Liwa Plastics Project: Document Title: Process Description

Liwa Plastics Project
Page 1 of 34
Document Title: PROCESS DESCRIPTION
Document No: S-S500-5223-031
Issued for BDEP 1 12-02-2014 F. Valente R. Pesare P. L. Di Federico

Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 34
THIS DOCUMENT IS LYONDELLBASELL PROPERTY AND CANNOT BE USED FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Document Title: Document No. Rev:

PP 5000 – Process Description S-S500-5223-031 1
Table of Contents
1. PURPOSE .................................................................................................................................................. 4
2. GENERAL ................................................................................................................................................. 4
3. UNIT 5000 ................................................................................................................................................. 4
4. CATALYST, CO-CATALYST AND LIQUID ADDITIVE STORAGE AND METERING (PFD 111A, 111B,
111C) ......................................................................................................................................................... 5
4.1 Aluminum alkyl storage and metering ............................................................................................. 5
4.2 Donor Storage and Metering............................................................................................................ 6
4.3 Preparation and Storage of the Catalyst Dispersion in Grease ......................................................... 7
4.4 Catalyst Paste Metering ................................................................................................................... 8
4.5 Liquid Additive Storage and Metering ............................................................................................. 9
4.6 Catalyst Component Feeding Criteria .............................................................................................. 9
5. PRECONTACTING AND PREPOLYMERIZATION (PFD 112)............................................................. 10
5.1 Precontacting ................................................................................................................................. 10
5.2 Catalyst injection into the propylene .............................................................................................. 10
5.3 Prepolymerization ......................................................................................................................... 11
6. LIQUID MONOMER POLYMERIZATION (PFD 112) .......................................................................... 11
6.1 Prepolymer feeding ........................................................................................................................ 12
6.2 Propylene fed to R-5201 ................................................................................................................. 12
6.3 Slurry in R-5201 ............................................................................................................................ 12
6.4 Hydrogen fed to R-5201 ................................................................................................................. 13
6.5 Ethylene fed to R-5201 ................................................................................................................... 13
6.6 Butene-1 fed to R-5201 ................................................................................................................... 13
6.7 Slurry discharge from the reactor .................................................................................................. 13
6.8 Slurry concentration in the loop reactor ........................................................................................ 13
6.9 V-5202 (Damper) with Vaporizer (E-5203)..................................................................................... 14
6.10 Pump P-5201 ................................................................................................................................. 14
6.11 Loop Reactor Cooling System ........................................................................................................ 14
6.12 Stand-by connections ..................................................................................................................... 15
6.13 Emergency devices ......................................................................................................................... 15
7. FLASH, HIGH PRESSURE DEGASSING AND PROPYLENE RECYCLE (PFD 113 A – 113 B)............ 16
7.1 Flash and degassing ....................................................................................................................... 16
7.2 Vapor Monomer Scrubbing ........................................................................................................... 16
7.3 Propylene storage and plant feed ................................................................................................... 17
8. LOW PRESSURE DEGASSING, GAS RECYCLE (PFD 113A) .............................................................. 18
8.1 Low pressure degassing filter S-5301 ............................................................................................. 18
8.2 Recycle gas streams washing and compression C-5302-ME-5301-K-01 (ME-5301) ......................... 18
9. GAS PHASE COPOLYMERIZATION (PFD 114) ................................................................................... 20
9.1 Gas phase reactor (GPR) R-5401 ................................................................................................... 20
9.2 Ethylene stripper C-5401 ............................................................................................................... 22
Page 2 of 34

9.3 Monomers feed to the gas phase reactor ......................................................................................... 22

9.4 Cooling system ............................................................................................................................... 22
9.5 Pressure control in the gas phase reactor ....................................................................................... 22
9.6 Emergency devices ......................................................................................................................... 23
10. STEAMING AND RECOVERY OF MONOMERS DISSOLVED IN THE POLYMER (PFD 115A - 115B)23
10.1 Steamer V-5501 ............................................................................................................................. 23
10.2 Scrubbing ...................................................................................................................................... 23
10.3 Compression and recovery ............................................................................................................. 24
11. DRYING (PFD 115B) ............................................................................................................................... 24
11.1 Drying ........................................................................................................................................... 24
11.2 Dryer V-5502 ................................................................................................................................. 25
11.3 Drying nitrogen system .................................................................................................................. 25
11.4 Condensation of water from nitrogen recycle ................................................................................. 25
12. BLOW DOWN (PFD 116A) ..................................................................................................................... 26
13. PROCESS FACILITIES (PFD 116A – 116B) ........................................................................................... 27
13.1 Refrigeration unit .......................................................................................................................... 27
13.2 Low pressure steam condensate recovery ....................................................................................... 28
13.3 Centralized mineral oil system ....................................................................................................... 28
13.4 Waste oil treatment ........................................................................................................................ 29
13.5 Instrument air buffer drum ........................................................................................................... 29
14. PROPYLENE PURIFICATION (LIGHT ENDS STRIPPING, H2S REMOVAL, DRYING) (PFD 117A) 30
15. HYDROGEN COMPRESSION AND BUFFERING (PFD 117B) ............................................................. 30
16. ETHYLENE COMPRESSION (117B) ..................................................................................................... 30
17. BUTENE PURIFICATION (CO) AND FEED TANK (PFD 117C) ........................................................... 30
18. PP POLYMER TRANSPORT, STORAGE AND METERING TO EXTRUSION - ADDITIVES
METERING TO EXTRUSION (PFD 118A, 118B, 118C, 118D, 118E) ..................................................... 31
19. EXTRUSION (PFD 118E) ........................................................................................................................ 32
20. HOMOGENIZATION AND TRANSPORT TO BAGGING (PFD 119A, 119B) ........................................ 33
Page 3 of 34

1. PURPOSE
The purpose of this document is to provide a detailed description of the Polypropylene Spheripol Plant of
LyondellBasell licensor related to the Liwa Plastic Project.
2. GENERAL
The plant consists of one polypropylene unit (Unit 5000).
The design capacity of the plant is achieved via a bulk polymerization in liquid phase (one loop reactor) capable
of producing the homopolymer and random copolymer grades. Unit has an additional gas phase reactor for the
production of high impact copolymer grades and facilities to feed butene-1 in the loop reactor for the production
of random terpolymer and butene random.
3. UNIT 5000
1. Catalyst, Co-Catalyst and Liquid Additive Storage and Metering

2. Precontacting and Prepolymerization
3. Liquid Monomer Polymerization
4. High Pressure Degassing and Propylene Recycle
5. Low Pressure Degassing
6. Gas Phase Copolymerization
7. Steaming and Residual Monomers Recovery
8. Polymer Drying
9. Blow Down
10. Process Facilities
11. Waste Oil Treatment
12. Propylene drying and COS guard column
13. Ethylene Compression
14. Hydrogen Compression (also for PE Plant)
15. Butene-1 Purification column and feed tank
16. PP Polymer Transport, Storage Metering to Extrusion, Additives Metering to Extrusion
17. Extrusion
18. Pellets homogenization
Page 4 of 34

4. CATALYST, CO-CATALYST AND LIQUID ADDITIVE STORAGE AND METERING

(PFD 111A, 111B, 111C)
The catalyst system consists of three components:

o Titanium catalyst supported on MgCl2 (solid)
o Triethyl aluminum (TEAL) (liquid)
o Donor (liquid)
The three components are fed separately to a precontacting pot (V-5201), where they are contacted and
then fed to the reaction system.
4.1 Aluminum alkyl storage and metering
Teal is used as a cocatalyst in conjunction with the high mileage catalyst.

The aluminum alkyl (TEAL), which is used pure, reaches the Plant Battery Limit in cylinder of approximately
5 m³ volume or ISO container of 20 m³ volume .
The cylinders are unloaded by nitrogen pressure into the TEAL metering drum V-5101 with the help of
unloading arms, included in package LA-5102.
Metering drum V-5101 and metering pumps P-5101A/B are located in a reinforced concrete box. One pump is
running and the other one is in spare.
Since manual operations are carried out to connect of the process line to the cylinder, safety devices are
provided as flame detectors connected to interlock that shuts-off the discharge in case of TEAL leakage.
The connection of the nitrogen and TEAL transfer lines to the cylinder is the only operation done inside the
box.
All the valves installed on the pressurization nitrogen, blanketing and TEAL transfer lines are pneumatically
controlled from a local control panel, mounted out of the TEAL building.
After filtering by S-5101, TEAL is pumped by means of P-5101A/B to the precontacting pot V-5201.
The cartridge filter S-5101 retains solid particles having dimensions bigger than 10 m.
The pumps are in closed loop feedback flow control. Before entering the precontacting pot, TEAL is mixed
with Donor. The low temperature in the precontacting pot is maintained by A-5212 TEAL/Donor cooler.
This allows an easily constant temperature control in V-5201.
The TEAL metering drum V-5101 is operated at atmospheric pressure, under nitrogen atmosphere, which is
maintained by a small continuous flow of nitrogen, fed to the vessel and coming out through the hydraulic
seal A-5103. The only event when V-5101 has to be pressurized is after oil washing, when exhaust oil is
transferred by pressure to the exhaust oil drum V-5102.
Due to the hazardous nature of TEAL, the system is provided with oil washing and nitrogen purging/
blanketing to allow easy maintenance. A centralized oil system provides fresh oil to the section. Fresh oil,
stored in V-5611 oil storage vessel is first filtered in S-5602A/B and then pumped to the various equipment
handling TEAL, such as TEAL pumps, filter, and instruments that may require maintenance. The total
quantity of washing oil is metered in order to assure that the oil wash volume used is ten times bigger than
the equipment/piping volume.
The contaminated (i.e. exhaust) oil is collected in V-5102 exhaust oil drum, from which it is transferred to the
oil treating drum V-5607 by means of the exhaust oil pump P-5102.
Page 5 of 34

In steady state operation P-5101 A (or B) stroke is controlled by a mass flow meter installed on pump delivery,
which is in cascade with the catalyst feed to the reaction in fixed ratio, or with the propylene feed to R-5201 (
loop reactor) always in fixed ratio according to a dedicated selector.
TEAL (Triethylaluminum) is pyroforic, which means that the pure compound or concentrated solution of the
product will burst into flame if it comes in contact with air or explodes in contact with water. Usually the burning
is accompanied by loud explosions.
TEAL storage and handling facilities have been designed in such a manner that the hazards have been
substantially eliminated. All the vessels, tanks and lines in TEAL handling facilities are kept under nitrogen
pressure at all times. Air is never admitted to this equipment during normal operations. Oil flushing and
nitrogen purge systems have been installed to allow pumps, transfer lines and instruments to be disassembled
without the hazard of TEAL release to the atmosphere.
If TEAL is released to the atmosphere, and a fire should erupt, water must be avoided to extinguish the fire
(Water will react with TEAL and result is a more intense fire or explosion). Dry chemical extinguishers are the
only extinguishing media to be used.
4.2 Donor Storage and Metering
Donor is used as a cocatalyst in conjunction with the high mileage catalyst, as stereo regulating agent.
The polymerization via the high mileage catalyst, without Donor, would produce high concentrations of atactic
polymer. Unlike the isotactic polymer, the atactic polymer is very sticky and can cause severe handling and
quality problems. A small amount of atactic polymer is however desirable (according to the produced grade) in
the final product to prevent brittleness and improve impact strength. This is generally maintained between 2-
4%. The atactic polymer content in the final product is controlled by adjusting the Donor feed.
Donor (Donor C or Donor D) is brought into the plant in 200 liters drums, at a concentration of 100%. Donor is
loaded with pneumatic pump P-5103 into one of three identical Donor storage drums (V-5110A/B/C) equipped
with agitators (M-5110A/B/C).
Donor, contained in the storage drums V-5110A/B/C under nitrogen atmosphere, is fed to the precontacting
pot either in pure form or diluted with oil, depending on the total rate required by the product recipe. The
Donor metering pumps P-5104A/B have a minimum operating flow rate and therefore if the recipe needs a
very low Donor flow, it is necessary to dilute it with paraffinic oil.
During operation, Donor feed rate is in ratio with the TEAL flow, which is on its turn in ratio with the total
propylene flow.
Donor is a clear liquid with specific gravity close to the water one. It must be stored in a cool dry place away
from direct sunlight. It will react with water to release methyl alcohol. Water should not be used to extinguish
Donor fires. Dry chemical or carbon dioxide foam must be used on these fires.
Page 6 of 34

4.3 Preparation and Storage of the Catalyst Dispersion in Grease
The catalyst (Titanium catalyst supported on MgCl2) is a crystalline solid having a controlled particle size; it is
dispersed in a mixture of paraffinic oil and grease so that it can be pumped to the precontacting pot by
means of the catalyst transfer syringes A-5113A/B. The oil/grease mixture ratio is 70/30 by weight, and it is
mixed with catalyst to have a concentration ranging from 200 to 260 grams of catalyst per liter of mixture.
Grease is brought in the plant in drums and is melted (inside its shipping drums) by E-5102 grease melter;
then it is pumped (hot) by means of the loading pump P-5105A into the steam jacketed grease drum. V-
5105A; V-5105A is continuously stirred by M-5105A grease agitator. P-5105A has two additional purposes:
1) To continuously circulate melted grease in V-5105A through a steam jacketed piping to

maintain the temperature at about 100°C
2) To deliver melted grease on a batch basis to V-5106A/B , for mixing with oil and catalyst.
Grease in V-5105A is continuously stripped from residual water and oxygen by a sparger A-5105A that
bubbles nitrogen in the bottom of the vessel.
Grease is filtered in S-5105A, when transferred to V-5106A or B.
The oil system used for catalyst mixing is very similar to the grease system, except that oil is loaded directly
to the storage drum from the centralized oil system. Same as grease, oxygen and moisture are stripped out
by bubbling nitrogen in a dip tube by means of a porous gas sparger (A-5105B).
The oil system dedicated to catalyst preparation consists of the oil drum V-5105B with the agitator M-5105B
and nitrogen sparger A-5105B, the oil loading pump P-5105B, and the oil filter S-5105B.
V-5105A and V-5105B are refilled when the level reaches 20%. V-5105A and V-5105B are kept under nitrogen
blanketing and the vents are collected to the oil hydraulic guard V-5114.
Oil, grease and solid catalyst are mixed according to the following procedure:
- The required amount of oil is fed from V-5105B by oil loading pump (P-5105B) filtered in S-5105B and
metered by a dedicate flow control. Oil is loaded into V-5106A or B while M-5106A or B is running
and the temperature control is working.
- A single drum of catalyst is hoisted into position using A-5104 catalyst drum hoist and connected to
the catalyst drum blanketing. The drum is then emptied into the dispersion drum with the aid of the
catalyst drum vibrator A-5102. The amount of catalyst transferred is measured by weighing the
drum before and after emptying by means of A-5101 catalyst drum scale.
- The required amount of melted grease is fed from V-5105A by grease loading pump (P-5105A),
filtered in S-5105A and metered by a dedicate flow control.
Catalyst dispersion drums V-5106A/B are continuously mixed by means of the ribbon mixers M-5106A/B,
and cooled with refrigerated water in the jacket. By adding the hot oil and catalyst first, a uniform (liquid)
suspension is made. Then hot grease is added and the mixture is therefore chilled, to obtain a well-
dispersed paste of suspended catalyst particles at a constant solid concentration.
Page 7 of 34

4.4 Catalyst Paste Metering
The high mileage catalyst used in bulk polymerization is brought into the plant in drums (40 or 80 kg net
weight) as a dark brownish powder.
It must be stored in a cool dry environment, under an inert atmosphere and at 40 °C.
The catalyst paste is transferred from V-5106A (or B) to the metering cylinders ME-5101-A-08A/B using the
catalyst transfer cylinder A-5113A (or B). The transfer cylinder allows for gentle handling of the catalyst and
allows to completely emptying V-5106A (or B).
The catalyst loading syringes A-5113A/B , the catalyst cylinders ME-5101-A-08A/B and all the lines from
dispersion drums (V-5106A/B) to precontacting pot (V-5201) are jacketed and thermostated with chilled
water pumped by cylinder and jacket pumps (P-5106A/B and P-5113) in order to give to the mud the
desired consistency and to prevent catalyst settling.
The metering syringes ME-5101-A-08A/B are two carefully machined and finished jacketed barrels, each
equipped with a close-tolerance piston. On one side of the piston there is the catalyst paste (or mud) while
on the other side there is the hydraulic oil. This oil is the same type used throughout the plant for flushing
and seals lubrication. The oil is pressurized and pumped by pumps ME-5101-P-08A/B into the barrel at a
controlled volumetric rate to move the piston and thus feed the catalyst mud to the process.
The hydraulic oil for pumps ME-5101-P-08A/B is stored in the hydraulic oil surge drum V-5107 where it goes
back when the cylinders are refilled with catalyst mud.
The drum V-5107 is longitudinally divided by an internal baffle. The purpose of this configuration is to have
in one single vessel, both oil for catalyst metering, on one side, and seal oil for other uses in the line, on the
other side.
Initially both catalyst syringes are empty; the filling is made via the transfer syringe A-5113A/B.
When the plant is started, one cylinder feeds the process while the other one is either in filling phase or is
sitting idle (and full). Switchover from one cylinder to the other is automatic, and is triggered off by limit
switches on the cylinder travel. During the filling phase the metering syringes are not pressurized with
hydraulic oil, however, when filled-up, the cylinders are pressurized with oil to higher pressure and held
there for switching. Pre-pressurize the filled idle cylinder allows for a bumper switching of the catalyst feed
cylinders. Interlock systems are installed in the control logic to prevent a cylinder from being put in service if
the hydraulic oil pressure is too low.
Note that the transfer cylinders A-5113A/B and the catalyst cylinders ME-5101-A-08A/B can be operated in
reverse mode (manually) to empty the catalyst paste back into the catalyst dispersion drum V-5106A (or B).
The solid-support catalyst fed to the polymerization is fixed according to the required polymerization rate.
Actually the catalyst mud, which is fed to the precontacting pot, is measured indirectly by a mass flow meter
on metering oil fed to ME-5101-A-08 A/B.
Page 8 of 34

4.5 Liquid Additive Storage and Metering
Liquid additive Atmer 163 (stored in the tank V-5112) is fed to the outlet of the loop reactor R-5201 and to
the suction of ME-5401-K-01 (recycle gas compressor for the gas phase reactor, R-5401) during high impact
copolymer runs. Addition of Atmer has some effects:
o to allow the preferentially distribution of the bipolymer inside the homopolymer matrix rather than on
the surface;
o to decrease the residual high reactivity of polymer fines coming from the loop reactor, that can, in
some cases, lead to a plugging in the gas phase reactor.
Another purpose is to feed Atmer 163 to C-5302 in order to protect the reciprocating compressor ME-5301-
K-301 by removing any traces of TEAL (that could degrade to Aluminum inside the compressor cylinders,
damaging them), giving stable liquid complexes, soluble in oil.
Atmer 163 is also fed into waste oil treatment drum (V-5607) to neutralize TEAL contained into the
recovered exhausted oil, to C-5301 bottom to neutralize TEAL traces (if any) before opening the column for
maintenance reasons and as antistatic additive in extrusion section according to the additivation recipe.
Atmer flow is rationed against TEAL flow. It is fed by P-5110A/B pumps.
Atmer 163 is brought into the plant in drums, which are loaded with a gear pump (P-5109) into the liquid
additive surge drum (V-5112).
A hot recycle via P-5109 and a dip tube with a porous nitrogen sparger, A-5112 are provided to strip
moisture and oxygen in a batch wise operation.
The drum V-5112 is kept under blanketing flow, nitrogen vent bubbles through an oil hydraulic guard (V-
5114) before being discharged to the atmosphere.
V-5114 is also used for vent lines from V-5110A/B/C, V-5107, V-5105A/B.
The metering drum V-5115 has been provided as an independent feed to the plant when a new batch is
loaded and undergoes stripping.
4.6 Catalyst Component Feeding Criteria
Catalyst paste flow rate is an independent process variable and at a given yield (or mileage: grams of
polymer generated, per gram of catalyst), sets the throughput of the plant.
TEAL pumped to the plant is rationed against the total monomer feed to the loop reactor (R-5201). This is
necessary to maintain an excess of TEAL in the loop reactor, in order to scavenge any residual impurity in
the monomer fed (i.e. water, oxygen and/or alcohol) that could otherwise cause marked fluctuations in the
catalyst yield and/or product isotacticity index. As an alternative, TEAL can be rationed versus the catalyst
feed to the precontacting pot V-5201.
Donor is controlled in flow ratio against TEAL flow. Setting of the flow ratios maintains the TEAL/Titanium
and Donor/Titanium mass ratios within the required ranges, at normal plant operating conditions. This
assures the control of polymer quality. In particular, the Donor/Titanium ratio is the parameter used to
control the isotacticity index in the 94 to 98% wt of xylene insoluble range in the loop reactor.
Page 9 of 34

5. PRECONTACTING AND PREPOLYMERIZATION (PFD 112)
5.1 Precontacting
The catalyst paste from ME-5101-A-08A/B is precontacted and activated with TEAL and Donor in the
precontacting pot V-5201.
Catalyst, Donor, and TEAL are fed through independent metering pumps to the precontacting pot V-5201.
The Donor and TEAL supply lines are joined into a common line and cooled in A-5212 (by chilled water), in
order to achieve a better temperature control in V-5201. The catalyst mud enters the precontacting pot
through a separate dip tube.
The pot is a small, constantly stirred vessel of about 3.5 liters, with chilled water circulating in the jacket to
maintain a constant temperature of about 10°C.
The precontacting pot operating temperature can be controlled at about 10°C through a thermosetting
system consisting of V-5201 jacket and circulating pump P-5203A/B. That system guarantees a constant
chilled water flow rate circulation whose temperature is controlled by acting on chilled water supply.
Feed streams enter the pot from the top through dip tubes. The pot is operated full of liquid to prevent gas
pockets; the overflow feeds the prepolymerization reactor R-5200. The precontacting pot has a magnetic
coupled agitator, V-5201-M01. The inner seal of the magnetic drive is continuously flushed with oil, supplied
from the centralized oil system. The flushing oil is limited to 200 - 300 ml/h by means of a capillary feed line.
Catalyst mixture leaving the precontacting pot is injected into a stream of cold propylene, which feeds the
prepolymerizer reactor (R-5200).
Propylene, coming from propylene feed tank (V-5302), is filtered in S-5201 A (or B), where particles bigger
than 10 m are retained. Propylene is cooled down to 10°C in E-5201 then joins catalyst mixture in A-5203A
(or B). The propylene upstream E-5201 is controlled and settled by a dedicate flow control.
The slurry is fed to a prepolymerizer reactor (R-5200) where reaction takes place at low kinetics. In fact,
propylene is polymerized under controlled conditions of temperature (20°C), pressure and residence time
(at least 10-15 minutes) in the prepolymer reactor. A very small amount of propylene also polymerize
through the flush line between the precontacting pot and the prepolymer reactor. The aim of
prepolymerization is to slowly form a shell of polymer around the catalyst particles which is acting as a
protection vs. the subsequent polymerization stage.
5.2 Catalyst injection into the propylene
The catalyst mixture leaving the precontacting pot is injected into a stream of propylene cooled down to
10°C in E-5201.
The propylene flow to the injectors A-5203A (or B) has to be kept constant at abt. 2500 - 3000 kg/h to
prevent plugging of prepolymerizer feeding/discharge lines and to control the prepoly residence time inside
a fixed range.
Page 10 of 34

5.3 Prepolymerization
The reaction is carried out in a small loop reactor at the following conditions:
o Temperature: 20 °C
o Pressure: 34-45 Barg (as in the reactor)
The reactor is operated completely full of undercooled liquid propylene (the pressure exceeds the liquid
3
vapor pressure). It has a geometric capacity of 1.1 m . The axial flow pump P-5200 provides the slurry
circulation.
Only 200-300 grams of propylene will be polymerized for each gram of catalyst fed. The purpose of the
prepoly reactor 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 is directly fed to the loop without
encapsulation the catalyst particles would not be strong enough, resulting in excessive production of fines.
The precontacting pot, prepolymerizer, and loop reactor are all operated continuously and in series.
The slurry velocity in the Prepoly reactor is about 3  4 m/sec. The heat of reaction is removed by jacket
cooling with chilled water. Pump P-5204A/B keeps a constant water flow rate in the jacket. Thermal control
is obtained by adjusting the water temperature with cold make-up of water.
The pump P-5200 is equipped with mechanical seal arranged “tandem” out ward, and back to back in ward.
The seals are lubricated and cooled by two separated oil circuits:
-for the out tandem seal , at atmospheric pressure
-for the inner back to back seal under pressure.
The pressure of flushing liquid sets the pressure of the barrier/lubricating oil between the two mechanical
seals, by means of the pressure rising piston P-5200-A-00, which increases the pressure of about 10%.
Continuous propylene flush is provided inward the reactor (abt. 400 kg/h) to prevent polymer from reaching
and blocking the seal surfaces.
In case of emergency of the reactor (propylene shortage, failure of P-5200 etc.), E-5201 and all the piping
involved are quickly discharged to blow-down after automatic cut-off.
6. LIQUID MONOMER POLYMERIZATION (PFD 112)
The main polymerization reaction for homopolymer, random copolymer, random terpolymer and butene
random production takes place in the loop reactor.
For Homopolymers and Random Copolymers conventional grades:
o Reaction temperature : 70-73 °C
o Pressure: 34 – 45 Barg
o Slurry concentration: 50-55% by weight
o Inerts concentration (mainly liquid propane) : not more than 40% by weight
Page 11 of 34

o Residence time: 1h – 1:10 h (according to the grade).
Reduced reaction temperature (60°C) is required during terpolymer (propylene + ethylene + butene
polymer) production to cope with the global increased reactivity of the system and the lower melting point of
this kind of polymer, while the other operating parameters like residence time, pressure etc. remain
unchanged.
Liquid propylene (and propane) is used as carrier fluid. The loop reactor has its own circulating pump, which
continuously recirculates the contents of the loop. The circulating pump is critical for maintaining uniform
temperature and pressure through the reactor.
The pressure of the prepoly reactor and loop reactor is controlled by the reactor surge drum (V-5202), which
is a vessel connected to the reactor R-5201. The pressurization drum is equipped with a steam heated
propylene vaporizer (E-5203).
Operating pressures in the higher range are required to increase the Hydrogen solubility in the liquid phase,
according to the operating conditions required.
The typical yield varies between 25000 to 40000 kg PP/kg CTZ, according to grade and catalyst.
6.1 Prepolymer feeding
The polymer coming from prepoly reactor flows with propylene from R-5200 directly into R-5201 where it is
dispersed in the slurry, which is kept circulating in the reactor.
6.2 Propylene fed to R-5201
The propylene from filters S-5201A/B is fed to R-5201 under density control in the reactor.
The total feed is divided into 5 streams:
o Propylene fed to prepolymerizer, kept constant via flow rate control.
o Propylene flushing the prepolymerizer pump P-5200 , kept constant via flow rate control.
o Propylene flushing the pump of R-5201 (P-5201) kept constant via flow rate control.
o Propylene fed directly to R-5201 under flow rate control slave to the reactor density controller.
o Reactor pressurizing propylene fed to E-5203 under pressure control.
6.3 Slurry in R-5201
R-5201 is operated completely full of undercooled liquid.
Page 12 of 34

6.4 Hydrogen fed to R-5201
Hydrogen is used to control the Melt Flow Rate of the polymer produced in the loop reactor, by acting on the
length of the polymer chains. It is injected into the propylene stream fed to the loop reactor.
Hydrogen stream is fed under flow rate control, based on gas-chromatograph analysis, to take into account
any amount of hydrogen already present in the recycled propylene and any possible leakage.
6.5 Ethylene fed to R-5201
In the case of Random Copolymer productions, ethylene is fed to the loop reactor by a separate line under
flow rate control. Gaseous ethylene is mixed with the liquid propylene upstream the reactor and polymerizes
to produce a copolymer.
The total amount of comonomer will be set according to the desired polymer Ethylene content, as a function
of the plant load.
6.6 Butene-1 fed to R-5201
In the case of Random Butene and Terpolymer productions, also butene is fed to the loop reactor. Butene -
1 will be fed into the V-5302 (feed tank). The added butene, sent from area 5700 will be composed by fresh
butene (coming from battery limit after purification).
From V-5302 the mixture (in a fixed ratio) propylene / butene-1 will be sent to loop reactors by means of the
feed pumps P-5301A/B.
The total amount of comonomers will be set according to the desired Ethylene/Butene-1 content of polymer
as a function of the plant load.
6.7 Slurry discharge from the reactor
The slurry is discharged from R-5201 through the valves LV-2301A/B (installed on the bottom, the first on
the lower side whilst the second on the upper side) to the flash line, controlled by the level controller on the
reactor surge drum V-5202. LV-2301B is normally used at start-up only, in order to minimize prepolymer
short-circuiting to the reactor outlet due to centrifugal effect on the solid particles when the reactor is still
diluted. A board switch is provided to operate either valves separately, if needed.
6.8 Slurry concentration in the loop reactor
The slurry density is limited by the capacity of the axial pump to circulate the slurry in the loop. Industrial
3
experience has shown that the reactor can be easily operated with a slurry density up to 560/565 kg/m that
is a concentration of solids of 50% by weight at 70-75°C of reaction temperature. Above this concentration,
the power consumption of the axial pump rises very quickly leading to unstable operation.
Page 13 of 34

To maximize productivity and catalyst yield, the reactor slurry density is operated at the maximum value
allowed by the circulating pump.
Slurry density in the loop reactor is regulated by a density controller, adjusting the propylene feed.
Assuming pure propylene and a solid concentration of 50% by weight, the monomers feed is in the order of
twice the production rate. Industrial experience has highlighted that because of the centrifugal forces acting
in the loop elbows the actual polymer concentration at the outlet of the reactor can reach values up to 55%
by weight. As consequence, monomers feed is in the order of 1.8-1.9 times the production rate.
For plant loads lower than 60% of design capacity, the reactor polymer concentration is usually lower.
6.9 V-5202 (Damper) with Vaporizer (E-5203)
Pressure balance in the reactor is managed by V-5202 (expansion drum, damper) and E-5203 (vaporizer).
The pressure in V-5202 is controlled by means of the vaporizer E-5203 at 4 bar above the monomer vapor
pressure at the reactor temperature, in order to avoid the gas formation in the reactor and to minimize the
risk of cavitation in the axial pump. Expansion drum V-5202 also assures that the reactor work completely
full of liquid.
Expansion drum V-5202 is equipped with a level control that regulates the hydraulic seal of the vessel
adjusting the polymer flow at the outlet of the loop reactor.
6.10 Pump P-5201
The axial pump P-5201 allows the slurry circulation inside the reactor. For safety reasons, the pump is
equipped with a triple mechanical seal arranged "tandem" outward, and "back to back" inward. The seals
are lubricated and cooled by two separated oil circuits:
o For the outer Tandem seal, at atmospheric pressure.
o For the inner back-to-back seal, under pressure.
The inner seal is pressurized by means of the pressure raising piston P-5201-A-01 (the same system is
present on P-5200). The outer pump bearings are lubricated by means of a separate lube oil unit.
Continuous propylene flush is provided inward the reactor (abt. 800 kg/h) to prevent polymer from reaching
and blocking the seal surfaces.
6.11 Loop Reactor Cooling System
The heat of reaction of the loop is removed by circulating water in the reactor jackets.
The water circulation inside reactor jackets is held at a constant flow rate by means of the pumps P-5205
A/B.
The reactor jacket water temperature controller is slaved to the reactor’s temperature controller; controlling
the jacket water flow from the jacket water cooler E-5208.
Page 14 of 34

E-5208, a plate heat exchanger, ensures the removal of the reaction heat from the jacket water, by means
of cooling water.
The reactor cooling system is connected with the expansion drum V-5203 which is elevated above the
highest point on the loop reactor jackets to keep the jackets liquid full, and to provide volume available for
water expansion due to changes of temperature. V-5203 is blanketed with nitrogen.
During plant startup, the reactor jacket water is steam heated by E-5204, in order to bring the monomer
temperature from the ambient one (at which it is fed to the reactor) up to the reaction temperature, ready to
receive the catalyst from the prepoly reactor.
The system is protected against corrosion by nitrogen blanketing of the expansion drum, by accurate pH
control and passivation additives make-up, added in a dedicated small pot (A-5209).
6.12 Stand-by connections
Each top reactor elbow is provided with a pressure control valve, controlled by the Control Room, for gas
venting during reactor filling.
Each bottom elbow is provided with a discharge valve, operated from the Control Room, to drain the reactor
to the degassing section through the flash line.
6.13 Emergency devices
In case of emergency (huge propylene leakage, failure of the slurry circulation pump etc.) the reactor can be
automatically shut-off and isolated from the rest of the plant.
Three actions are taken to protect the reactor:
o Emergency killing: whenever it is necessary to stop the reaction quickly, a mixture of carbon
monoxide diluted with nitrogen can be injected into the lower part of each reactor leg. The operation
can be done automatically via Interlock System or can be manually actuated from the control room.
o Polymer discharge from the bottom: in case of failure of the slurry circulation pump and ineffective
killing, the solid phase can be discharged to the High Pressure blow-down vessel V-5601, where
the reaction stops because of the low temperature/pressure conditions. This operation can be
performed by the operator via a board Hand Switch, or automatically through Pressure Switches
installed on the lower reactor bends.
o As ultimate solution, the reactor is protected by safety valves located on the upper bends,
connected to the High Pressure blow down.
Page 15 of 34

7. FLASH, HIGH PRESSURE DEGASSING AND PROPYLENE RECYCLE (PFD 113 A – 113
B)
7.1 Flash and degassing
Slurry discharged from the reactor consists of about 53% wt polymer and 47% wt liquid propylene +
propane mix. The slurry from the reactor is discharged to the flash pipe at the temperature up to 90°C for
Homopolymer run.
In the flash pipe, the mixture tends to cool down because of the pressure drop from 34 (or up to 45 Barg in
case of higher matrix MFI grades production) to 18 Barg, so that the system must be steam heated to keep
the temperature at the desired value and to provide liquid vaporization.
Since a large quantity of hydrocarbons is involved, it must be recovered. The first operation consists of a
complete vaporization of the liquid, carried out in a flash pipe at high velocity. The required heat is supplied
through a steam-heated jacket. A cascade control sets the steam pressure to the jacket one through a
temperature controller on the vapours coming out the top of the degassing stage. This solution provides the
possibility to adjust the flash evaporating capacity to the plant load, keeping the wall temperatures as low as
possible.
After leaving the flash pipe, solid is separated from gas in the medium pressure filter S-5300. This is a bag
type filter, automatically cleaned by back pulsing with process gas flow, taken from the delivery of the
propylene feed pumps P-5301A/B after vaporization in a steam jacketed pipe.
A liquid separator pot V-5300 prevents that liquid propylene can reach the bags during the bags pulsing
phase.
Polymer drops to the bottom cone of the S-5300 for discharge under level control. The gas stream of the
filter flows to the recycle propylene scrubber C-5301.
In case of upsets in the medium pressure filter (S-5300) the reactor discharge can be diverted to the blow
down section during downtime through the 3-way valve installed upstream S-5300.
During homopolymer ,random copolymer, butene random and random terpolymer runs the polymer
collected from the bottom of medium pressure filter S-5300 is discharged under level control to the recycle
gas filter S-5301, instead during high impact copolymer runs polymer from S-5300 is routed to the gas
phase reactor R-5401.
Temperature and flow rate of the gas leaving S-5300 are automatically controlled. The temperature
controller acts on the steam pressure in the flash pipe jacket while a flow rate controller acts on the flushing
propylene inlet valve at the beginning of the flash pipe.
7.2 Vapor Monomer Scrubbing
The scrubbing section operating conditions are depending on the plant production conditions:
o Homopolymers , Random Copolymers, Butene random and Random Terpolymer
o High Impact Copolymers
Page 16 of 34

In any case all the monomers recovered from the degassing section are sent to the propylene scrubber C-
5301.
The propylene scrubber (C-5301) is a trays-type column, allowing counter-current contact of the upward
flowing gas stream with liquid propylene reflux. The operation removes residual polymer fines –if any-
carried over from the medium pressure guard filter as heavier components, discharged at the bottom. In
addition to that, C-5301 may be useful because the transition time from a lower to a higher Teal/donor ratio
run may be shortened.
The bottom stream flow is kept constant and lined-up to S-5301, according to the plant arrangement.
In case of High Impact Copolymers production, the bottom stream of the Ethylene stripper C-5401 joins the
vapor stream leaving the top of C-5301.
The vapor leaving the top of the column C-5301 is condensed in the downstream condenser E-5301 using
CW and in the post-condenser E-5310 (with CHW). The aim of the post-condenser is to reduce the
incondensable stream flow rate during campaigns with high hydrogen content in the loop.
The liquid discharged from E-5301 is then pumped (via P-5302A/B) to 2 streams:
o Reflux stream to C-5301 under C-5301 level control (ab. 7 - 11 t/h)
o Recycle stream to the feed tank V-5302, under pressure control
The gas stream leaving the top of E-5301 is purged under flow control to the off-gas header in order to be
able to purge a few accumulation of inert gas in the system.
The pressure of the complete degassing section (S-5300, C-5301 and E-5301) is maintained at about 18
Barg by a pressure controller installed on C-5301 top.
7.3 Propylene storage and plant feed
Fresh propylene is received under level control and combined with the recycle, to be fed to the reactor by
the high-head pumps P-5301A/B. In order to keep the pressure of the propylene header as stable as
possible, these pumps are operated at constant capacity through flow rate control acting on the recycle line
of V-5302. The pressure inside V-5302 is kept constant (18÷20 Barg) by vaporizing part of the pumped
liquid via E-5302 increasing also the NPSH available on pumps P-5301A/B. The cooler E-5305 on V-5302
recycle line prevents heating-up of propylene while the plant is not running. The recycled condensed
propylene is then sent to the feed tank V-5302. The propylene feed tank V-5302 is normally maintained at
70% level and the pumps P-5301A/B work continuously.
The propylene feed pumps are operated at constant flow rate by a dedicated flow control and consequently
the discharge pressure is constant. Whenever the fresh propylene supply fails and cannot be restored
quickly, the loop reactor has to be put in safe conditions within 20 minutes, so that the residual propylene in
V-5302 will be enough to dilute the reactor.
Variations of level cause small variations of pressure. Significant decrease of pressure on V-5302 can occur
when steam fails on E-5302. Steam needs to be restored quickly otherwise a too low pressure in feed tank
can generate cavitation in the feed pumps P-5301A/B and interrupt the propylene flow to the reactor.
Page 17 of 34

8. LOW PRESSURE DEGASSING, GAS RECYCLE (PFD 113A)
8.1 Low pressure degassing filter S-5301
S-5301 is a bag type filter, automatically cleaned by back pulsing with process gas flow, taken from the
delivery of the recycle compressor ME-5301-K-01after a pressure reduction.
A liquid separator pot V-5303 prevents that liquid propylene can reach the bags during the bags pulsing
phase.
In case of homopolymer, random copolymer, random butene or terpolymer productions, the polymer and the
carrier are routed from the medium pressure filter S-5300 to the low pressure degassing filter S-5301.
During heterophasic copolymer runs, S-5301 receives the polymer from R-5401 discharge.
The polymer collected at filter bottom is continuously discharged to the steaming section under level control.
The filtered gas is sent to washing and compression. Guard filters S-5302A/B prevent any massive amount
of powder from reaching the compressor in case of failure of the bags of the primary filter.
Highly flammable hydrocarbon vapours, propane and propylene are handled in high concentrations in the
bag filter and related equipment. The entire system operates under a slight positive pressure to avoid the
formation of an explosive mixture. For the same reason, it is necessary to purge with nitrogen the system
before putting it into service. A by-pass around relief valve to flare on discharge of compressor allows
venting and purging the system to the flare.
In the event of increase of pressure in the bag filter, a pressure controller operates an automatic pressure
control valve in the vent line to the flare.
Any oil collected in the compressor system is sent back to C-5302.
8.2 Recycle gas streams washing and compression C-5302/ME-5301-K-01 (ME-5301)
Gas stream leaving filter S-5301 is washed with a mixture of 50% paraffin oil and 50% Atmer 163 in C-5302
tower in order to remove any powder entrainment and minimize the aluminum alkyl content to the
compressor, producing with it a stable complex.
The washing mixture, which gets with the time richer and richer in aluminum, must be replaced as soon as
the concentration of aluminum reaches about 1.6 %wt.
This oil is kept circulating in C-5302 by the pumps P-5304A/B. Gear pump P-5303 is used to transfer
exhaust oil to treating unit V-5607.
The gas stream leaving C-5302 is cooled down to 45°C in E-5304. Any entrainment liquid is removed in V-
5304. The compressor suction pressure is controlled by recycling some gas to C-5302. Pressure controller
should recycle the monomers (from ME-5301-K-01 delivery to C-5302) needed to maintain the desired
pressure to the bag filter and compressor suction.
Page 18 of 34

The delivery of ME-5301-K-01 is sent to C-5301 in case of homopolymer, random copolymer, random
butene or terpolymer runs or to the ethylene stripper C-5401 when producing heterophasic copolymers.
Once process reaches a stable operating condition, bag filter S-5301, scrubber C-5302 and propylene
recycle compressor ME-5301-K-01 should require little or no adjustment.
If there is a large increase or decrease in monomers feed to the compressor it might be necessary to
increase or decrease the load on compressor.
Page 19 of 34

9. GAS PHASE COPOLYMERIZATION (PFD 114)
In this section a rubbery ethylene-propylene phase is added to the homopolymer matrix (coming from bulk
polymerization inside the loop reactor) to produce a high-impact heterophasic copolymer.
9.1 Gas phase reactor (GPR) R-5401
The polymerization step for the production of the rubbery phase is managed in a vertical cylindrical fluidized
bed reactor, R-5401, fed with homopolymer matrix from S-5300.
Polymer that enters into the GPR falls downward and is contacted with an upward flowing gas stream. This
monomer stream is pumped through the slotted conical tray located at the bottom of the GPR by the
fluidization compressor ME-5401-K-01.
When the gas passes through the polymer, three physical effects take place:
o The polymer is fluidized.
o Monomers contact the catalyst within the polymer granules and polymerize.
o The temperature of the upward flowing gas increases, while removing heat of reaction.
Gas superficial velocity must never be less than about 0.7 m/s in order to achieve good fluidization and
good heat exchange.
Ethylene and propylene (plus hydrogen for molecular weight control) are fed at constant flow rate and in
suitable ratios to meet the required properties of the copolymer products.
Normal operating conditions of gas phase reactor are:
o Pressure : 14 Barg.
o Temperature : 75-80 °C
o Average bed density : 300-350 kg/m³
The copolymer produced is discharged from the reactor bottom to S-5301 second stage degassing.
The depth of polymer in the reactor is regulated with excess (equal to the amount entering plus the gas
polymerized amount) discharge through two level control valves.
Most of the circulating gas in GPR does not react and it is recycled back to the reactor through the
fluidization compressor ME-5401-K-01.
The reactive polymer granules must be kept in constant motion to reduce the risk of plugging the reactor.
This is caused by polymer fusion and could happen also in the GPR bottom outlet because there is no
fluidizing gas or area cooling capacity.
To prevent any problems at the GPR bottom, it is important to assure continual rapid movement of the
polymer away from the bottom outlet.
Page 20 of 34

This is accomplished with a “fast loop”. The “fast loop” is a loop pipe that takes the majority of the GPR
bottom discharge and allows it to flow by means of a pneumatic transport from the bottom of the GPR near
the top, dumping its content back into the reactor.
This constant flow is large enough to assure no hot spots develop.
Page 21 of 34

9.2 Ethylene stripper C-5401
While polymer from S-5301 bottom is discharged to the steaming and drying section, for high impact
copolymer runs the filter top stream is compressed by ME-5301-K-01 and fed, after cooling in E-5403, to the
ethylene stripper C-5401.
Ethylene rich top gas is recycled to R-5401 while the propylene/propane bottom stream joins the C-5301
o C-5301 top gas stream to E-5301, for condensation and liquid recycle to the feed tank V-5302.
o C-5401 condenser temperature set point is adjusted in order to keep the desired inert content inside
R-5401.
The cooling medium for the condenser E-5405 is refrigerated water.
9.3 Monomers feed to the gas phase reactor
Ethylene, propylene and hydrogen are fed to the gas phase reactor under flow rate control.
The feed rates are set by:
o the total homopolymer production rate from the loop reactor
o the desired rubber composition (ethylene to propylene ratio) and the total percentage of rubber, in
relation to homopolymer content
o the desired rubber viscosity (based on the hydrogen to ethylene ratio)
o the reacting gas composition necessary to produce the targeted rubber composition, taking into
account flow rate and composition of the gas recycle stream
The gas phase reactor composition is monitored by a gas chromatograph to have a feedback control.
9.4 Cooling system
Heat of reaction is removed from the fluidizing gas in the vertical heat exchanger E-5401. The jacket water
supply flow to exchanger is under the temperature control of the gas leaving the top of the reactor. Jacket
water is itself cooled in a dedicated plate exchanger E-5411.
Pumps P-5401A/B are necessary for jacket recirculation.
A dedicated steam-heated exchanger E-5409 is installed in the jacket water closed loop circuit to allow the
startup of the reactor.
9.5 Pressure control in the gas phase reactor
Pressure inside gas phase reactor should be kept close to the operating set point (14 Barg) for the following
reasons:
Page 22 of 34

o To ensure ME-5401-K-01 operating conditions (flow rate and head), to keep the polymer bed
thoroughly fluidized. To do this, pressure must never fall below 8/10 Barg.
o To ensure an adequate heat exchange coefficient in E-5401.
o To maintain sufficient monomers concentration to guarantee the required production rate.
The pressure is controlled by adjusting the solids level inside reactor, according to the required polymer
production rate.
9.6 Emergency devices
Since the system does not have large monomers hold-up, the operating risks are not particularly high.
The most severe process emergency can result from the failure of the fluidization compressor, due to power
black-out or any other reason. In this case the emergency killer is automatically injected by means of the
relevant Interlock System.
During homopolymer, random copolymer random butene or terpolymer runs, the plant sections relevant to
R-5401 and C-5401 are bypassed.
10. STEAMING AND RECOVERY OF MONOMERS DISSOLVED IN THE POLYMER (PFD

115A - 115B)
10.1 Steamer V-5501
From the low-pressure degassing filter S-5301 the polymer, which still contains abt. 1% wt of dissolved
monomers (propylene + propane), beside a 1-1.5% wt of gas flowing across the filter discharge valve, is fed
by gravity to a moving bed steam-treated in V-5501. Deactivation of catalyst residues and stripping of the
dissolved hydrocarbons are obtained in this unit by means of the contact between steam and polymer.
The Steamer is a vertical cylindrical vessel with a slow-speed mixer (V-5501-M-01) which guarantees a
polymer plug flow through the vessel.
Steam is fed into the steamer from the bottom through special sieve plates and through a ring distributor
located in the cylindrical part of the vessel. Polymer is discharged by gravity under level control. The
outgoing gas flows from the top through a cyclone (HO-5501) for the separation of entrained polymer fines.
In order to avoid water condensation on the walls, the unit is completely steam jacketed.
10.2 Scrubbing
The vapor stream from V-5501 is sent to the scrubber C-5501 and condensed in E-5501.
The pumps P-5501A/B provides water circulation for the scrubber.
Page 23 of 34

Steam is injected into C-5501 bottom to keep temperature high enough to prevent the presence of
hydrocarbons in solution.
A plate inside the column collects the water condensed from E-5501 and sends it to a decanter V-5509.
The overflow of lighter hydrocarbons gas stream is sent, together with the top outlet stream of C-5501, to
the liquid ring compressor, while water is recycled through the column reflux pumps (P-5501A/B).
The condensate (and some polymer traces) are discharged from C-5501 bottom under level control to the
dryer scrubber C-5502, and then to the process water basin, located away from polymerization. Wet
overhead gas is sent to compression for recovery and/or purge.
10.3 Compression and recovery
Uncondensed gas is pulled from the top of the scrubber by ME-5501-K-01 compressor, which sucks the gas
(hydrocarbon and steam) and compresses it till 4 Barg. The condensate collected in the plate located in the
upper part of the column C-5501 flows through V-5509 to separate organic liquids and goes back to reflux
pump suction; from the top of V-5509, about 10 kg/h of water and organic liquid are sent together with the
top column stream to ME-5501-K-01.The compressor discharge is sent to ME-5501-V-03 gas/water
separator. Then, compressed vapours are cooled at 10°C in E-5504 with refrigerated water, in order to
reduce the water content. Condensed water and cooled vapours are discharged to the water collector V-
5506.
From the bottom of V-5506 the liquid phase is sent back to ME-5501-V-03. Water and organic residues flow
continuously from ME-5501-V-03 to the water organic separator S-5503.
Water is recycled to waste water separator V-5505 under ME-5501-V-03 level control, while the organic
liquid phase flows under level interface to the waste oil collector V-5504.
From the top of V-5506 a continuous stream is sent to off-gas header in order to purge propane and keep
the desired inert composition in the reaction system.
In V-5505 a nitrogen sparger (A-5505) is provided to strip out hydrocarbons from the water before the
discharge to the process water basin T-5501.
The organic phase is collected in V-5504 to be degassed by nitrogen injection and discharged in drums.
11. DRYING (PFD 115B)
11.1 Drying
Polymer leaving the steamer contains about 2.5% by weight of condensed water. A fluid bed dryer V-5502,
operated in a closed-loop nitrogen circulation, allows the water removal from the polymer particles.
Nitrogen is used as an inert atmosphere in all vessels and process line to prevent explosive atmosphere
(dust cloud), as well as polymer degradation. A positive nitrogen pressure is maintained to prevent vacuum
conditions, where air could possibly enter the system forming an explosive mixture.
Page 24 of 34

Hydrocarbons analyzer is provided in the nitrogen circuit of the drying section to indicate possible presence
of hydrocarbons, due to improper operation of the steaming section.
11.2 Dryer V-5502
The dryer is a vertical vessel where hot and dry nitrogen is fed to remove the moisture from the polymer. It
consists of three sections:
1. the upper part (head) is designed to have a gas velocity below the fluidization limit, to prevent
polymer fines from being carried to the dryer scrubber
2. the cylindrical section is designed to have a fluidized bed where the polymer runs through a spiral
route, going from the inlet to the outlet gate
3. the bottom section is designed to have a plug flow acting as a final guard against moisture
11.3 Drying nitrogen system
In the dryer, the polymer is separated from residual water. The gas leaving the upper part of the dryer, flows
to the cyclone HO-5502 for the fines entrained separation. Then, the gas is washed and cooled in the
scrubber C-5502 in order to match a dew point of 45°C. The nitrogen recycle stream, compressed by K-
5502A/B, is heated up to 90-100°C in E-5503, then is divided in two streams:
o The first stream fluidizes the bed inside the dryer.
o The second stream feeds the grid of the plug-flow section.
The drying process led to a temperature decrease, so the polymer leaves the dryer at a lower temperature
than it enters (i.e. it enters at 100°C from the steamer and exits the dryer at 75 to 80°C).
The outlet temperature is controlled by a temperature control valve on the steam of the heater E-5503.
The heat removed from polymer cooling goes primarily to vaporize the water. The heat input from the
nitrogen heater E-5503 is small compared to the heat of vaporization, thus there is a net cooling of the bed.
11.4 Condensation of water from nitrogen recycle
This operation is carried out in the dryer scrubber C-5502.

Nitrogen from HO-5502 enters at the bottom of C-5502, flowing up through the scrubber and contacts the
cool water; steam condenses from the nitrogen and polymer fines are scrubbed from the nitrogen.
The nitrogen flows through a demister from the top of the scrubber to the gas blower (K-5502A/B). Blower
suction pressure is maintained at abt. 400 mm H 2O by nitrogen make-up through a pressure control valve to
the blower suction.
Water is kept circulating by pumps P-5502A/B and cooled in the heat exchanger E-5502A/B. This circulation
of water is cooling the nitrogen to abt. 40  45°C, thus condensing out all of the water picked up in the dryer.
The nitrogen leaves the scrubber at saturation at abt. 40  45°C.
Page 25 of 34

The scrubber C-5502 receives also the water condensate stream coming from the steamer scrubber C-5501
; the bottom is equipped with a hydraulic seal from which the condensed water is continuously drained
together with some polymer fines that may have been captured.
12. BLOW DOWN (PFD 116A)
The plant is provided with three blow down vessels, and a guard cyclone HO-5601 that has a collector on
the bottom for separated solids. The hydrocarbons relieves from the plant are split into high pressure and
low pressure systems.
The first vessel, item V-5601, can operate in pressure, while item V-5602, as well as the II low pressure
vessel V-5603 and the guard cyclone HO-5601 operates at the flare header back pressure.
The outlet gas from the top of either system flows through the guard cyclone, then to the flare. Some
discharges bypass both the high and low pressure systems, and are sent directly to the cyclone, then to the
flare.
The high-pressure system is designed to capture relieves that may contain significant portions of liquid
hydrocarbons and/or solids with gas. Vessel V-5601 receives emergency vents from the loop reactor, in
particular the discharges of the safety valves from the prepoly and the loop reactor: as a result of the
relative low pressure, compared to the reactor one, residual activity of the catalyst discharged with polymer
is remarkably decreased, therefore the reaction ceases.
V-5601 has sufficient volume to contain the combined slurry volume of all loop reactor, at about 50% fill.
The low-pressure system is intended to catch relieves that have substantial entrained solids in gas, with
small or no amount of liquid hydrocarbons.
The first low-pressure blow down vessel V-5602 receives flows from:
o loop reactor top depressurizing vents
o medium pressure filter inlet (via three way valve)
o low pressure filter inlet (via three way valve)
If V-5602 requires maintenance, the above mentioned flows can be routed to V-5601 temporarily via three
way valves, maintaining the plant in operation. Note that if V-5601 requires maintenance, the plant must be
shut down. All low-pressure gaseous vents and high-pressure vents without polymer are routed directly to
the cyclone HO-5601. These are including the gas phase reactor, the off-gas and miscellaneous streams
from areas 5200, 5300, 5400. Also, the outlets from V-5601 and V-5602 flow through the cyclone to prevent
any entrained polymer to reach the flare header. The cyclone discharges solids into the second low
pressure blow down vessel V-5603.
A typical operating scenario for an emergency relief of the loop reactor is described below:
o In the normal configuration, V-5601 gas outlet is lined up to the restriction orifice RO 6006 via a
three-way valve. V-5602 is lined up to collect the loop reactor top depressurizing vents, the flash
drum inlet (valve 3001), and the bag filter inlet (valve 3101).
Page 26 of 34

o Since V-5601 is operated at a lower pressure than the loop reactor, during an emergency relief,
most of the liquid monomer flashes in the vessel. This fact strongly reduces the catalyst activity,
stopping effectively the reaction. The restriction orifice on the gas outlet is designed to flow the
same rate as the safety valves installed on top of V-5601 at the same inlet pressure. Thus at the
start of a relief, the V-5601 pressure rises before dropping off. Due to its volume, the vessel has a
damping effect on flow, reducing the peak rate to the flare.
o After the emergency, the jacket on V-5601 is heated-up to vaporize any remaining liquid propylene.
o Then, V-5601 gas outlet is lined up to PSV-6001, which is set at 5 Barg. The vessel is pressurized
with nitrogen, and then the solids are discharged by pressure to the low pressure blow down vessel,
V-5602. Once V-5601 is emptied, the gas outlet is again lined up to the restriction orifice RO-6006.
Note: V-5601 gas outlet may be kept lined up to PSV-6001 at all times, to make sure that the
temperature of the gas flowing to the flare is always higher than 0°C throughout any emergency
discharge.
o V-5601 and V-5602 are equipped with multiple sparger system where low pressure steam and
nitrogen are blown by K-5610 and heated by E-5610 to strip out propylene from polymer to flare,
and to kill residual traces of TEAL and catalyst.
Steam is fed to this circuit in a ratio with nitrogen that avoids condensation.
When stripping is completed, polymer is discharged into containers for disposal.
Gas flowing from V-5601 and V-5602 first crosses HO-5601 to prevent entrained powder from reaching the
flare header. HO-5601 bottom can be discharged in the collector V-5603. All low-pressure gaseous vents
and high-pressure vents without polymer are sent directly to flare through the cyclone HO-5601.
Any solid collected in V-5603 from the cyclone discharge can be treated in a similar way as V-5602.
13. PROCESS FACILITIES (PFD 116A – 116B)
13.1 Refrigeration unit
Chilled water is supplied by a compression/expansion type refrigeration unit ME-5601 which cools down
refrigerated water, made of condensate and ethylene glycol (20%), to about 2°C.
Refrigerated water is mainly used in the process in catalyst preparation and metering unit, to cool down the
V-5607 and the precontacting pot, V-5201, the prepolymerization reactors, R-5200, to control the
temperature in V-5607 during exhaust oil treatment and during copolymer running in the heat exchanger E-
5405 (C-5401 condenser).
Each unit is provided with an expansion drum: V-5612.
The chilled water return header is connected to an expansion drum V-5612 located 1 m min. above the
highest point in order to keep the system full of liquid; V-5612 is nitrogen flushed and is operated at
atmospheric pressure; a low level alarm and high level alarm is provided to start/stop the refilling of the
system.
Page 27 of 34

Refrigerated water from V-5604 is pumped with P-5601A (or B) to the refrigerated water network. A
minimum flow by-pass recycles back the water to A-5601 in case the plant consumption is very low; this
pipe is partially jacketed with low pressure steam in order to bring the temperature at the normal inlet value
in the refrigeration unit, in order to simulate the heat load of the plant.
13.2 Low pressure steam condensate recovery
Steam condensate recovered is collected in the vessel V-5606, which operates at atmospheric pressure. A
small nitrogen purge keeps the vessel under inert atmosphere.
The vessel is operated under level control acting on the condensate flow rate discharged to B.L. through the
pumps P-5603A or B. After the pump, there is a cooling water exchanger, E-5607, to maintain the outlet
temperature at value less than 46°C. Part of steam condensate can be sent from P-5603A or B to a steam
st
condensate header in order to be used (instead of demineralized water) as 1 filling for reactors cooling
circuit, as make-up of refrigerated water system, as water make up of liquid ring compressor (ME-5501) and
as refilling of extrusion cutting water system.
13.3 Centralized mineral oil system
The fresh oil distribution unit supplies mineral oil to various users throughout the plant. The most significant
consumption is in the preparation of the catalyst. Mineral oil is also used for centrifugal pumps seal pots and
occasionally for lines and equipment flushing before maintenance (e.g. Teal section maintenance).
Mineral oil is discharged from drums into V-5611 by means of the pump P-5605.
Oil is kept circulating through a steam jacketed pipe to be heated up to about 90°C and nitrogen is bubbled
into the tank through the porous sparger A-5611, to strip out oxygen and moisture.
The pumps P-5606A/B are utilized under pressure control to supply mineral oil to various users of the plant
after filtration in S-5602.
Centralized mineral oil system is provided for the following areas:
o Teal metering area
o Flushing of Teal lines for maintenance operations (waste oil is collected in V-5102; from V-5102 the
waste oil can be sent to the Teal deactivation system by means of P-5102).
o Oil drying drum (V-5105B)
o Filling of S-5302A/B cartridge filters for maintenance purposes
o Extrusion section
o Peroxide section in extrusion area, for cleaning purpose
o Pressurized oil system
The treated oil is used for:
o Stored in V-5105B
Page 28 of 34

o Donor dilution for metering (V-5110 A/B/C)

o Catalyst dispersion and metering (V-5106A/B - A-5113A/B )
o Low pressure propylene scrubber (C-5302)
o To refill the hydraulic oil surge drum V-5107 – both internal chambers.
13.4 Waste oil treatment
Mineral oil is used in the process area for the following purposes:
o Flushing of TEAL lines, before maintenance. The oil used for this service is collected in V-5102
o Scrubbing of propylene gas fed to the compressor ME-5301. Oil plus liquid additive is fed to the
column and periodically replaced.
o Flushing of precontacting pot for maintenance.
An oil treating unit is provided in order to deactivate TEAL and obtain a safe handling of waste oil.
st rd
For the 1 and the 3 items above mentioned, batch-wise operation is carried out as follows:
o Waste oil is fed to the TEAL treating tank V-5607 where it is neutralized by adding Atmer 163.
Starting from ambient temperature, steam starts circulating in the first coil of the drum and activates
the neutralizing reaction. When the temperature reaches 100 °C, the Refrigerated Water circulating
in the second coil of the drum starts removing the heat. Steam and Refrigerated Water are
controlled in split range.
o When treatment is over (a few minutes after Atmer 163 addition), the oil is cooled by setting down
the temperature to 40°C, and it is discharged in drums.
nd
For the 2 item above mentioned, waste oil is already treated with additive (Atmer 163) and V-5607 is used
to purge propylene from the oil plus additive mixture before being discharged into a drum.
13.5 Instrument air buffer drum
An air buffer drum (V-5605) provides up to half of an hour of instrument air availability for the polymerization
train, extrusion and downstream areas excluded, in the event that the normal system fails.
In case instrument air from battery limit fails, interlock connects the buffer tank to the plant network and air
is supplied through a pressure control valve. One check valve with soft seat avoids leaks of air back to
battery limit.
When air availability from OSBL is resumed, the interlock can be reset by pushing a dedicate push button.
Instrument air hold up in V-5605 is maintained at high pressure (25 bar g) by means of the compressor
package ME-5602.
Page 29 of 34

14. PROPYLENE PURIFICATION (LIGHT ENDS STRIPPING, H2S REMOVAL, DRYING)

(PFD 117A)
Propylene make-up coming from B.L. passes through a propylene drying unit, ME-5701, composed by two
adsorption towers, ME-5701-C-03A/B. Then the monomer crosses the COS removal guard tower, C-5704.
Regeneration system for drying uses hot nitrogen in open circuit as a regeneration medium.
Before reaching the propylene feed tank V-5302, the make-up propylene is filtered in S-5701.
15. HYDROGEN COMPRESSION AND BUFFERING (PFD 117B)
Hydrogen coming from B.L. is filtered in S-5705A/B, to be sent to gas phase reactor R-5401 (copolymer
production).
When hydrogen has to be sent to the loop reactor of only one or two both units (PP and Polyethylene Unit),
a compression stage is provided by ME-5709A/B (one compressor in standby) to increase the pressure up
to the required value (55 Barg for PP).
An hydrogen buffering system, composed by three packs of cylinders is installed to guarantee up to six
hours of gas availability for the polymerization train (PE + PP), in the event that the normal feeding from B.L.
fails. The packs are pressurized by ME-5710-K-10, hydrogen high pressure booster compressor, that is
designed with low rated capacity, but high differential pressure.
16. ETHYLENE COMPRESSION (117B)
Ethylene from Battery Limits is sent to the filter S-5702A/B, then to the polymerization unit.
When ethylene has to be sent to the loop reactor, a compression stage is provided (ME-5704) to increase
the pressure up to the required value (50 Barg).
17. BUTENE PURIFICATION (CO) AND FEED TANK (PFD 117C)
Butene from Battery Limits is sent to the plant, via purification section. This section is only used during
terpolymer and random C4- grade production.
Butene-1 make-up is fed to the light-end stripper C-5730, provided with a reboiler E-5730 and a condenser
E-5731. Light-ends are purged from the top of the condenser under flow rate control. Tower bottom stream
is sent to the butane feed tank V-5732, while a small light-ends stream joins the off-gas to be recovered at
B.L.
Butene-1 is feeding to propylene feed tank under flow control and mixed with the propylene feed.
Page 30 of 34

18. PP POLYMER TRANSPORT, STORAGE AND METERING TO EXTRUSION -

ADDITIVES METERING TO EXTRUSION (PFD 118A, 118B, 118C, 118D, 118E)
PP polymer, discharged by level control from the dryer V-5502, is sent to the intermediate silos HO-
5802A/B, by means of nitrogen pneumatic haulage ME-5801B. HO-5802A/B is installed on the top of the
extruder building.
The silos HO-5802A/B are equipped with a bag type filter, ME-5801B-S-20 and ME-5801B-S-30 and they
operate under nitrogen atmosphere.
The pneumatic transport is made of a closed loop transfer system, supplied by the compressors ME-5801B-
K-01A/B (one as spare).
The transfer system receives the polymer from the dryer (operating pressure abt. 0.1 Barg) through the
feeding hopper ME-5801B-HO-01 and the rotary feeders ME-5801B-FF-01A/B and sends the polymer to the
intermediate silos HO-5802A/B by means pneumatic transport blower ME-5801B-K-01A/B.
A minor feed consisting of P.P. powder fines from dryer can be transferred separately to ME-5801B through
a line coming from rotary feeder ME-5801A-FF-01B (installed under ME-5801A-HO-08 fines discharge
collector) to the silos HO-5802A/B.
Coolers (ME-5801B-E-00 and ME-5801B-E-01) are provided in order to avoid the heating of the product and
to take out the blower compression heat.
In order to prevent air infiltration, the pressure in the closed circuit is maintained above atmospheric
pressure.
Nitrogen is recycled after passing through the filter ME-5801B-S-20/ ME-5801B-S-30 directly installed on
HO-5802A/B top.
These filters (ME-5801B-S-20 and ME-5801B-S-30) are equipped with a cleaning pulse system with
nitrogen controlled by a timer.
The recycled nitrogen stream coming from HO-5802A/B passes through a guard filter ME-5801-S-01A (or
B).
The pressure in the circuit is controlled by adding nitrogen make-up when required.
The filters ME-5801-S-01A/B act as guard filters in case of bag rupture of ME-5801B-S-20/S-30, while the
exchanger ME-5801B-E-00 cools the nitrogen before feeding it to the blowers.
HO-5802A/B is equipped with a system providing a continuous indication of polymer hold up.
The polymer from silos HO-5802A/B is sent to the metering system ME-5802-FF-01 via the screw feeders
ME-5802-FF-11/12.The feeders ME-5802-FF-11/12 are speed-variable type and are controlled directly by
ME-5802-FF-01. From ME-5802-FF-01 polymer is discharged to the screw feeder M-5801.
The solid additives, coming from unloading stations ME-5811-LA-02A/B, ME-5811-LA-03A/B, ME-5811-LA-
04A/B and ME-5811-LA-05A/B are discharged into the screw feeder, via loss in weight feeders ME-5802-
FF-02, 03, 04, 05.
Page 31 of 34

The additive from unloading stations ME-5811-LA-06A/B is discharged directly into the extruder hopper via
loss in weight feeders ME-5802-FF-06.
Reworking product can be loaded in ME-5811-LA-01, transferred through a pneumatic transport to the silo
HO-5809 and discharged in the screw feeder M-5801 via the rotary feeder ME-5802-FF-10.
ME-5802-FF-01 polymer instantaneous flow rate signals are used to set all solids additives flow rate
according to the recipe.
A liquid peroxide metering station is provided for special polymer grades production. The surge drum V-
5810 and the metering pumps P-5810A/B are used to feed the liquid peroxide into the extruder feed hopper.
The equipment and lines in peroxide service shall be maintained at temperature less than 40 C. For safety
reasons the peroxide station is located in a separate room with explosion proof walls.
The extrusion building is also equipped with a suction system (ME-5810). The system consists of a
centralized suction group (ME-5810-K-10, plus ME-5810-S-10) collecting various emission points before
releasing them to the atmosphere. The aim of this system is to avoid any contamination of the working area
because of nitrogen and powder.
19. EXTRUSION (PFD 118E)
Additives and polymer mixture from M-5801 are fed to the extruder through the feeding hopper. Nitrogen is
also fed to this hopper to prevent oxygen entering the extruder itself.
Liquid additives like organic peroxide and Atmer 163 are injected pure directly into the extruder hopper.
PP polymer powder and additives are homogenized, extruded and granulated by an under-water pelletizer
in the extruder ME-5803-EX-03.
Granulation occurs in an underwater pelletizer. In the extruder, the melted polymer is pushed against a die
plate: as soon as polymer emerges as strands from the holes in the die-plate, it is cut into pellets by a set of
rotating knives.
Pellets are then transported by a water stream in which both the die-plate and the knives are submerged.
Temperature and flow rate of cutting water are function of the type of polymer to be produced.
The cutting water is circulating by means of the pumps ME-5803-P-01A/B and cooled in the plate
exchangers ME-5803-E-03A/B. Cutting water is collected in ME-5803-T-06 tank.
The make-up of water is made with demineralized water.
Pellets and water stream leaving the underwater pelletizer are normally conveyed to the dryer ME-5803-A-
05, via a gross separator, ME-5802-S-02. Water is separated from the pellets first by gravity and then by
centrifugal force. The pellets take a spiral path from the bottom to the top of the dryer.
Final drying is accomplished by the flow of dry air through the pellets.
Drying air from fan ME-5803-K-04 is discharged to atmosphere. ME-5803-K-04 fan increases the airflow
and consequently improves the drying.
Page 32 of 34

Water/pellets separator ME-5803-S-08 is equipped with agglomerate catcher, which consists of a series of
inclined bars with a pneumatic operated gate at the bottom. Agglomerates are continuously and
automatically removed when the gate is open.
Dried pellets leaving ME-5803-A-05 are conveyed by gravity to the vibrating screen ME-5803-SC-03 which
separates fines and coarse from pellets.
Coarse and fines are sent to off-size pellets recovery package ME-5807, while the on-spec pellets are
discharged in the pneumatic transport hopper ME-5807-HO-19.
In case of any trouble, it is possible, through a diverter valve, to by-pass the ME-5803-SC-03.
From ME-5807-HO-19 the pellets are fed to pneumatic haulage ME-5804 for the conveying to the
homogenizing silos.
Finished PP pellets from the extrusion unit are collected by means of a pneumatic haulage ME-5804 in 10
blender silos HO-5901A-E and HO-5902A-E.
The pneumatic haulage is air open-circuit type.
Conveying air, filtered in the filter ME-5804-S-07A/B, is compressed with blower ME-5804-K-02A/B and
cooled in the air cooler ME-5804-E-05.
The pellets are discharged from the hopper ME-5804-HO-07 and fed to the pneumatic haulage through the
rotary valve ME-5804-FF-06A/B.
20. HOMOGENIZATION AND TRANSPORT TO BAGGING (PFD 119A, 119B)
Pelletized product is conveyed from the extrusion and pelletizing unit, to the homogenization silos by a pneumatic
transport in air (ME-5804).
Pelletized product homogenization is carried out in 10 homogenization silos HO-5901A-E and HO-5902A-E.
3
All these silos have a capacity of 800 m each and are provided with an internal arrangement of specially designed
drilled pipes in order to shortening the time required for the operation.
Recirculation of pellets is provided by means of an open-circuit air pneumatic conveyor ME-5901.
The blending target is to obtain a product that is fully homogenized, starting from a product having an analysed MFI
included in the acceptable blending limits (for values, reference shall be made to HO-5901A-E and HO-5902A-E
and ME-5901 equipment datasheets).
Pneumatic conveying ME-5901 also performs the transfer of pellets to the downstream bagging and bulk loading
section.
Conveying and ventilation air is vented to the atmosphere through the vents on top of silos. In case of too high
emission of VOC’s it will be necessary to switch the stream to RTO (according to local authority requests).
Page 33 of 34

Heat of compression is removed by heat exchangers located on compressors header delivery
Pellets plus additives, using more than 0.35 kg of peroxide per ton of PP (350 ppmw) have flammable
decomposition products from the peroxides, that can take several days to diffuse from the polymer, depending on
the temperature of the polymer. If these vapours are not purged from the silo it is possible for the accumulated
vapours to reach the flammable range. On the other side pellets accumulate electrical charges during the
conveying and blending process. These charges have sufficient energy to ignite the flammable vapours. The
amount of flammable vapours that are released is dependent on the type of organic peroxide used and the pellet
temperature.
Continuous purge of pellet/blender silos with air at a minimum rate of 0.5 meters/minute air flow velocity over the
cross-sectional area of the silo for visbroken polymer is granted by dedicated silo venting blowers ME-5910-K04.
Air ventilation must be assured for a minimum of 6 hours, and for the entire time it is in the pellet/blender silos.
If the purge air is interrupted, nitrogen (with sufficient flow to reduce oxygen concentration below 8%) should be
used to purge the silo.
System, composed by ME-5910-T-12, ME-5910-P-01, ME-5910-SC-12A/B and P-5910 provides the washing of the
silos, to avoid any contamination among two or more different type of pellets.
Polymer handling facilities (Bagging, Palletizing, Warehousing) downstream the homogenization section is out of
seller scope of work.
The acceptable fines content in the final product may vary depending on the application; generally though it is in the
range of 200 ppm wt.
As generation of fines in the pellets conveying system is possible, an elutriation system might be part of ME-5901
package unit, if Vendor deems it necessary, after giving due consideration to the final system lay-out. An elutriation
scheme is shown on P&ID’s and it is specified in TDS of the project.
Page 34 of 34

Liwa Plastics Project: Document Title: Process Description

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Liwa Plastics Project: Document Title: Process Description

Uploaded by

Copyright:

Available Formats

Liwa Plastics Project

Document Title: PROCESS DESCRIPTION

Document No: S-S500-5223-031

Issued for BDEP 1 12-02-2014 F. Valente R. Pesare P. L. Di Federico

Document Title: Document No. Rev:

Document Title: Document No. Rev:

9.3 Monomers feed to the gas phase reactor ......................................................................................... 22

Document Title: Document No. Rev:

The plant consists of one polypropylene unit (Unit 5000).

1. Catalyst, Co-Catalyst and Liquid Additive Storage and Metering

Document Title: Document No. Rev:

4. CATALYST, CO-CATALYST AND LIQUID ADDITIVE STORAGE AND METERING

The catalyst system consists of three components:

4.1 Aluminum alkyl storage and metering

Teal is used as a cocatalyst in conjunction with the high mileage catalyst.

Document Title: Document No. Rev:

4.2 Donor Storage and Metering

Document Title: Document No. Rev:

4.3 Preparation and Storage of the Catalyst Dispersion in Grease

1) To continuously circulate melted grease in V-5105A through a steam jacketed piping to

Document Title: Document No. Rev:

4.4 Catalyst Paste Metering

Document Title: Document No. Rev:

4.5 Liquid Additive Storage and Metering

4.6 Catalyst Component Feeding Criteria

Document Title: Document No. Rev:

5. PRECONTACTING AND PREPOLYMERIZATION (PFD 112)

5.2 Catalyst injection into the propylene

Document Title: Document No. Rev:

6. LIQUID MONOMER POLYMERIZATION (PFD 112)

Document Title: Document No. Rev:

o Residence time: 1h – 1:10 h (according to the grade).

6.1 Prepolymer feeding

6.2 Propylene fed to R-5201

6.3 Slurry in R-5201

R-5201 is operated completely full of undercooled liquid.

Document Title: Document No. Rev:

6.4 Hydrogen fed to R-5201

6.5 Ethylene fed to R-5201

6.6 Butene-1 fed to R-5201

6.7 Slurry discharge from the reactor

6.8 Slurry concentration in the loop reactor

Document Title: Document No. Rev:

6.9 V-5202 (Damper) with Vaporizer (E-5203)

6.10 Pump P-5201

6.11 Loop Reactor Cooling System

Document Title: Document No. Rev:

6.12 Stand-by connections

6.13 Emergency devices

Document Title: Document No. Rev:

7.1 Flash and degassing

7.2 Vapor Monomer Scrubbing

Document Title: Document No. Rev:

7.3 Propylene storage and plant feed

Document Title: Document No. Rev:

8. LOW PRESSURE DEGASSING, GAS RECYCLE (PFD 113A)

8.1 Low pressure degassing filter S-5301

8.2 Recycle gas streams washing and compression C-5302/ME-5301-K-01 (ME-5301)

Document Title: Document No. Rev:

Document Title: Document No. Rev:

9. GAS PHASE COPOLYMERIZATION (PFD 114)

9.1 Gas phase reactor (GPR) R-5401