PPIV PLANT

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

Homo Poly, Random poly, High-impact Co Poly

MFI range

0.3 to 400

Additives

Irganox 1076,Irgaphos PEPQ, Irgaphos 168,Irganox 1010,

Calcium Stearate.

Product name

REPOL

Reaction Killer

CO

Department

Polypropylene Applications:
Sr.
No

Product

MFI g/10 min

Applications

AS030N

3.0

Woven fabrics, Raffia, Sacks & Monofilaments

AS160N

16.0

Staple fiber & Multifilament yarn.

AM120N

12.0

Industrial moulding, Rigid Packing & Furniture

AM650N

65.0

Thin walled injection moulded articles,

Housewares, Compounding

AER003N

0.3

Pipes, Fittings, Sheets & Thermoforming, High

clarity bottles, containers, sheets

AMI400N

40

Thin walled moulding, compounding

AS4000N

400

Melt blown and compounding applications

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

Basell Spheripol Process:

Maximum number of plants worldwide
High yield high stereo specific (HYHS) mgcl2 supported ZN. Catalyst originally
developed by Mont Edison and Mitsui.
No catalyst removal stage
Two stage process - single or twin bulk loop configuration with gas phase reactor in
series
Polymerization at 60-80c & 30-40 bar
Very wide MFI range
Spherical polymer beads with no pelletization - Addipol process

Department

Capabilities :

Department

Process Flow Diagram

Department

10

Process Flow Diagram:

LOOP REACTOR

Proplyene to Loop Reactor

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 FEED TANK

PROPYLENE FOR
POLYMERISATION

Department

15

Propylene Specifications:

Department

16

Catalyst System:
CATALYST :

ZN118

( TITANIUM TETRA CHLORIDE ON MAGNESIUM CHLORIDE

SUPPORT)
SENSITIVE TO POISONS LIKE H2O, CO, MA-PD, S, COS, ARSINE ETC.
COCATALYSTS :
TEAL
( TRI ETHYL ALUMINUM )
It activates the catalyst to initiate the chain growth
C- DONOR
( CYCLO HEXYL METHL DI METHOXY SILANE )
It blocks the atactic sites and controls the isotactic content.

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

Pre Poly Reactor:

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.

Density ~ 510 Kg/M3

Head 4 meter

Yield ~ 300 gm/gm/cat.

Pump

Polymer Conc. 14 % wt.

Department

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

Density 560 kg/M3

LOOP REACTOR

Res. Time 1.5 hr

34-36.5 Kg/cm2, 70 Deg C

Surge
Drum
DMW

Hydrogen

From
Prepoly
Reactor

Flow 7000 M3/hr.

DMW

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

HI Press. & Low Press. Degassing:

RPM 1450
PP +
Propylene
vapor from
Flash line

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

HI Press. & Low Press. Degassing:

High pressure degassing:

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.

Low pressure degassing:

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

Gas Phase Reactor:

RPM - 2
M
From
Flash
Drum
14 kg/cm2

DMW

80 Deg C
Res. Time 30 min.
DMW

C3 + H2

Volume 35.6 M3

C2

Gas Surface Vel. 0.7 M/Sec.

Flow 10000 M3/hr

Head 500 M
To Bag Filter
Department

26

Gas Phase Reactor:

Production of high impact copolymers in the bulk plant is carried out in
the gas phase reactor.
Homopolymer flows by differential pressure from the flash drum to the
copolymer reactor where it is fluidized by a predetermined mixture of
propylene, hydrogen and ethylene.
The polymer level determines the residence time and hence the extent of
polymerization that takes place.
All unreacted monomer is recycled back to the fluidizing compressor
suction.
Finished high impact copolymer is discharged to the bag filter for
separation of residual monomer

Department

27

Steamer And Dryer:

From Bag
Filter

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

Steamer And Dryer:

Steaming:
The polymer discharged from bag filter flows by gravity to a low speed
stirred steamer. Low pressure steam entering the bottom of the
steamer serves to deactivate catalyst and donor residues and to drive
off monomers remaining with the polymer.

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.

PolymerAdditive mixture is blended and discharged to the second horizontal

mixer where solid additives are fed to aim the stabilization.

Department

32

Polymer Additivation
Liquid additives
1.

Irganox 1076

32 %

2.

Irganox 1010

45 %

3.

Irgaphos PEPQ

13.5 %

4.

Irgaphos 168

9.5 %

Additive batch of the above additive is made in Vaseline oil.

Solid additive
CALCIUM STEARATE

200 ppm

It is used as acid scavenger to neutralize the acidity of polymer and as

an external lubricant.

Department

33

Beads Cooling & Screening

Polymer from Blender
60 deg C

BEADS
COOLER
45 deg C

Nitrogen

SCREEN

OVER SIZE >10 mm

REGULAR
PRODUCT

FINES < 1 .4 mm

Department

34

Product Silos & Homogenization

Product from Addipol Section

PRODUCT
SILO

PRODUCT
SILO

PRODUCT
SILO

PRODUCT
SILO

PRODUCT
SILO

HOMO
SILO

To
Bagging
Silos

Capacity : 500 M3 each

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

Product Bagging Machine

36

Offsite & Utilities

Department

37

Offsite & Utilities

N2O2 Plant
Supplier:

Liquid Air Engineering India(P) Ltd.

Type:

Air Liquefaction

Capacity:

1420 NM3/ Hr.(Gas Nitrogen) at 5.0 Kg/cm2

80 NM3/ Hr.(Liq. Nitrogen)
845 NM3/ Hr.(Oxygen Gas) at 0.3 Kg/cm2

Purity:

Nitrogen: 99.99%(Vol.)
Oxygen: 99.5%(Vol.)

Department

38

Offsite & Utilities

Instrument Air System
Supplier:
Capacity:
Pressure:

Clean Air
1600 M3/Hr
5.5 Kg/cm2

Cooling Tower
Supplier:
Flow rate:

Paharpur
2200 CMH/Cell

Department

39

Power & Utilities

Requirements

Department

40

Power & Utilities

Utilities

Specific
Consumption

Parameters

Source

Pressure

Temperature

Cooling Water

0.099 KM3/MT PP

5.0 Kg/cm2

30 Deg C

O & U, BBP

Low Pressure Steam

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

Catalyst loading and

unloading Procedures

Department

42

Catalyst System:
CATALYST :

ZN118

( TITANIUM TETRA CHLORIDE ON MAGNESIUM CHLORIDE

SUPPORT)
SENSITIVE TO POISONS LIKE H2O, CO, MA-PD, S, COS, ARSINE ETC.
COCATALYSTS :
TEAL
( TRI ETHYL ALUMINUM )
It activates the catalyst to initiate the chain growth
C- DONOR
( CYCLO HEXYL METHL DI METHOXY SILANE )
It blocks the atactic sites and controls the isotactic content.

Department

43

Catalyst loading and unloading Procedures

CATALYST BATCH PREPARATION :
Standard Operating Procedure for Making Catalyst (Zn-118) Batch
1. Roll the catalyst drum to site (100 area) from storage room.
2. Check N2 blanketing pressure after opening the lid.
2.1 Discard the drum, if N2 blanketing is completely lost.
3. Mount the drum on D106 distance piece used to connect drum with
D106 should be completely cleaned.
4. Take 115 liter of oil in D106
5. Raise A106 speed to maximum
6. Heat the oil and hold it at 90 Deg C for half an hour.
7. Pour the catalyst from drum into D106
7.1 Do it slowly & uniformly use vibrator only for short time.
7.2 Take min half an hour to charge 40 kg of catalyst.
7.3 Hold it for half an our. Let catalyst absorb the oil.
7.4 Lower the temperature to 20 Deg C .

Department

44

Catalyst loading and unloading Procedures

CATALYST BATCH PREPARATION :
Standard Operating Procedure for Making Catalyst (Zn-118) Batch
8. Add 65 liter of grease in D106 slowly such that D106 temperature does not go beyond
20Deg C-25 Deg C.
8.1 Cool the contents to 10oC as far as possible.
9. Fill catalyst mud in D113 from D106 slowly in about hr.
9.1 Take 20-30 gm. of sample in open mouth glass bottle.
9.2 Send it to laboratory for determination of mg concentration
9.3 Expected value of mg conc. is 33 gm. / kg of catalyst.
9.4 Remove catalyst strainer cartridge for cleaning.
9.5 Box up strainer housing without strainer.
9.6 Return catalyst mud from D113 to D106.
9.7 Box up strainer housing with clean strainer in place.
10. Reduce A106 speed to 5 rpm.
11. Dismount catalyst drum.
12. Wash distance piece thoroughly with water, dry it with N2 and leave it with blanketing
on.

Department

45

Catalyst loading and unloading Procedures

Department

46

Catalyst loading and unloading Procedures

Department

47

Drain, Blow down, Vent

& safety relief

Department

48

Drain, Blow down, Vent & safety relief

Department

49

Drain, Blow down, Vent & safety relief

Department

50

Drain, Blow down, Vent & safety relief

Department

51

Department

52