International Process Plants

Stock #600316

Plasticizer Plant
Producing:

Phthalate Plasticizers & Multi-Product Esters (MPE)

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General Overview
Capacity: Raw Materials: Produces: Catalyst: Overall Yield: Process: 210 MM lbs/yr to 230 MM lbs/yr Long chain (C6 C13) alcohols, phthalic anhydride, adipic acid, maleic anhydride, trimellitic anhydride 13 different plasticizers are currently produced. (Plant has the capability to produce 20 standard grades) Toluene Sulfonic Acid Acid 96.0% - 98.5% Alcohol 94.0% - 96.0% Batch-type esterification with three reaction trains: #2 (59 MM lbs/yr) #3 (70 MM lbs/yr) #4 (51 MM lbs/yr) P&IDs, Process Flow and other documents are available

Documentation:

General Plant Comments

The plasticizer unit is based on technology including a novel purification method to improve quality. The installation provides the flexibility to produce 20 standard plasticizer grades and the plant can custom blend to suit customer requirements. Plasticizers are produced by reacting a dibasic acid (e.g. phthalic anhydride) with alcohol in the presence of a catalyst. Phthalic anhydride and 2-EH are received from another plant. Maleic anhydride is produced on site and other alcohols, adipic acid and trimellitic anhydride are purchased. Raw materials are received by barge or rail car. Plasticizer products are shipped by barge, rail car, tanker truck or in drums.

Process Overview
The plasticizer process reacts with acid anhydride or acid with an alcohol, in the presence of a catalyst, to form an ester. Upon reaction completion, catalyst and reaction byproducts are removed, excess alcohol and residual water are stripped from the product and the plasticizer is treated with activated carbon to improve purity. The plant has (3) separate processing units. (2) units produce phthalate plasticizers while the 3rd unit, the MPE unit, has the capability for producing specialty plasticizers such as maleates, adipates, and trimellitates in addition to phthalates. Each unit is a batch system, sequentially controlled using Rosemounts Distributive Control System (DCS). In addition, operators monitor process operation using standard data logging techniques and statistical process control techniques. Documented procedures and various mechanisms used are ISO 9002 certified. Product formulations and standard operating conditions used to produce each plasticizer are listed on operating specification sheets. Each reactor train has its own distinct set of operating specifications. These sheets are maintained by the plasticizer plant process engineer and are stored in the plants computer. A current set of the operating specifications is available at each reactor trains control room for use by the operators. The operating specifications direct the operators to set such parameters as raw material charging volumes, catalyst addition quantities, temperatures, etc.

Process Overview (continued)

A set of operating procedures have been developed for each plasticizer process train. These procedures are used in training new operators and are accessible to all operators, at all times, to assure that operations are carried out in a safe and consistent manner. The procedures include specific instruction for raw material charging, reactor operation, product recovery, product transfer, and product sampling testing. Production runs of different types of plasticizer are scheduled in such a way that the potential for cross contamination between products is minimized. Production planning schedules production based on the compatibility of the products. When it is not possible to schedule compatible products successively, the operators follow a detailed flushing procedure which is designed to clean out the system and eliminate cross contamination problems. Phthalic anhydride is charged to each reactor using a programmable controller and meter. Other raw materials are either metered into the reactor or weighed in weigh tanks prior to charging. Meter checks and calibrations of weigh cells are completed on a regular basis to ensure charging accuracy. Charging of the reactor is accomplished by the DCS system. During the reaction, temperatures, flow rates and pressures are automatically controlled by the DCS controllers and are also routinely monitored.

Process Overview (continued)

Reactors are sampled by the operators at specified intervals to monitor reaction progression. The samples are analyzed for residual acidity and color. Both values are plotted on control charts by the operator. The control charts are used to monitor process equipment operation and to verify that raw materials are being charged in the proper proportions to assure that finished product will meet specification. Test results are also entered on the individual batch sheet prepared for each batch. Once the esterification is complete, the crude plasticizer is transferred to the treater. Reaction catalyst is neutralized and impurities are broken down for later removal. Proper treater conditions are listed on the operating specification sheets. The operator samples the batch and analyzes the material to verify that all of the catalyst has been removed. Following these procedures, the plasticizer is transferred to the stripper feed tank. The material is then pumped at a controlled rate into the stripper where the product is vacuum stripped to remove excess alcohol and residual water. Samples of the stripper effluent area are analyzed by the Quality Control Laboratory to determine assay and residual alcohol. Analytical results reflect process performance and indicate if adjustment of stripper operating conditions is required. Stripper operating conditions are given on the operating specifications.

Process Overview (continued)

Stripped plasticizer is treated with activated carbon on trains 2 & 3, and a funda filter on train 4 to remove any residual color producing impurities. Product from carbon treatment is collected in batch product receivers and held for final approval. Stripper and carbon column conditions are monitored hourly by operators. Each receiver is checked for color, residual acidity, moisture and odor by the operator and must meet specifications before getting transferred to the field storage tanks. Wastewaters from the process are transferred to the wastewater treatment plant for processing with subsequent discharge of the treated wastewater and sludge to a facility. A single stage activated sludge biological treatment process is used. Operating parameters are controlled by a distributed control system with sample analysis and process monitoring by an operator.

Process Flow Diagram

Equipment Overview
This batch production operation consists primarily of processing equipment, material of construction of 316SS, 304SS, Glass Lined tanks and reactors and Hastelloy C reactors. Most all of the equipment has been upgraded from original construction. There were multiple upgrades in the 1980s and 1990s.
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DIRECTOR, PLANTS DEPT. Tele: 609-838-5930 (direct) Mobile: 609-516-9107 MichaelJ@ippe.com

MICHAEL JOACHIM

VP GLOBAL PLANT SALES Tele: 609-838-5938 (direct) Mobile: 609-510-2616 SanjeevR@ippe.com

SANJEEV REGE

IPP World Headquarters 17A Marlen Drive Hamilton, NJ 08691 USA Tele: +1 (609) 586 8004 Fax: +1 (609) 586 0002 Visit us at: www.ippe.com