag filter

PF201 in which the polymer powder is separated from the unreached monomer (Fig.13) which

is cycled to the propylene purification section by the screw compressor P-202. During the

homopolymer run, the polymer powder from the bag filter PF-201 is transferred to the bag filter

PF-203 by the gas (transfer gas) separated from the bag filter PF-203.

17
 Fig. 13 : typical bag filter
1. - Bag support and shaking mechanism
2. - Clean gas side (unreacted monomer)
3. - “Dirty” gas side (containing the
polymer powder)
4. - Polymer powder discharged
A gaseous stream coming from PS-203 (unreacted monomers) is passed through the bag filter

PF-202 and continuously recycled to the blenders by means of the compressor P-203, passing

through the cooler E-107; a portion of this stream is purged to the propylene purification.

3.2.5 SECTION 300 –POLYMER ADDITIVATION AND EXTRUSION

1. Polymer Additivation and Blending

The polymer powder collected in the surge silo D-301 A/B is additivated with appropriate
chemicals and discontinuously blended in PS-301 A/B. In the meantime a hot nitrogen sweep
gas flow is passed through the blenders PS-301 A/B to remove the residual solvents and
screens PV – 301 A/B and pneumatically conveyed by Y – 302 A/B transfer system (4,000 kg/h
of pellets maximum capacity) to the weighed test bins (Fig. 14). Four test bins divided in two
sections are provided: D 309 A – D (26 m3 total capacity each).

Pellet samples are drawn from the bin sections in order to test the quality of the product. After
the analysis, the product is pneumatically conveyed to storage silos. The configuration and
design of the section are based on the installation of two extrusion units, normally producing the
18
same type of product with the same additives. There are times when one extruder may be
producing off-grade while the other is not. There are also times during transition when one
extruder is finishing one product while the other is starting a new one. Provisions must be taken
to put the product from these extruders into different lots.

Weighed test bins are installed downstream extruders, to allow strict quality control of the
production and minimization of off-grade grades. Each test bin section will be able to receive a
quality of pellets corresponding to an additive blender batch. The duration of the pellets analysis
from the test bins is fixed at 2 hours.

Fig. 14 – Extrusion and Pelletizing of Plastic Powers

1 – Plastic powder
2 – Extruder
3 – Plastic thread
4 – Cutter
5 – Plastic pellets

3.2.6 SECTION 400 – STORAGE AND BAGGING.

1. Homogenization and storage

On – grade product is stored in the silos D – 402 A – F (250m3 each) and D – 405 A/B (100 m3

each) while off-grade product is stored in the silos D-403 A/B (100 m3 each) The

homogenization is performed by using one blending silo D – 401 (250m3).

The Y – 401 pneumatic haulage (10,000 kg/h pellets maximum capacity) is used for conveying
the pellets from the test bins to the above said storage silos. The product is homogenized and

19
conveyed between the storage and blending silos by pneumatic haulage Y – 402 (20,000 kg/h of
pellets maximum capacity).

Provisions are made for washing the silos with demineralized water.

The configuration of the unit is based on the following points:

- The product homogenization is performed in 100 ton/lot by using one blending silo.

- The storage capacity is based on a production of 56 hours (week-end) during which the
bagging is not performed. Some extra storage silos have been added in order to increase the
storage capacity (one 250m3 silo and two 100m3 silos).

- All off-grade produced is assumed to be bagged. Silos are washed at every product change

or after 5 lots of the same product. The blender silo is washed after each lot.

2. Bagging and palletizing

The bagging section is shown in Fig.15

By the pneumatic haulage Y – 403 (40,000 KG/H of pellets maximum capacity), the product is

conveyed to the surge silo D-404 (50m3) which feeds the bagging machine PX-401 (Fig.12).

The capacity of bagging unit is 600 bags/hr with 25 kg bags. Using the belt conveyor T-401, the

bags are sent to the marking device PX-404 and then to the bag control unit which consist of:

metal detector PX-402, bag weight check scale K-401 and bag rejecting device PX-403. Bags

are conveyed from bagging unit, by the sloped belt conveyor T-402, to the palletizing unit PX-

405; Pallets are conveyed by the roller table T-403 to the wrapping machine PX-406 and then to

the thermoshrinking unit PX-407. Pallets are then parked on the roller platform T405 and then

stored in the warehouse by fork-trucks.

The configuration and design of the unit is based on the following points:

 The pallets product is to be handled in 25 kg bag on 1 ton pellets.

20
 The bagging is to be performed in 5 days per week and in two 8 hours shifts per day.

Fig. 15: Bag Packing and Pallet Forming

1 – Bins
2 – Hopper
3 – Weighing
4 – Packing
5 – Final weighing
6 – Pallet forming

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4.0 CHAPTER FOUR
4.1 WORK EXPERIENCE/KNOWLEDGE ACQUIRED
• Main properties and characteristics of commercial polypropylene

• Homopolymer and a co-polymer production

• Differences between low-yield and high – yield processes

• Simple block-diagram of the polypropylene

• Main sections of the polypropylene production process

• The main steps of the polypropylene process with the help of a simple flow-diagram.

• Raw materials, products, and the capacity of the polypropylene plant

• The sections of the polypropylene plant

• Description of the production process

• Recognition of the equipment of the plant on the process flow-sheet

• Description the main equipment and their function

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5.0 CHAPTER 5
5.1 RECOMMENDATION/CONCLUSION

During my SIWES I gained a lot of experience and I met a lot of professionals that assisted me
during my stay at WRPC. As a result, I will like to recommend that SIWES should be done by
every student in Higher Institutions. It exposes students to the life outside school and prepares
them for real world challenges. The Program also gives students the opportunity to interact
with industrial workers in their respective field of study and even have mentors in the industry.

There is no doubting the important role SIWES plays in the educational system. I am very
glad and grateful for the opportunity to have practiced what I was taught in school, because
wisdom is the right application of knowledge. It is not enough to know something alone, but
also to know how to apply it to solve real world problems.

SIWES gave me the exposure I needed and at the right time. I was exposed to the “Real World” and
saw that everything indeed has an application and a purpose.
In conclusion I highly recommend that any institution not currently engaged with SIWES
should because it gives students technical skills needed for real jobs and also gives them an
idea of what they would encounter after school.

23