International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
A Study on the Process Plant Design for the Production of
Polypropylene Plant
Dr A M Saravanan1, Khalid Ali Sulaiman2
Department of Mechanical and Industrial Engineering, Caledonian college of Engineering
Abstract--Polypropylene is considered as one of the
important polymer products that it has started to grow in a
wide range among other plastics. The reason of that is several
materials such as steel, wood, glass, paper and other metals
can be replaced by polypropylene from the point of effective
cost and performance.
This project will be theoretical project for the studies on
the production of polypropylene of 500 tons per day.
In this project the following are studied: properties,
various method production polypropylene, Selection of
process, Process description, Flow diagram of the selection
process, Plant location, Plant layout, Cost estimation, Safety,
Recommendation
Keywords--Polypropylene, propylene, Isotactic, random
copolymer, homopolymers
I. INTRODUCTION
Polypropylene is considered as one of the important
polymer products that it has started to grow in a wide range
among other plastics. The reason of that is several materials
such as steel, wood, glass, paper and other metals can be
replaced by polypropylene from the point of effective cost
and performance. Also, the application of polypropylene
can be found from household furniture, carpets, packaging
containers to pipes, automobile parts and many other
products that we even cannot imagine.
The first commercial production of PP began in the USA
in 1957 then followed in Europe in 1958. Since the 1980s
and until nowadays after passage of some 60 years from
Natta and Ziegler invention, polypropylene production,
consumption and application have increased and became
the first common large volume among the group of
thermoplastic industries used all over the world.
In general, the polymerization of Polypropylene is done
by contacting propylene and Zieglar-Natta catalyst.
Metallocene catalyst can be used instead of Zieglar-Natta
catalyst. The chemical structure of polypropylene
represents by the tacticity which is formed by different
ways, it depends on how the substituents are arranged on
the polymer backbone. So polypropylene can be isotactic,
syndiotactic or atactic.
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Polypropylene is classified to three major types:
homopolymer, random copolymer, and impact copolymer.
Propylene monomers are used to make homopolymer while
in random and impact copolymer ethylene and propylene
are used.
1.1 Application of polypropylene
Polypropylene is a product of one of petrochemical
industries. It is considered one of the most commonly used
and versatile plastics nowadays and use in many
commercial and specialized products for both long and
short application.
Polypropylene is used widely in manufacturing piping
systems which concerned with high purity and designed for
strength and rigidity as well as chairs, and plastic items.
Most plastic items for laboratory and medical use are made
from polypropylene because it has ability to withstand heat
for example in an autoclave. Also food containers made
from it, so it will not allow the containers melt in the
dishwasher and do not melt during cooking. For this
reason, most plastic tubs for dairy products are made from
the polypropylene.
Indeed, the different properties and uses of
polypropylene make it very common choice for various
industries. It is largely used among our life. We can say it
is very necessary in our life and we cannot live without it
nowadays.
1.2 properties of polypropylene
Lowest density which is 0.9 g/cm3, Melting point 160 –
165 C, PP remains unaffected when it comes in contact
with chemicals such as alkaline substances, acids,
electrolytic attacks, etc., Polypropylene does not get
damaged by water exposure because its moisture
absorption is very low, Its tensile strength is quite high. It
shows strong resistance towards stress and cracking,
abrasion resistance, it is a non-toxic substance.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
II. V ARIOUS METHODS O F P RODUCTION O F
P OLYPROPYLENE
2.1 Slurry Polymerization
Slurry polymerization, sometimes this polymerization is
called solvent polymerization. It was the common
manufacturing process in the first generation. An autoclave
and an agitator are provided in the reactor to use this type
of manufacturing process. 1 MPa pressure and a
temperature of 50 to 80 ◦C are used as typical operating
conditions to fulfill the reaction successfully which are
carried out in an inert hydrocarbon solvent such as hexane
or heptane. To get polypropylene particles in the first
generation, a series of treatment units are done starting
from separation and unreacted propylene recovery,
deashing (using alcohol to decompose and eliminate the
catalyst activity), washing in water, centrifugal separation
and drying for the aftertreatment processes. Moreover,
there is a secondary product which is AP of approximately
10% of amount polymerized that should be separated using
its solubility in the polymerization solvent.
2.2 Bulk polymerization process
Bulk polymerization, sometimes this polymerization is
called mass polymerization. Unlike slurry polymerization,
no need for using hexane or heptane solvents. A pressure of
2 to 4 MPa and a temperature of 50 to 80 ◦C are used as
operating conditions to fulfill the reaction successfully. The
reaction is carried out in liquefied propylene as the diluent
for the slurry. As mentioned, liquefied propylene is the
only solvent that is used in this kind of manufacturing
process, so solvent recovery is not required which leads to
reduction in the energy costs for the steams, electricity, etc
which would require in case of present solvent recovery
unit. Bulk polymerization was the common manufacturing
process in the second generation but also it has been used
with the first generation and even now in some cases, it is
still used with the third main current generation. The
comparison between the first generation solvent
polymerization process and the second generation bulk
polymerization, gives a clear and much simpler process for
the second one. A continuous extraction tower is used
which characterize this process. The tower was developed
by Sumitomo Chemical. Also, a catalyst of high
performance has been developed and is used in bulk
polymerization. Refined liquefied propylene in a
countercurrent washing system is supplied to the process
which aims to simplify dishing and eliminate the AP
product.
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2.3 Gas phase polymerization process
Gas phase polymerization placed as the third generation,
the main current one. In this type of process the propylene
and solid catalyst (3rd generation catalyst) are contacted
together and then dispersed in a dry polymer powder of an
agitated bed. The polymerization takes place in two
different methods:
- In the fluidized-bed reactor.
- In the stirred bed process, by using either vertical stirred
reactor or a horizontal stirred reactor with compartments
include mixing blades to agitate the particles of polymer.
2 to 4 MPa pressure -depending on the grades of
polymer- and a temperature of 50 to 80 ◦C are used as
typical operating conditions to fulfill the reaction
successfully which is carried out in the gas phase. This
process is more convenient process in production of
homopolymer and copolymer. Moreover, it is the most
common process used in modern plants among the several
existed processes in polypropylene production. The main
advantage of gas phase polymerization is an economical
and flexible technology in which the deashing and AP
secondary product are omitted at all.
III. SELECTION P ROCESS
After giving some amount of information above about
the three processes of manufacturing of polypropylene
(slurry, bulk and gas phase polymerization) and based on
my knowledge I has gained from reading the related books
and other resources and from visiting a polypropylene plant
i put some criteria to go through in order to assess each
process. The most important criteria I has focused on them
to select my manufacturing process was in term of
availability and consumption of raw materials, plant
construction cost, utilities required for each process,
flexibility, operational conditions, safety and environmental
issues and production rate. Based on these criteria my
decision was to employ gas phase polymerization as the
suitable process for my polypropylene production.
3.1 Process Desicription Of PP
There are two main processing areas in polypropylene
production, which are polymerization area and extrusion
area. Polymerization area contains polymerization reactor,
Powder Purging, Powder Silos. And extrusion area contains
an extruder, centrifugal drier, pellet water tank.
1. Polymerization area: Fresh propylene which is fed to
the polymerization reactor together with the required
catalyst (ZIEGLER NATTA), co-catalyst (TEA), hydrogen
and silane.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
Here, the purpose of co-catalyst that called Tri Ethyl Then the pellets are fed to degassing unit to remove any
Aluminum, is the catalyst activator (co-catalyst) for the off gases which can be found. Finally, the pellets are
polymerization catalyst system , using hydrogen to control transferred to packing area.
the molecular mass of the polymer (chain length) and the
3.2 flow Diagram
purpose of Silane which called cyclohexyl methyl
dimethoxi silane is used as a stereomodifier in the
polymerization process and is the main parameter used to
control the balance of crystalline – amorphous polymer in
the product. And by using catalyst, Propylene is converted
to polypropylene.
The solid catalyst will convert to catalyst slurry by mix it
with white oil, because we cannot feed the catalyst to the
reactor as solid. So, at high velocity through a small
injection nozzle, the propylene of gas phase and catalyst
slurry is entered to the reactor. By all these conditions,
Polypropylene product powder is produced and is blown
out of the reactor under propylene pressure into the powder
discharge vessel.
The function of the powder discharge vessel is to IV. DESIGN O F EQUIPMENT
separate between the powder and carrier gas. The carrier
4.1 Design of dryer
gas is fed to a cyclone and a following filter to remove any
residual powder, and then fed to a wash tower where co- 1. Water in feed = 139320kg/hr
catalyst traces are scrubbed. The cleaned gas is compressed 2. Dry Solid in feed(PP) = 20322 kg/hr
and recycled to OSBL. On the other hand, the powder from 3. The amount of water that need drying 1016 kg
discharge vessel is fed to purge vessel. And the purpose of 4. QH2O = QAir
purge vessel is to purge the powder of residual monomers
by nitrogen. Off gases from the purge vessel is conducted 5. m air =
to a membrane unit for nitrogen recovery and then recycled 6. Area of the dryer = 11.15 m2
back to the purge vessel for further use. The product 7. Inner Diameter of dryer =
powder from purge vessel is fed by nitrogen conveying 8. Overall heat transfer ( Ua ) Btu/Hr ft3 ºF
system to the powder silos where used as buffer storage
9. Length of dryer ( Z ) =
between the polymerization and extrusion process.
10. Number of flights = 37.2=38
2. Extrusion area: Powder product from these silos is 11. The radial height of the flight = 1.6 ft
fed by gravity to the extruder. And before the extruder 12. Speed of rotation RPM = 2.6 = 3
there are feed hoppers, where additives are mixed and then 13. Working Pressure in the drier =0.1013 N/mm2.
flow by gravity to the extruder. Peroxide is fed to the 14. Design pressure = 0.152 N/mm2
extruder to control melt flow rate (MFR). 15. Thickness of dryer shell ( ts ) = 2.74mm
By the contra-rotating screws, the polymer powder and 16. Outer diameter of dryer = 3.82 m
additives are mixed, melted, and homogenized. After all 17. Volumetric feed flow rate m3/hr
these functions of extruder have been done, Pelletizing of
18. Cross sectional area of the feed pipe = 1.648 m2
the final product is carried out in an underwater pelletizer
19. Diameter of the feed pipe =
where the extruded polymers, after passing the die plate
(Hot oil is used to heat the die plate which come in the end 20. Volumetric flow rate of air = m3/s
of the screws), are cut under water by a set of rotating 21. Cross sectional area of the inlet air pipe = 2.74 m2
knives to convert the products to pellets. The extruder has 22. Diameter of the feed air pipe
parallel windows, to maintain the extruder temperature at 23. Volumetric flow rate of air = m3/s
230oC. Water and pellets from the underwater pelletizer, 24. Cross sectional area of the outer air pipe = 2.61 m2
are fed to a centrifugal drier where the pellets and water are 25. Diameter of outer air pipe
separated. Water is recycled to an underwater pelletizer. 26. Volume of shell diameter = 0.7 m3

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
27. Weight of dryer = 5334.25 Kg When you are handling or processing of polypropylene
28. Volume of the dryer filled with material = 7.2 m3 resins, exposure to hot material, fumes and dust may take
29. Weight of the material in drier at any time = place. For such activities exposure should be controlled by
30. choosing and applying the appropriate risk management
measures. Spillage of polypropylene resin may cause
4.2 Design of reactor exposure to the environment, which can be minimized by
handling procedures, correct design of equipment and
Design Data of reactor cleaning-up spilled pellets or granules directly.
Volume 75 m3
VII. CONCLUSIONS
Pressure (bar) 40
This project has introduced the design plant of
Design Temperature (oC) -48 production polypropylene at 500 Ton/day and chemical
Pressure(Min/Max, 70-85 processes of polypropylene production. Polypropylene
production is very essential in the development of our
Operating bar)
country. The productions of Polypropylene include 2
Temperature(Min/M 27-32 processing area which are (polymerization and Extrusion).
ax oC) This project has also identified the manufacturing process
Min, Diameter( mm) 3620 which has includes the design aspects of the equipment‟s
Constructio (design equation and calculations of PP. The main in this
Height (inside) 7240 project is calculating material balance, energy balance,
n Data
Design for two equipment and cost estimation.
 The result in material is the amount which inlet is
V. COST ESITIMATION equal to the amount outlet in steady state.
 In the energy balance, the temperature of the feed is
The total purchased 210, 595 R.O. deferent and the specific heat is depending on
temperature. The energy balance for reactor and dryer
equipment cost specific heat and latent heat is depends on
temperature.
Total capital investment
 Design for dryer, the amount of feed of PP enter in
Fixed charges dryer around 20322kg/hr and Water in feed is 139320
kg/hr .
Variable capital cost  For cost estimation, the total of purchased cost is 210,
595 R.O. and the total product cost equal to 390935
Total production cost 390935 R.O
R.O.
(operating cost)
VIII. RECOMMENDATION
Expected life of the project 10years
 Instead to use one reactor can be using two or three
reactor to increase the production of PP.
VI. S AFETY  The plant should be far away from school, college or
Polypropylene is considered the best one on all plastic university, agriculture and communities.
from the side of safety. this is the stronger plastic that is  The waste disposal should be throwing far from plant.
heat resistance because of its high heat tolerance.  Health and Safety consideration.
Polypropylene is not likely to leach even when uncovered
to hot water or warm. This plastic is approved for use with Acknowledgement
food and beverage storage. Polypropylene plastics able to I know that everyone in the life needs others to help
reused safely and with hot beverages. Also, it resins are not them to finish their work. And I know that one hand dose
likely to be toxic to the environment. Polypropylene is not not clap so I would like to thank all people who help me to
considered biodegradable as it biodegrades at a slow rate. complete this project.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)
But before that I want to thank at the first my God REFERENCES
because everything happened by him and because of him I [1] Peter J. T. Morris (2005). Polymer Pioneers: A Popular History of
doing this project. I want to thank my Supervisor Dr the Science and Technology of Large Molecules. Chemical Heritage
Saravanan A.M because he helped me to choose the correct Foundation. p. 76. ISBN 0-941901-03-3.
direction to finish my project on time. Also he explain all [2] Edward P. Moore, Jr,1996, Polypropylene Handbook,
Hanser/Gardner Publications, Inc., Cincinnati.
things about this project and brief the difficult points which
[3] K. Miyazaki,1998 ,“Chemical Process”, edited by The Society of
facing me during the project. Also, I want to thank people Chemical Engineers, Japan, published by Tokyo Kagaku Dozin Co.
that help me in making interview with them like, Hani, the Ltd., (1998), p.191.
Engineering of Petroleum and gas in Orpic company .In the [4] Tripathi,D.(2002), for Practical Guide to Polypropylene. Rapra
other side I want to thank Caledonian College of Technology Limited Shawbury, Shrewsbury, Shropshire, SY4 4NR,
Engineering for giving us a chance for doing this project UK.
and help me to finish my project without any difficulty. [5] van Oosten, T.B (2002) „A survey of problems with early plastics‟,
in Contributions to Conservation, Research in Conservation at the
Netherlands Institute for Cultural Heritage, J. Mosk and N.Tennant
(eds). London: James and James.

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