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Operating / Troubleshooting
‘STEPS’ for off-line grade
changeover from Parallel ‘B’
Grade
(B63A003N/W52ASR009N)
TO
Parallel ‘A’ Grade
(W52A009N/W55A004N)
in HDPE-II Plant
Operating and Trouble Soothing Steps for ‘Off-Line Grade Changeover’
from B63A003N/W52ASR009N TO W52A009N/W55A004N in HDPE
1. SCOPE:
For B63A003N
Page 1 of 18
For W52ASR009N
For W55A004N
Page 2 of 18
AT catalyst feed rate Kg/hr 25~35 25~35
(Conc. 200 mmol/lt)
PZ conc. In reactor Mmol/lt HX 0.011 0.011
AT conc. In reactor Mmol/lt HX 0.5 0.5
Reactor pressure Kg/cm2 g 4 ~ 4.5 4 ~ 4.5
Ethylene part. Press. Kg/cm2 g 1.6~1.7 2.1
H2/C2 ratio in MAPS Mol/Mol 0~1 0~1
Slurry Conc. gm/l-Hx 400 400
Additive Dosing
AE-IRGANOX 1010 PPM 450
AK-IRGAFOS 168 PPM 1000
HA- CALCIUM STEARATE PPM 1200
AJ-IRGANOX 1330 PPM 300
PPA(25%) PPM 200
For W52A009N
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1. Reduce plant load to 10 T/Hr.
2. Take out both slurry coolers from the system.
3. Dump each slurry coolers to second flash drums (VV 223) in such a rate so that there is no significant
change in vessel pressure & as well slurry concentration.
4. After dumping fill both slurry coolers with hexane and again dump out to flush
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Precaution: Flush Dilution drum outlet line properly to avoid chocking of line.
15. Dumping speed although will depend upon the level of VV301 & VV701.
3. High Level in High rate of Slurry Actuation of Slow down dumping rate from
VV-203 & dumping from reactor LSHH on VV- reactors
VV-223 or 203 & VV-223 Hexane flushing in
high current Slurry transfer which will close PA-201/PA-221 suction line
of restriction in PA- XV2301/2501 Change over pump and clean
VM-203/VM- 201/221 suction or and spool piece of PA-201/PA-221
223 discharge line. LV2302A/B & to remove suspected lump.
LV2502A/B.
4. Level not Chocking of reactor Reactor dump Stop dumping and flush
rising in VV- dump out line. out delayed till reactor dump out line.
203 /VV-223 further dumping Immediately send maintenance
during Malfunctioning of get started. team to attend any malfunction
dumping HV2303/2503 or LV- valve.
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2302B/LV-2502B. If due to any reason, reactor
dump out is not possible from
dump out line, another option
could be PA-203/223 suction
loop dump out line. This
practice should be followed
during emergency only.
5. Centrifuge LV-2701 opening is Centrifuge Control slurry dumping rate
running on high and high flow of Shear pin may and further reduce opening of
high torque slurry from VV-223. damage LV-2701.
i.e. greater Centrifuge can
than 80% trip on HH
torque which
can delay
reactor
dumping
6. Dryer running High slurry dumping Less powder Control slurry dumping rate if
on high rate conveyed to dumping rate is high.
current above Steam condensate extruder as well Check PPPPU pump in field
50A in HDPE- accumulation in dryer as damage to and if not working properly
1 and 80A in and volatile removal is dryer. Powder change over it. Still not
HDPE-2 low in dryer volatile content working properly then open
Powder accumulation will increase. local drains.
in dryer because of Check KB-401 and GF-303 in
restriction in field for any abnormalities.
pneumatic conveying Also observe discharge
line via KB-401. pressure of KB-401. It should
be 0.4-0.6 Kg/cm2g.
7. VV-701 level High slurry dumping VV-701 Control slurry dumping rate
High-High rate overflow to and never go beyond 70%
and above VV-702 which level in VV-701.
70% can further
actuate
LSHH7307
causing I9.1:
Distillation
ESD.
Distillation
ESD will
completely shut
down A-700.
8. VV-301 level LV-2701 opening is Centrifuge may Control slurry dumping rate
on Higher high and high flow of trip on HH level and further reduce opening of
side. Avoid slurry from PA-223. of VV-301. LV-2701.
level above LV-3109 opening is Increase ML flow to VV-701
60% low and ML flow to if level permits.
A-700 is not Changeover PA-301 pumps
sufficient. and clean suction spool/suction
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PA-301 pump flow is line.
restricted because of Attend LT3101/3102 if
suction spool/suction doubtful.
line chocking.
Flushing hexane may
be opened in PA-301
loop.
LT-3101/3102
malfunctioning and
PA-301 under
cavitation.
9. Low discharge High HX makeup flow More time Check recirculation valve
pressure of rate to A-200 needed for bypass and close if open.
PA-708 or PA-708 recirculation Hexane makeup Check HX flushing opened in
High current valve bypass in open in reactors field in any area.
of PA-708 condition unless flow is
HX may be opened in high in reactor.
other flushing lines.
W52/W55 Dumping
Task Description
Ethylene cut off in R-1
R-1 Slurry Dumping 1.5 hrs
R-1 20 Ton Washing 1.5 hrs
HX feed
R-1 HX circulation 0.5
R-1 Washing HX 1.5 hrs
dumping
Ethylene cut off in R-2
R-2 Slurry Dumping 1.5 hrs
R-2 20 Ton Washing 1.5 hrs
HX feed
R-2 HX circulation 0.5
R-2 Washing HX 2 hrs.
dumping
R-1 17T HX intake 1.5 hrs
R-2 17 T HX intake 1.5 hrs
Page 7 of 18
4.2 Washing of Reactors:
1. Take 20 MT fresh washing hexane in Reactor-1 and start HX circulation for 45 minutes, while RB-221
slurry is being dumped. After HX circulation in Reactor-1, isolate slurry cooler, dump washing hexane.
2. After completion of RB-221 slurry dumping, take 20 Ton fresh Hexane in Reactor-2 and start HX
circulation for 45 minutes.
3. After HX circulation in Reactor-2, isolate slurry cooler, dump washing hexane.
4. Feed 17 Ton Hexane in both reactors one by one for plant start-up.
1. Before Ethylene feeding, Initial Hydrogen concentration is maintained in reactor which is more than
normal running condition. Pressure of reactor should not be below 1.2 Kg/Cm2g to avoid RG blowers KA-
201/221 tripping. Initial parameters for parallel polymer grades are as below,
Note: As we are starting in Parallel-A mode, reaction as well as catalyst feeding in both reactors will
start simultaneously. So we have to wait till completion of 17T HX in both reactors. Although in series
mode, we can start catalyst feeding in RB-201 before completion of 17T HX in RB-221 considering
time margin of 2 hrs. Between start-up of both reactors.
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5.2 Catalyst (PZ) & Co-catalyst (AT) Feeding
1. Start PZ (Conc. 4 mmol/lt) & AT (Conc. 200 mmol/lt) feeding in both Reactors.
2. Start 1 T/hr. HX simultaneously in both reactors for catalyst nozzle flushing till reactor overflow.
RB-201 RB-221
Ti concentration in reactor mmol/l-Hx 0.011 0.011
Al concentration in reactor mmol/l-Hx 0.5 0.5
PZ catalyst flow Batch lit/hr 36/27 45
(at conc. 4 mmol/l-HX) Continuous lit/hr 35~40/30~45 35~40/30~45
AT catalyst flow Batch lit/hr 39 39
(at conc. = 200 mmol/l-HX) Continuous lit/hr 25~35 25~35
RB-201 RB-221
% DC 90% 90%
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5.4 Hexane Run: Ensure that vessels are lined up as per parallel-B as shown in figure;
VV- VV-
RB-201
202 203
VV- VV-
223 301
VV-
RB-221
222
1. After 2 hours of catalyst feeding, Ethylene feeding will be started in both reactors simultaneously.
2. Increase RB 201and RB221 jacket temperature to up to 90o C so that reactor temperature stays around
50o C & keep reactor pressure at 2Kg/cm2 and 1.5 Kg/cm2 respectively.
3. Keep RG flow of KA 201/KA221 as low @ 3500 M3/h.
4. Continue catalyst / TEAL/ hexane flow same throughout the process.
5. Observe rise in reactor temperature to confirm reaction is taking place in reactor and then gradually
increase Ethylene flow after reactor temperature reaches @ 60 o C keeping temperature rise ratio <= 1 o C
per minute.
6. Increase Ethylene flow up to 5.0 T/H gradually & keep RB 201/RB221 temperature 85 o C.
7. Maintain reactor H2/C2 ratio during start-up as per sheet.
8. Reactor overflow will come around 40-45 % level of RB201/RB221 @ 2 hours after ethylene injection.
0 1 2 3 4 5 6 7
0 0 0 0 0 0 0 0 8
B63A003N Start-up
Task Description
PZ feeding in RB-201 2 hrs
AT feeding in RB-201 2 hrs
PZ feeding in RB-221 2 hrs
AT feeding in RB-221 2 hrs
Ethylene feed in R-1 2 hrs
Ethylene feed in R-2 2 hrs
DC-1 Line up Continuous Mode
DC-2 line up Continuous Mode
Dryer residence time 0.
5
Extruder start-up Continuous Mode
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Ethylene Reactors O/F
Feed
Note: Special care should be taken during the overflow and mixing of both reactors product into
VV223 as the final product is the mixture of slurry of reactor 1 & 2. Ethylene flow will be
maintained equal in both reactor and overflow should come at same time. Otherwise quality of
pellet may not achieve as desired.
5.5.3 Troubleshooting during Reaction start-up
Page 11 of 18
load timely, reaction can Reduce jacket temperature
LV-2201/2401 run away and If reaction is not controlled
opening not sintering may by above means, stop
optimum happen ethylene and open vent till
temperature become stable
5. Catalyst line Flow of PZ in Low catalyst feed Catalyst lines should be
chocking B63A003N grade will slow down flushed towards vessel side.
is very less reaction and Never flush catalyst line
compare to series increase pressure of towards reactor side as this
grade reactor will increase sudden increase
flow of catalyst in reactor
and reactor temp. may rise
abruptly
6. Product Reactor condition Generation of OFF- Ethylene feed should be
quality are not optimum Spec product equal in both reactor so
Blend ratio of slurry of both reactor mix
both reactor are equally in VV-223.
not equal
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Page 13 of 18
7.0 Standard Recipe Sheet at 15 MT/Hr load:
PRODUCT SPECIFICATION-
Page 14 of 18
STANDARD RECIPE SHEET FOR GRADE W55A004N
PRODUCT SPECIFICATION
RB-
Sr. Parameter Unit RB-221
201
gm/10 0.35 ~
1 Slurry MFR range 0.35 ~ 0.50
min 0.50
2 Slurry blend ratio % - -
3 Ethylene feed for start up MT/hr 7.50 7.50
4 Propylene as wt% of Ethylene % 1.1 1.1
5 Total Hexane feed MT/hr 13.46 13.46
6 DC % ( theoretical ) % 85 85
7 Fresh Hexane feed (1) MT/hr 1.00 1.00
8 ML recycle - FC-3110/3111 MT/hr 12.46 12.46
mmol/l-
9 Ti concentration in reactor 0.011 0.011
Hx
mmol/l-
10 Al concentration in reactor 0.5 0.5
Hx
40 ~
11 PZ catalyst flow (3) lit/hr 40 ~ 50
50
12 AT catalyst flow (3) lit/hr 45~55 45~55
13 Polymerization Temperature deg.C 85 85
14 Temperature - High alarm deg.C 88 88
15 Temperature - Trip setting deg.C 90 90
16 Total pressure of reactor kg/cm2,g 4~4.5 4~4.5
0.60 ~
17 H2/C2 in vapour phase (3) mol/mol 0.45 ~ 0.55
0.65
1.6~1.
18 C2 partial pressure range kg/cm2,g 2.1
7
19 Slurry concentration gm/l-Hx 400 400
2109
20 Hydrogen FT selection - 2110 B
B
2107
21 Comonomer FT selection - 2108 B
B
22 H2/C2 ratio range in MAPS - 0~1 0~1
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STANDARD RECIPE SHEET FOR GRADE W52A009N
PRODUCT SPECIFICATION:
Page 16 of 18
STANDARD RECIPE SHEET FOR GRADE W52ASR009N
PRODUCT SPECIFICATION-
Page 17 of 18