Volume 1 - General_v1-ch05-process Design Basis Rev1
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VOLUME 1
CHAPTER 5
PROCESS DESIGN BASIS
1
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CONTENTS
1.
GENERAL
2.
FEEDSTOCK PREPARATION UNIT
3.
CATALYST FEEDING
4.
POLYMERISATION UNIT
5.
POWDER DEGASSING AND POWDER CONVEYING
6.
LIQUID RECOVERY UNIT
7.
EXTRUSION FEEDING AND PELLETISATION
8.
PELLET CONVEYING AND BLENDING
9.
UTILITIES
10.
ADDITIVE / CATALYST STORAGE BUILDING
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.
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1.
GENERAL The information contained within the polyethylene gas phase plant.
2.
this
chapter
details
the
design
basis
for
FEEDSTOCK PREPARATION UNIT The ethylene and pentane systems are sized to meet Innovene-G specification. Pentane storage is sized for 24h at maximum normal consumption. The pentane treater is sized for 6.3 t/h feed from OSBL. An ethylene compressor is required to maintain a minimum flow through the treater beds to avoid exotherm. The comonomer (Butene-1, Hexene-1 and Octene-1) system is sized to meet InnoveneG specification. Two identical treaters are used (one in operation, one spare used during regeneration) and are sized on the most constraining comonomer. Comonomer Buffer Storage is sized for 20 min residence time. A comonomer recycle is provided to ensure minimum flow through the treaters. The Hydrogen system is sized to meet Innovene-G specification. A hydrogen compressor is required to increase the pressure from Battery Limit. Hydrogen system is sized for the reactor loop gas phase composition make-up flowrate. All systems are sized for 60-110% of normal capacity, except for treaters and where minimum flows are specifically requested by Vendor. Treaters are sized based on normal maximum flow for catalyst quantities and design flow for hydraulics. Adsorption time is at least 21 days on ethylene and comonomers and 30 days for pentane and hydrogen. Nitrogen system is sized to meet the different required Innovene-G specifications. It is designed to ensure purification of nitrogen peak flowrates. The Feedstock Preparation Unit and Nitrogen treaters regeneration system is sized for one regeneration at a time.
3.
CATALYST FEEDING Ziegler (SDx or NCT) catalyst and Metallocene catalyst will be delivered by tote bin and stored ISBL in a safe area until required (Metallocene catalyst to be stored in a storage area maintained under 25°C). The tote bin dimensions, engineering details and supply
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will be through INEOS. Although the tote bin design is outside the scope of this PDP, the catalyst quantity per tote bin is about 350 kg. 3 catalyst transfers (one for Ziegler SDx, one for Ziegler NCT and one for Metallocene) but 2 injection systems (one for Metallocene and one for the two Ziegler catalysts) are installed. Catalyst is transferred on a batch-wise basis by gravity to the catalyst injection unit. The frequency of transfers will depend on the catalyst productivity (grade dependant) and the production output. The sizing of the storage capacity allows transfer of a full totebin without interruption to the polymerisation process. A dedicated vent collection system for streams containing catalyst powder is provided. Ziegler catalyst is normally injected into the reactor through a single line, the additional line is spare. Metallocene catalyst is normally injected through three lines and no additional spare line is foreseen.
4.
POLYMERISATION UNIT The Polymerisation Unit is designed for the production of LLDPE and HDPE products using continuous direct injection of catalyst (Ziegler SDx or Ziegler NCT or High Performance Metallocene). The design grade mass balances are detailed in Chapter 7 of this volume. The mass balance information is typical of each grade of product only. The polymerisation reactor operating conditions for the design grade mass balances are detailed in Table 4.1 given at the end of this chapter. The Main Loop Condenser 3200-E-400 is designed without any margin other than that contained in the fouling factor. The recirculating cooling water temperature is adjusted to compensate for the variation in 3200-E-400 heat duty by acting on fresh make-up (the cooling water flow rate to 3200-E-400 being fixed). Minimum PU production rate is 60% for each grade. TEAL area is sized for 2 containers connected to process. Pumps are sized for normal operation and purification / passivation in Ziegler operation. Volume of container for one change-over every 14 days minimum. Liquid additives S1 and B1 system are injected pure.
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5.
POWDER DEGASSING AND POWDER CONVEYING Degassing design operating criteria are given in Table 5.1 given at the end of this chapter. Envelope of conditions for safe degassing is shown in table 5.2 Recycle Gas compressor 3200-K-675 operates from 0% to 100% of the machine capacity via variable speed motor and recycle valves, including the nitrogen case for which lower pressure is allowed. 3200-K-675 will be a non-lubricated screw compressor. The suction KO drum 3200-V-675 is equipped with a vane pack demister and continuous liquid recycle. Recycle around the Degasser 3200-V-628 by the means of 3200-DX-632 is sized for the minimum speed of the rotary valve 3200-X-628. Recycle around the Purge Column 3200-V-640 through 3200-X-666 is at low speed of 3200-X-666 but not less than 2,000 kg/h. Transfer of start-up powder from 3200-V-640 to the reactor 3200-R-400 via 3200-X-666 and 3200-X-667 is maximised using 3000 Nm3/h of HP nitrogen. Powder conveying package 3200-A-660 is sized for 105% of the production rate (46200 kg/hr). Purge column outlet rotary valve 3200-X-640 is sized for the extruder design rate (53000 kg/hr). The surge capacity of 3200-V-640 is sized for 4 hours at design production rate. The Vent Recovery Unit is sized to recover comonomer and pentane extracted from the powder and to purify the stripping gas to the Degasser by lowering the temperature to -35°C at Recycle Gas Compressor outlet pressure. This temperature is achieved by means of Refrigeration on Package 3200-A-675. The Refrigeration Package 3200-A-675 is operable with no-load. In C8 operation only, additional degassing is carried out in the 3200-V-638 C8 Degasser. Powder from the Degasser, 3200-V-628 is diverted to the C8 Degasser to remove heavier hydrocarbons from the powder. A dedicated low pressure C8 VRU including a refrigeration unit 3200-A-684 (Process conditions : 2.2 bara / -35°C) recovers the hydrocarbons from the off gas and a centrifugal one stage compressor 3200-K-685 recycles the nitrogen-rich gas back to the bottom of the C8 Degasser.
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.
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6.
LIQUID RECOVERY UNIT HCD storage drum 3200-V-711 is sized for plant deinventory or for 3 days storage of normal liquid purge in Ziegler operation. LRU distillation unit is sized for 1000 kg/h allowing treatment of full HCD storage drum contents in about 2 days. Residue contains up to 5% wt of TEAL. Distillate (HCC) to OSBL is free of fines and aluminium (less than 50 ppb wt). Clean HC drain drum 3200-V-714 and LRU residue buffer drum 3200-V-713 are sized for 1 hour operation. For C8 operation, LRU Recycle Fan 3200-K-711 is used to provide sparge gas to reboiler 3200-E-711 to separate C8 / TEAL whilst maintaining low temperature in the reboiler.
7.
EXTRUSION FEEDING AND PELLETISATION In this section, the virgin degassed powder from the Purge column 3200-V-640 goes through a Polymer Vibrating Screen 3200-S-820 which removes oversized polymer and then feeds the Extruder First and Second Feed 3200-M-820/821 through 3200-X-640 under flow control. 3200-X-640 and 3200-M-820/821 are designed to operate up to 120% of max production rate. 3200-M-820/821 are designed for 10 seconds minimum residence time and are equipped with variable speed drive to control the powder rate at extruder start-up. Additives are fed to the Extruder First and Second Feed Screws 3200-M-820/821 by Loss in Weight Feeders. Individual neat additives are used. They are fed from 6 unloading stations 3200-X-835 A to F for FIBCs (also known as big bags), via additive feeders 3200-W-835 A to F designed to operate from 200 ppm dosing rate on extruder turndown (except for antioxidants feeders, which is extruder start-up rate) up to 2500 ppm dosing on extruder design rate depending on additives. Different types of screw internals may be used to cover the flow range. Each unloading station has the facility to also handle 25 kg bags. The loading station hoppers of 3200-V-835 A to F are sized to contain at least 20 minutes of most of additives to allow change of big bag. The virgin powder and additives are then fed directly to the extruder package 3200-A-820.
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Pellet Purge Silo 3200-V-855 (1h storage) is used at start-up and feeds directly the Extruder Feed Hopper 3200-V-840 via rotary valve 3200-Q-855 designed to operate up to 15% of max normal extruder rate. The Extruder package 3200-A-840 has an overdesign capacity of 20% (53000 kg/h). The Extruder package 3200-A-840 has a turndown capacity of 60% of design rate. Pellets from the extruder are dried and screened to remove oversize and undersize pellets, and pass to the Pellet Conveying Hopper 3200-V-850. The Pellet Conveying Hopper is normally empty, but is designed with 7 minutes residence time at LAHH at extruder design rate, with a 2 minutes residence time above LAHH at extruder design rate, to allow an extruder stoppage. Pellets are then transferred to the Pellet conveying and Blending Unit using a pneumatic air conveying system 3200-A-850 designed for a pellet capacity of 56 t/h for all grades.
8.
PELLET CONVEYING AND BLENDING The pelletising line is followed by a dedicated Pellet Blending Unit with two Pellet Blenders, 3200-M-880 A/B, with a capacity of 650 m3 each at LAHH. Any of these silos can be used as a transition silo when necessary. Pellets are blended continuously under weight or level control and are transferred to OSBL via an elutriation unit using a pneumatic air conveying system 3200-A-880 (outside of PDP scope) with a 64 t/hr pellet capacity.
9.
9.1
UTILITIES
VENTS & FLARE The final sizing of all Vent and Flare Systems is the responsibility of the Engineering Contractor. The PDP gives a preliminary sizing based of preliminary effluent balances. Relief Vent Drums 3200-V-150 and 3200-V-152 are cyclonic design optimised for highest discharge flow. Catalyst Vent Filter 3200-S-151 is designed to remove all particles larger than 0.5 microns.
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.
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9.2
Utilities battery limits and distribution It consists of metering and distribution of steam, steam condensate, cooling water, other waters, instrument air and standard quality nitrogens.
9.3
Nitrogen distribution Nitrogen is letdown to generate the various required pressure levels of nitrogen.
9.4
Primary aqueous treatment facilities The polymer water pit 3200-T-161 recovers the polymer powder and pellets coming from the plant. The volume is the addition of:
Rainfall hourly intensity and a holding time of 15 minutes,
The pellet water loop drain on extruder shutdown.
Oily water effluents and storm water effluents are sent to OSBL.
10.
ADDITIVE / CATALYST STORAGE BUILDING The additive / catalyst storage building is sized for 30 days storage for catalyst and additives.
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TABLE 4-1 - POLYMERISATION DESIGN OPERATING CRITERIA
LL0220
LL6209
PF6130
PF8130
44,000
44,000
44,000
40,000
- Ethylene % wt
91.87
90.0
90.3
87.69
- Butene-1 % wt
8.13
-
-
-
- Hexene-1 %wt
-
10.0
9.7
-
- Octene-1 %wt
-
-
-
12.31
16.64
9.89
5.54
5.78
MT
MT
Production Rate (kg/hr) Polymer composition:
Catalyst productivity (kgPE/gcatalyst) Catalyst type
Zg (SDX) Zg (NCT)
Reaction: Catalyst Flow to Reactor (kg/hr)
3.7
5.4
8.8
8.0
87
88
78
78
Operating pressure (bar a)
24.0
24.0
24.0
24.0
Fluidisation velocity (cm/s)
65
60
60
60
Fluidised bed height (m)
20
20
20
20
- Ethylene
10.0
10.0
15.0
15.0
- Butene-1
4.6
-
-
-
- Hexene-1
-
1.45
0.10
-
- Octene-1
-
-
-
0.03
- Hydrogen
2.7
1.4
0.08
0.08
- Pentane
2.5
0.1
2.6
2.8
Reactor top: Polymerisation temperature (°C)
Gas phase composition: Partial pressure (bar.a)
Reactor Diameter = 5.1 m
Working Bed Height = 20 m
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TABLE 5-1 - DEGASSING SYSTEM DESIGN OPERATING BASIS
Grade
LL0220
LL6209
PF6130
PF8130
Degasser 3200-V-628 Diameter (mm)
5000
Powder height (mm) (1) NL above (upper) gas distributor
5050
LSLL height (mm) (1) level above (upper) gas distributor
3800
Stripping gas Trip Flow (m³/h) (4)
1550
2130
2370
2370
Stripping gas Normal Flow (m³/h) (4)
1830
2570
2830
2840
C8 Degasser 3200-V-638 Diameter (mm)
10500
Powder height (mm) (1) NL above (upper) gas distributor
7875
LSLL height (mm) (1) level above (upper) gas distributor
7605
Stripping gas Trip Flow (kg/h) (4)
-
-
-
17100
Stripping gas Normal Flow (kg/h) (4)
-
-
-
23250
Purge Column 3200-V-640 Diameter (mm) (2)
2900
Powder height (mm) (1) NL above (upper) gas distributor
6100
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LSLL height (mm) (1) level above (upper) gas distributor
2290
Stripping gas Trip Flow (kg/h) (4)
660
1280
1280
1280
Stripping gas Normal Flow (kg/h) (3) (4)
780
1500
1530
1540
Notes: (1) Level at base of powder cone. (2) Upper degassing section. (3) 3200-V-640 start-up flow to lower section: 772 kg/h. (4) This flow includes degasser outlet rotary valve leakage.
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TABLE 5-2 – ENVELOPE OF CONDITIONS FOR SAFE DEGASSING The following table displays the different deviation cases that can occur in operation and which have been verified for degassing train design.
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Notes
Reactor
Temp. Normal Case 1 Case 2 Case 2bis Case 3 Case 4 Case 5 Case 6 Case 7 Case 8 Case 10 Case 11 Case 12 Case 13 Case 13bis Case 13ter Case 14 Case 15 Case 16 Case 17
All grades All grades All grades C6 grades All grades All grades All grades All grades All grades All grades All grades All grades All grades All grades C6 grades C8 grades C8 grades C8 grades C8 grades C8 grades
Normal TSL Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal
Gas Phase Composition Normal Normal SVP (1) SVP (1bis) Normal Normal Normal Normal Normal Normal Normal Normal Normal PC5 drift (5) PC6 drift (5bis) PC8 drift (5ter) Normal Normal Normal Normal
Production
rate 100% 100% 100% 100% 115% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
Degasser V628 Powder level Normal LAL LAL LAL LAL LSLL LAL LAL LAL LAL LAL Normal Normal LAL LAL LAL LAL LAL LAL
Stripping flowrate Normal FAL FAL FAL FAL FAL FSLL FAL FAL FAL FAL FAL Normal FAL FAL FAL FAL FAL FAL
Pressure Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal PSH Normal Normal Normal Normal Normal Normal Normal
V628 VRU
Temper.
Pressure
Normal Normal Normal Normal Normal Normal Normal TSHH (2) Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal
Normal Normal Normal Normal Normal Normal Normal PSLL (3) Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal
Purge Column V640 Powder level Normal Normal Normal Normal Normal LAL Normal Normal LSLL Normal Normal Normal Normal Normal Normal Normal LAL Normal Normal
Stripping flowrate Normal Normal Normal Normal Normal Normal FAL Normal Normal FSLL Normal Normal FAL Normal Normal Normal Normal FAL Normal
Pellet cooling water temp.
Pressure Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal PSH Normal Normal Normal Normal Normal Normal
60 60 60 60 60 60 60 60 60 60 90 (4) 60 60 60 60 60 60 60 60
Degasser V638 (C8) Powder level -
Stripping flowrate -
LAL LSLL LAL LAL LAL
FAL FAL FSLL FAL FAL
Trip cases consider the deviation of one single parameter at a time, with low stripping gas flow alarm and low level alarm on 3200-V-628, 3200-V-638 or 3200-V-640 as above. Design of the degassing section ensures that final product hydrocarbon levels cannot lead to LEL being exceeded downstream regardless of the case considered above. Notes: (1) Pentane accumulation until its dew point is reached at T=Tpoly. (1bis) Hexene accumulation until its dew point is reached at T=Tpoly. (2) High temperature trip means stripping gas poor gas quality to V628 or V638. (3) Low pressure trip means stripping gas poor gas quality to V628 or V638. (4) Trip temperature to adjust typically 90°C. (5) PC5 is increased in order to reach 50% LEL and getting the dT interlock trip on degasser. (5bis) PHexene is increased in order to reach 50% LEL and getting the dT interlock trip on degasser. (5ter) POctene is increased in order to reach 50% LEL and getting the dT interlock trip on degasser.
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V638 VRU (C8)
Pressure
Temper.
Pressure
-
-
-
Normal Normal Normal Normal PSH
Normal Normal Normal TSHH (2) Normal
Normal Normal Normal PSLL (3) Normal
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VOLUME 1
CHAPTER 5
PROCESS DESIGN BASIS
1
14-DEC-12
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CONTENTS
1.
GENERAL
2.
FEEDSTOCK PREPARATION UNIT
3.
CATALYST FEEDING
4.
POLYMERISATION UNIT
5.
POWDER DEGASSING AND POWDER CONVEYING
6.
LIQUID RECOVERY UNIT
7.
EXTRUSION FEEDING AND PELLETISATION
8.
PELLET CONVEYING AND BLENDING
9.
UTILITIES
10.
ADDITIVE / CATALYST STORAGE BUILDING
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1.
GENERAL The information contained within the polyethylene gas phase plant.
2.
this
chapter
details
the
design
basis
for
FEEDSTOCK PREPARATION UNIT The ethylene and pentane systems are sized to meet Innovene-G specification. Pentane storage is sized for 24h at maximum normal consumption. The pentane treater is sized for 6.3 t/h feed from OSBL. An ethylene compressor is required to maintain a minimum flow through the treater beds to avoid exotherm. The comonomer (Butene-1, Hexene-1 and Octene-1) system is sized to meet InnoveneG specification. Two identical treaters are used (one in operation, one spare used during regeneration) and are sized on the most constraining comonomer. Comonomer Buffer Storage is sized for 20 min residence time. A comonomer recycle is provided to ensure minimum flow through the treaters. The Hydrogen system is sized to meet Innovene-G specification. A hydrogen compressor is required to increase the pressure from Battery Limit. Hydrogen system is sized for the reactor loop gas phase composition make-up flowrate. All systems are sized for 60-110% of normal capacity, except for treaters and where minimum flows are specifically requested by Vendor. Treaters are sized based on normal maximum flow for catalyst quantities and design flow for hydraulics. Adsorption time is at least 21 days on ethylene and comonomers and 30 days for pentane and hydrogen. Nitrogen system is sized to meet the different required Innovene-G specifications. It is designed to ensure purification of nitrogen peak flowrates. The Feedstock Preparation Unit and Nitrogen treaters regeneration system is sized for one regeneration at a time.
3.
CATALYST FEEDING Ziegler (SDx or NCT) catalyst and Metallocene catalyst will be delivered by tote bin and stored ISBL in a safe area until required (Metallocene catalyst to be stored in a storage area maintained under 25°C). The tote bin dimensions, engineering details and supply
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will be through INEOS. Although the tote bin design is outside the scope of this PDP, the catalyst quantity per tote bin is about 350 kg. 3 catalyst transfers (one for Ziegler SDx, one for Ziegler NCT and one for Metallocene) but 2 injection systems (one for Metallocene and one for the two Ziegler catalysts) are installed. Catalyst is transferred on a batch-wise basis by gravity to the catalyst injection unit. The frequency of transfers will depend on the catalyst productivity (grade dependant) and the production output. The sizing of the storage capacity allows transfer of a full totebin without interruption to the polymerisation process. A dedicated vent collection system for streams containing catalyst powder is provided. Ziegler catalyst is normally injected into the reactor through a single line, the additional line is spare. Metallocene catalyst is normally injected through three lines and no additional spare line is foreseen.
4.
POLYMERISATION UNIT The Polymerisation Unit is designed for the production of LLDPE and HDPE products using continuous direct injection of catalyst (Ziegler SDx or Ziegler NCT or High Performance Metallocene). The design grade mass balances are detailed in Chapter 7 of this volume. The mass balance information is typical of each grade of product only. The polymerisation reactor operating conditions for the design grade mass balances are detailed in Table 4.1 given at the end of this chapter. The Main Loop Condenser 3200-E-400 is designed without any margin other than that contained in the fouling factor. The recirculating cooling water temperature is adjusted to compensate for the variation in 3200-E-400 heat duty by acting on fresh make-up (the cooling water flow rate to 3200-E-400 being fixed). Minimum PU production rate is 60% for each grade. TEAL area is sized for 2 containers connected to process. Pumps are sized for normal operation and purification / passivation in Ziegler operation. Volume of container for one change-over every 14 days minimum. Liquid additives S1 and B1 system are injected pure.
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5.
POWDER DEGASSING AND POWDER CONVEYING Degassing design operating criteria are given in Table 5.1 given at the end of this chapter. Envelope of conditions for safe degassing is shown in table 5.2 Recycle Gas compressor 3200-K-675 operates from 0% to 100% of the machine capacity via variable speed motor and recycle valves, including the nitrogen case for which lower pressure is allowed. 3200-K-675 will be a non-lubricated screw compressor. The suction KO drum 3200-V-675 is equipped with a vane pack demister and continuous liquid recycle. Recycle around the Degasser 3200-V-628 by the means of 3200-DX-632 is sized for the minimum speed of the rotary valve 3200-X-628. Recycle around the Purge Column 3200-V-640 through 3200-X-666 is at low speed of 3200-X-666 but not less than 2,000 kg/h. Transfer of start-up powder from 3200-V-640 to the reactor 3200-R-400 via 3200-X-666 and 3200-X-667 is maximised using 3000 Nm3/h of HP nitrogen. Powder conveying package 3200-A-660 is sized for 105% of the production rate (46200 kg/hr). Purge column outlet rotary valve 3200-X-640 is sized for the extruder design rate (53000 kg/hr). The surge capacity of 3200-V-640 is sized for 4 hours at design production rate. The Vent Recovery Unit is sized to recover comonomer and pentane extracted from the powder and to purify the stripping gas to the Degasser by lowering the temperature to -35°C at Recycle Gas Compressor outlet pressure. This temperature is achieved by means of Refrigeration on Package 3200-A-675. The Refrigeration Package 3200-A-675 is operable with no-load. In C8 operation only, additional degassing is carried out in the 3200-V-638 C8 Degasser. Powder from the Degasser, 3200-V-628 is diverted to the C8 Degasser to remove heavier hydrocarbons from the powder. A dedicated low pressure C8 VRU including a refrigeration unit 3200-A-684 (Process conditions : 2.2 bara / -35°C) recovers the hydrocarbons from the off gas and a centrifugal one stage compressor 3200-K-685 recycles the nitrogen-rich gas back to the bottom of the C8 Degasser.
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.
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6.
LIQUID RECOVERY UNIT HCD storage drum 3200-V-711 is sized for plant deinventory or for 3 days storage of normal liquid purge in Ziegler operation. LRU distillation unit is sized for 1000 kg/h allowing treatment of full HCD storage drum contents in about 2 days. Residue contains up to 5% wt of TEAL. Distillate (HCC) to OSBL is free of fines and aluminium (less than 50 ppb wt). Clean HC drain drum 3200-V-714 and LRU residue buffer drum 3200-V-713 are sized for 1 hour operation. For C8 operation, LRU Recycle Fan 3200-K-711 is used to provide sparge gas to reboiler 3200-E-711 to separate C8 / TEAL whilst maintaining low temperature in the reboiler.
7.
EXTRUSION FEEDING AND PELLETISATION In this section, the virgin degassed powder from the Purge column 3200-V-640 goes through a Polymer Vibrating Screen 3200-S-820 which removes oversized polymer and then feeds the Extruder First and Second Feed 3200-M-820/821 through 3200-X-640 under flow control. 3200-X-640 and 3200-M-820/821 are designed to operate up to 120% of max production rate. 3200-M-820/821 are designed for 10 seconds minimum residence time and are equipped with variable speed drive to control the powder rate at extruder start-up. Additives are fed to the Extruder First and Second Feed Screws 3200-M-820/821 by Loss in Weight Feeders. Individual neat additives are used. They are fed from 6 unloading stations 3200-X-835 A to F for FIBCs (also known as big bags), via additive feeders 3200-W-835 A to F designed to operate from 200 ppm dosing rate on extruder turndown (except for antioxidants feeders, which is extruder start-up rate) up to 2500 ppm dosing on extruder design rate depending on additives. Different types of screw internals may be used to cover the flow range. Each unloading station has the facility to also handle 25 kg bags. The loading station hoppers of 3200-V-835 A to F are sized to contain at least 20 minutes of most of additives to allow change of big bag. The virgin powder and additives are then fed directly to the extruder package 3200-A-820.
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Pellet Purge Silo 3200-V-855 (1h storage) is used at start-up and feeds directly the Extruder Feed Hopper 3200-V-840 via rotary valve 3200-Q-855 designed to operate up to 15% of max normal extruder rate. The Extruder package 3200-A-840 has an overdesign capacity of 20% (53000 kg/h). The Extruder package 3200-A-840 has a turndown capacity of 60% of design rate. Pellets from the extruder are dried and screened to remove oversize and undersize pellets, and pass to the Pellet Conveying Hopper 3200-V-850. The Pellet Conveying Hopper is normally empty, but is designed with 7 minutes residence time at LAHH at extruder design rate, with a 2 minutes residence time above LAHH at extruder design rate, to allow an extruder stoppage. Pellets are then transferred to the Pellet conveying and Blending Unit using a pneumatic air conveying system 3200-A-850 designed for a pellet capacity of 56 t/h for all grades.
8.
PELLET CONVEYING AND BLENDING The pelletising line is followed by a dedicated Pellet Blending Unit with two Pellet Blenders, 3200-M-880 A/B, with a capacity of 650 m3 each at LAHH. Any of these silos can be used as a transition silo when necessary. Pellets are blended continuously under weight or level control and are transferred to OSBL via an elutriation unit using a pneumatic air conveying system 3200-A-880 (outside of PDP scope) with a 64 t/hr pellet capacity.
9.
9.1
UTILITIES
VENTS & FLARE The final sizing of all Vent and Flare Systems is the responsibility of the Engineering Contractor. The PDP gives a preliminary sizing based of preliminary effluent balances. Relief Vent Drums 3200-V-150 and 3200-V-152 are cyclonic design optimised for highest discharge flow. Catalyst Vent Filter 3200-S-151 is designed to remove all particles larger than 0.5 microns.
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.
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9.2
Utilities battery limits and distribution It consists of metering and distribution of steam, steam condensate, cooling water, other waters, instrument air and standard quality nitrogens.
9.3
Nitrogen distribution Nitrogen is letdown to generate the various required pressure levels of nitrogen.
9.4
Primary aqueous treatment facilities The polymer water pit 3200-T-161 recovers the polymer powder and pellets coming from the plant. The volume is the addition of:
Rainfall hourly intensity and a holding time of 15 minutes,
The pellet water loop drain on extruder shutdown.
Oily water effluents and storm water effluents are sent to OSBL.
10.
ADDITIVE / CATALYST STORAGE BUILDING The additive / catalyst storage building is sized for 30 days storage for catalyst and additives.
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.
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TABLE 4-1 - POLYMERISATION DESIGN OPERATING CRITERIA
LL0220
LL6209
PF6130
PF8130
44,000
44,000
44,000
40,000
- Ethylene % wt
91.87
90.0
90.3
87.69
- Butene-1 % wt
8.13
-
-
-
- Hexene-1 %wt
-
10.0
9.7
-
- Octene-1 %wt
-
-
-
12.31
16.64
9.89
5.54
5.78
MT
MT
Production Rate (kg/hr) Polymer composition:
Catalyst productivity (kgPE/gcatalyst) Catalyst type
Zg (SDX) Zg (NCT)
Reaction: Catalyst Flow to Reactor (kg/hr)
3.7
5.4
8.8
8.0
87
88
78
78
Operating pressure (bar a)
24.0
24.0
24.0
24.0
Fluidisation velocity (cm/s)
65
60
60
60
Fluidised bed height (m)
20
20
20
20
- Ethylene
10.0
10.0
15.0
15.0
- Butene-1
4.6
-
-
-
- Hexene-1
-
1.45
0.10
-
- Octene-1
-
-
-
0.03
- Hydrogen
2.7
1.4
0.08
0.08
- Pentane
2.5
0.1
2.6
2.8
Reactor top: Polymerisation temperature (°C)
Gas phase composition: Partial pressure (bar.a)
Reactor Diameter = 5.1 m
Working Bed Height = 20 m
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.
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TABLE 5-1 - DEGASSING SYSTEM DESIGN OPERATING BASIS
Grade
LL0220
LL6209
PF6130
PF8130
Degasser 3200-V-628 Diameter (mm)
5000
Powder height (mm) (1) NL above (upper) gas distributor
5050
LSLL height (mm) (1) level above (upper) gas distributor
3800
Stripping gas Trip Flow (m³/h) (4)
1550
2130
2370
2370
Stripping gas Normal Flow (m³/h) (4)
1830
2570
2830
2840
C8 Degasser 3200-V-638 Diameter (mm)
10500
Powder height (mm) (1) NL above (upper) gas distributor
7875
LSLL height (mm) (1) level above (upper) gas distributor
7605
Stripping gas Trip Flow (kg/h) (4)
-
-
-
17100
Stripping gas Normal Flow (kg/h) (4)
-
-
-
23250
Purge Column 3200-V-640 Diameter (mm) (2)
2900
Powder height (mm) (1) NL above (upper) gas distributor
6100
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LSLL height (mm) (1) level above (upper) gas distributor
2290
Stripping gas Trip Flow (kg/h) (4)
660
1280
1280
1280
Stripping gas Normal Flow (kg/h) (3) (4)
780
1500
1530
1540
Notes: (1) Level at base of powder cone. (2) Upper degassing section. (3) 3200-V-640 start-up flow to lower section: 772 kg/h. (4) This flow includes degasser outlet rotary valve leakage.
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TABLE 5-2 – ENVELOPE OF CONDITIONS FOR SAFE DEGASSING The following table displays the different deviation cases that can occur in operation and which have been verified for degassing train design.
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Notes
Reactor
Temp. Normal Case 1 Case 2 Case 2bis Case 3 Case 4 Case 5 Case 6 Case 7 Case 8 Case 10 Case 11 Case 12 Case 13 Case 13bis Case 13ter Case 14 Case 15 Case 16 Case 17
All grades All grades All grades C6 grades All grades All grades All grades All grades All grades All grades All grades All grades All grades All grades C6 grades C8 grades C8 grades C8 grades C8 grades C8 grades
Normal TSL Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal
Gas Phase Composition Normal Normal SVP (1) SVP (1bis) Normal Normal Normal Normal Normal Normal Normal Normal Normal PC5 drift (5) PC6 drift (5bis) PC8 drift (5ter) Normal Normal Normal Normal
Production
rate 100% 100% 100% 100% 115% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
Degasser V628 Powder level Normal LAL LAL LAL LAL LSLL LAL LAL LAL LAL LAL Normal Normal LAL LAL LAL LAL LAL LAL
Stripping flowrate Normal FAL FAL FAL FAL FAL FSLL FAL FAL FAL FAL FAL Normal FAL FAL FAL FAL FAL FAL
Pressure Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal PSH Normal Normal Normal Normal Normal Normal Normal
V628 VRU
Temper.
Pressure
Normal Normal Normal Normal Normal Normal Normal TSHH (2) Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal
Normal Normal Normal Normal Normal Normal Normal PSLL (3) Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal
Purge Column V640 Powder level Normal Normal Normal Normal Normal LAL Normal Normal LSLL Normal Normal Normal Normal Normal Normal Normal LAL Normal Normal
Stripping flowrate Normal Normal Normal Normal Normal Normal FAL Normal Normal FSLL Normal Normal FAL Normal Normal Normal Normal FAL Normal
Pellet cooling water temp.
Pressure Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal PSH Normal Normal Normal Normal Normal Normal
60 60 60 60 60 60 60 60 60 60 90 (4) 60 60 60 60 60 60 60 60
Degasser V638 (C8) Powder level -
Stripping flowrate -
LAL LSLL LAL LAL LAL
FAL FAL FSLL FAL FAL
Trip cases consider the deviation of one single parameter at a time, with low stripping gas flow alarm and low level alarm on 3200-V-628, 3200-V-638 or 3200-V-640 as above. Design of the degassing section ensures that final product hydrocarbon levels cannot lead to LEL being exceeded downstream regardless of the case considered above. Notes: (1) Pentane accumulation until its dew point is reached at T=Tpoly. (1bis) Hexene accumulation until its dew point is reached at T=Tpoly. (2) High temperature trip means stripping gas poor gas quality to V628 or V638. (3) Low pressure trip means stripping gas poor gas quality to V628 or V638. (4) Trip temperature to adjust typically 90°C. (5) PC5 is increased in order to reach 50% LEL and getting the dT interlock trip on degasser. (5bis) PHexene is increased in order to reach 50% LEL and getting the dT interlock trip on degasser. (5ter) POctene is increased in order to reach 50% LEL and getting the dT interlock trip on degasser.
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V638 VRU (C8)
Pressure
Temper.
Pressure
-
-
-
Normal Normal Normal Normal PSH
Normal Normal Normal TSHH (2) Normal
Normal Normal Normal PSLL (3) Normal
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