INPLANT TRAINING IN H.D.P.E PLANT AT HALDIA PETROCHEMICALS LTD.

21st MAY 2007 TO 30th JUNE 2007

PRESENTED BY

BY SUBHANKAR ROY RD 3 YEAR, DEPT. OF CHEMICAL ENGINEERING. HERITAGE INSTITUTE OF TECHNOLOGY, KOLKATA. 1ST JUNE TO 24TH JUNE 2011

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ACKNOWLEDGEMENT
After the completion of our In Plant Training we intend to thank all the staff of Haldia Petrochemical Ltd. who directly or indirectly were responsible for making our stay (during the training period) fruitful. We are very grateful to the staff of HPL who cooperated with us during the entire training period. First and foremost, we would like to thank Col. S. Chowdhury and Mr. Arun Chanda for making it possible for us to come to HPL and undergo the training. The people of HDPE plant (where we were deputed) deserve special mention. We extend our sincere gratitude to Mr. A.K.Ghosh. Mr. Sukheshwar Mondal Mr. Soumya Chakraborty Mr. Amaresh Sinha. Mr. Diptendu Pal Mr. Prasun Pramanik Mr. Prasenjit Ghosh Finally, we would like to thank the Field Engineers & HPL Family, who were in some way or other related to our successful training.

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PREFACE
In plant training is a vital part in the progress of fledgling engineers. For us this is the first rendezvous of practical knowledge with the theoretical concepts acquired during the years in college. We are very fortunate that we got the opportunity of undergoing training in one of the most sophisticated and modern petrochemical plant, HPL. The experience gained during this short stay here was fascinating to say the list. It was a tremendous feeling to see the practical operation of different equipments and processes, which until now existed for us only in books .We, were deputed in H.D.P.E. Plant for our training. Each one of us was overwhelmed by the sheer size and complexity of the plant. What still fascinates us is how such a big unit is being monitored and operated with the desired results. In this short stay it was possible for us to wholly decipher the detailed functioning of the plants; but still we are fortunate enough to get a sound overview of the unit, thanks to the guidance extended by the people of HDPE Departments

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BRIEF DESCRIPTION OF THE DIFFERENT UNITS

Units comprising in HPL Naphtha cracker unit (NCU) Associated unit (AU) High density polythene plant (HDPE) Linear low density polyethylene plant (LLDPE) Polypropylene plant (PP) Integrated offsite plant (IOP) Nitrogen plant Captive power plant (CPP)

Naphtha Cracker Unit: THIS plant is the mother plant for all the
polymer plants. It accepts naphtha as feedstock and produces polymer grade ethylene and propylene as main products along with the host of side products like mixed C4 stream, raw pyrolysis gasoline and C.B.F.S.

Major units of NCU:

Cracking and quenching. Charge gas compressor and acid gas removal. Charge gas drying and chilling. De-methanization. De-ethanization, acetylene hydrogenation and propylene fractionation. Methyl acetylene, Propyne hydrogenation and propylene fractionation. De-butanization. Propylene, ethylene and methane refrigeration.

Butadiene Extraction Unit: This plant is specifically designed to

extract butadiene out of the C4 fraction coming out of the NCU. The process involves two successive extractive distillations followed by a

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conventional distillation process. The C4 raffinate coming out of the extractive distillation is a feed for the C4 hydrogenation unit. The second extractive distillation is basically a crude distillation method.

Final products: Propylene

1-3-Butadiene. Acetylene.

Pyrolysis Gasoline Hydrogenation Unit: The Pyrolysis

Gasoline Hydrogenation Unit has been designed to hydrogenate the raw pyrolysis gasoline stream coming out of the NCU. Raw pyrolysis gasoline obtained from the crackers contain paraffins, olefins and aromatics.

Feeds:

C4-acetylenics. C4-C5 Heavies. C6 +Recycle.

Products Obtained: Hydrogenated pyrolysis gasoline (taken

IOC to mix with petrol to improve the octane number) Benzene heart cut (used as BEU feed). Cyclo Pentane (used as refrigeration insulation). Heavies. Wash Oil (used as lubricants).

Benzene Extraction Unit: The Benzene Extraction Unit has been

designed to extract benzene from the benzene heart cut coming out of the Pyrolysis Gasoline Hydrogenation Unit. It is based on the principle of extractive distillation. The feed for this plant is the C6 heart cut. The process consists of a conventional distillation followed by an extractive distillation. The C6 coming out of the conventional distillation step is sent to the PGHU. Benzene is obtained from the extractive distillation of the stream (consisting of C6) coming out of the conventional distillation step. N-methyl pyrolidone (NMP) is used as a solvent in this process.

C4 Hydrogenation Unit: The unit has been designed to hydrogenate

the C4-mix and/or the C4-raffinate coming out of the butadiene extraction unit. The C4 stream contains butadiene and butanes. The stream is hydrogenated by hydrogen and recycled to achieve better conversion. A single stage reactor with LD-265 catalyst (palladium-Al2O3) is used in the process.

Polymer unit: The polymer unit has the following three plants:

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High Density Polyethylene Plant (HDPE): This is a Mitsui Low

pressure, bimodal, twin reactor slurry process. This plant is designed to produce HDPE and has two trains of equal capacity. The main feeds of this plant are ethylene, co monomer (1-butene and propylene) and hydrogen. Each train of the unit is capable of running in both parallel and series mode.

Different sections: Catalyst, co-catalyst handling and metering.

Polymerization. Separation and Drying. Extrusion and Pelletization. Product Homogenization. Product storage and bagging.

Common sections for both trains:

Solvent Recovery. Process facilities.

Linear Low Density Polyethylene Plant (LLDPE): This is the

first Bimodal Spherilene LLDPE in India. The plant installed new generation Multi reactor Spheriline process. The technology used is termed as Swing Technology owing to its flexibility of producing both HDPE and LLDPE.

Different sections: Monomer purification unit.

Polymerization section. Catalyst, co-catalyst handling and metering. Prepolymerization. Polymerization. Polymer drying. Extrusion. Product homogenization. Product storage and bagging.

Polypropylene Plant (PP): This is Montell spheripol II; Gas phase,

Bimodal, Twin Reactor process. The plant is designed to produce various grades of homopolymer, high impact and random co-polymer and terpolymer grades of Polypropylene.

Different sections: Catalyst, co-catalyst handling and metering.

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Prepolymerization. Polymer degassing and steaming. Polymer drying. Extrusion. Product homogenization. Product storage and bagging. Polypropylene scrubbing and recycling. Gas phase co-polymerization.

Nitrogen Plant: The plant runs on Build Own Operate (BOO) basis. Different sections:
Air separation unit. Liquid nitrogen storage. Liquid nitrogen pumps. Cryogenic liquid storage. This unit can produce both gaseous and liquid nitrogen but only gaseous nitrogen is supplied to the process units and offsite.

Captive Power Plant (CPP): Combined cycle cogeneration power

plant (Capacity 116 MW) meets the power and steam requirement of the plant during continuous run, start up and emergency situations. The steam generated is supplied to the various units at four different pressure levels as given in the table below: Pressure Type Super High Pressure (SHP) High Pressure (HP) Medium Pressure (MP) Low Pressure (LP) Pressure (kg/cm2) 129 43 18.5 6 Temperature (C) 540 415 321 245

Integrated Offsite Plant (IOP): In order to meet the utility

requirements of the process units, necessary utility facilities that have been provided are: Raw water system. Fire water system. Plant and potable water system.
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Cooling water system. Demineralized water and condensate recovery system. Compressed air system. Fuel gas and diesel system. Flare system Nitrogen system. Steam generation and CPP

Units of IOP:

Feed storage. Intermediate storage. Product storage. Bulk chemical storage. Road tanker loading and unloading facility. Refrigeration system. Benzene recovery system. Hydrogen storage system.

DETAILS OF THE ABOVE MENTIONED UNITS

Plant units
Naphtha Cracking Unit (NCU) Butadiene Extraction Unit (BDEU) Pyrolysis Gasoline Hydrogenation Unit ( PGHU) Benzene Extraction Unit ( BEU) C-4 Hydrogenation Unit ( CHU) Polypropylene Plant ( PP) Linear Low Density Polyethylene ( LLDPE) High Density Polyethylene ( HDPE) Captive Power Plant ( BOO) Nitrogen Plant (BOO) IOP

Capacity
466 KTPA 82 KTPA 330 KTPA 85 KTPA 120 KTPA 230 KTPA 250 KTPA 220 KTPA 116 MW 9000Nm3/hr

Technology/Licensor
ABB LUMMUS, USA BASF, GERMANY/ ABB LUMMUS, USA IFP, FRANCE LURGI, GERMANY IFP, FRANCE MONTELL, HOLLAND MONTELL, HOLLAND MITSUI, JAPAN LARSEN & TOUBRO, INDIA PRAXIAR, USA

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HIGH DENSITY POLYETHYLENE

PROCESS DESCRIPTION
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BLOCK DIAGRAM OF THE PROCESS:

Recycle

Monome Not PZ reacting AT Co catalyst Solvent Catalyst Suspension Drum Ethylene Co monomer H2 Slurry Reactor Flash Drum Catalyst

Wet polymer Powder Rotary Steam Drier N2 Conveying System Silo

Centrifuge

Mother Liquor (Solvent)

Neutralizer & Extruder Additives Separator

Polymer Pellet Polyethylene Wax Homogenizing Silo Pneumatic Convey

Drier

Solvent

Moisture 5ppm. Bagging section 25 kg Bag Each Warehouse Dispatch

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CATALYST FEEDING SECTION

PZ/RZ CATALYST is charged into PZ feed drum 7V-1110A/B which has
been filled with specific quantity of hexane. PZ/RZ catalyst is dissolved in hexane by means of feed drum agitator. Preparation of PZ catalyst is carried out every three days. The frequency depends on the actual rate of catalyst consumption. The entire parts of PZ catalyst preparation system is operated under nitrogen pressure between 0.1&0.3 kg/cm2 g.Vent gas at the time of pressurizing or depressurizing is passed through vent gas condenser 7E-1104 &discharged into the flare. CATALYST PREPARATION PZ/RZ catalyst is charged into PZ feed drum system. Entrainment of hexane with the vent gas is condensed as it goes through 7E-1104 and is collected in drain pots 7V-1127. CATALYST FEED PZ catalyst which has been diluted to a specified concentration in 7V1110A/B is fed to each polymariser by PZ feed pump 7P-1105A/B and/or C. units served by this pumps are as follows 7P-1105A/B 7R-1201 7P-1105B/C 7R-1221

POLYMERISATION SECTION
For the poly reactor a low pressure (below 10kg/cm2) hexane slurry process is employed, using polymerisers7R-1201 AND 7R-1221Lined up in parallel or series. Ethylene monomer which is the main raw material, dehydrated hexane for adjusting the slurry concentration, and catalyst are continuously fed at specified rates to polymerizers. Hydrogen as molecular weight controller and either propylene or butane-1 for adjusting the density are continuously premixed with ethylene gas, such mixture is fed into the recycle gas line leading to the polymerisers. He heat of reaction is removed by the latent heat of hexane.Slurry cooling system and by the polymerisers jacket cooling. Control of polymer properties ,MFR, density and NNI of polymer in polimerisers.is carried out by adjusting polymerization conditions. Raw materials &hexane fed to polymerisers. 1. Ethylene
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Ethylene gas is controlled at 12kg/cm2 by PIC and is fed into the recycle gas line to the polymerisers under FRC control. 2. Hydrogen Hydrogen gas is controlled at 12kg/cm2 by PIC and is fed into the ethylene gas line to the polymerisers under AC/FC control to be premixed with ethylene. 3 a. Propylene High purity and liquefied propylene is fed to propylene vaporizer 7V-232 under LC control .the propylene so fed is heated by LP steam in 7V-232to become propylene gas having a pressure of 14 kg/cm2. Such gas is premixed with ethylene gas at a given rate under FC 3 b. butene-1 High purity and liquefied butene-1 is fed to butene-1vaporizer 7V-233 from butene-1 holder 7V-234,in which it is heated by LP steam in 7V232to become butene-1 gas having a pressure of 12 kg/cm2.Such gas is premixed with ethylene gas at a given rate under FC 4. Hexane Hexane pressurized up to 12 kg/cm2 by HP.Hexane pump 7P-708A/B is dehydrated in hexane dryer 7V-703a/bto become dehydrated hp hexane having a5ppm or less water content, then fed to each polymeriser under FC control with the purpose of controlling the slurry concentration in it. In the mean time, each catalyst line the polymeriser s connected to the hexane inlet nozzle so that the feed catalyst is washed with hexane stream all the time; in this way, it prevents clogging due to the partial polymerization. Part of mother liquor from the centrifuge is recycled back to the polymeriser.

Polymeriser recycle gas

Ethylene, hydrogen& either propylene or butene-1 are mixed with polymerisers recycle gas, and fed to 7R-1201 and 7R-1221 through the gas injection pipes. The feed raw material gases are thoroughly dispersed by the three stage turbine agitator to be dissolved in hexane and the ethylene gas polymerized in presence of catalyst and forms polymer slurry having a specified concentration at this time, the pressure is maintained by hydrogen partial pressure. Recycle gas comprising of ethylene & hydrogen is blown into the top of the polymeriser & ethylene is polymerized during its passage
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through the adequately agitated hexane phase. More than half of the heat generated by polymerization is removed by latent heat of hexane. The recycle gas containing plenty of hexane vapor is transferred to first overhead condenser 7E-1221 where it is condensed and cooled, and further transferred to the first hexane accumulator, 7V-1205 and second hexane accumulator 7V-1225 to be separated in to condensate hexane and recycle gas. The recycle gas so separated is pressurized in the first recycle gas blower 7B-1201 and second recycle gas blower 7B-1221 and blown in to the top of the pollymeriser while its flow rate is controlled under TC in order to maintain the polymerization temperature at a specified value. Condensate hexane separated in 7V-1205 and 7V-1225 is recycled to the polymeriser through the first condensate recycle pump 7P-1202 A/B and the second condensate recycle pump 7P-1222 A/B. part of the condensate hexane is used for flashing at a specified rate under FC in the gas outlet piping for 7R-1201 and 7R-1221.

SLURRY COOLER
Polyethylene slurry in 7R-1201 and 7R 1221 is circulated through the first slurry cooler 7E-1204 and second slurry cooler 7E-1224 by the first slurry cooler pump 7P-1203 and second slurry cooler pump 7P-1223 to remove polymerization heat together with recycle gas system and reactor jacket cooling system.

OVERFLOW SLURRY HANDLING

Since the over flow slurry contains bubbles of mixed gas in the polymeriser the slurry is separated in the first dilution slurry drum 7V1202 and second dilution slurry drum 7V-1222into liquid and gas phases, and the separated gas is sent back to the polymeriser through the gas balance lines between 7R-1201 and7V-1202 and between 7R-1221 and 7V-1222. The polymer slurry is flashed into the first flash drum 7V-1203 and second flash drum 7V-1223 and the temperature becomes about 65 degree C . The flashed gas from the flash drum is cooled to 0 degree C by the first flash gas condenser 7E-1202 and flash gas condenser 7E-1222 and the flash gas cooler 7E-1223.The gas is not condensate through the mentioned cooling step is passed through the compressor section drum 7V-226 and pressurized to 4.5kg/cm2G by the flash gas compressor 7K222 and sent to the naphtha cracker. The polymer slurry in 7v-1223 is

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transferred to the centrifuge 7SE-1301 through the slurry transfer pump 7P-1221A/B.

SEPARATION AND DRYING SECTION

SEPERATION
The product slurry is fed through the second slurry transfer pump 7P-1221A/B to the horizontal type centrifuge 7SE-1301 rotating at a high speed ,in which polymer is separated by centrifugal force . The polymer is discharge from the centrifuge by the screw conveyor provided in the bowl in the form of wet cake containing hexane by approximately 30% weight and fed to dryer 7SE-1302 via the wet cake screw feeder 7ME-1301. Meanwhile hexane overfl0ows the weir provided in the bowl and flows into the mother liquor drum 7V-1301 and then pressurized by the mother liquor transfer pump 7P-1301A/B so that part of it will be sent back to the polymerization section and the remainder will be fed to the hexane recovery section.

DRYING
STEAM TUBE ROTARY DRYER
Mixed gas consisting of nitrogen and hexane vapour flows through the dryer 7SE-1302 counter currently with the product. When three product powder leaves 7SE-1302 after about 30 min of holding time, it contains less than 0.2% volatile matter (as hexane) and its temp is approx 100 degree C .Low press steam is supplied to the steam tube in 7SE-1302 as heat source after its press& temp have been reduced to 0.2 to 0.35 kg/cm2G & approximately 107 degree C through the steam cooler 7E1304. The operating press of the system is about 400mm aqueous.

PELLETIZING, STORAGE & PACKING SECTION

POWDER HOPPERS
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The product powder which has left 7SE-1302 is transferred to the nitrogen gas pneumatic powder conveying system through the powder rotary valve 7ME-1303 the product which is forwarded by the powder transfer blower 7B-1401A/B is contentiously separated in the powder cyclone 7SE-1401 from nitrogen and dropped into powder hopper 7BN1402. Nitrogen gas is filtered through back filter 7SE-1402 to be recirculated.

POWDER BULK LOADING

From the powder hopper 7BN-1402 the polymer powder can be transferred by means of pneumatic transport 7X-1403 to the powder bulk loading silo 7BN-1405 .Below this silo a truck bulk loading station is provided. This facility is available only for line 1.

POWDER & STABILIZER FEED SYSTEM

The powder stream which has left the outlet of 7BN-1402 is metered by the powder measuring feeder 7W-1405 & is fed to 7EX-1425 through 7ME-1406. Solid stabilizer mixture in accordance with the stabilizer recipe predetermined for product type is prepared in 7ME-1409 & discharged batch wise into 7BN-1403 by gravity. Stabilizer mixture from 7BN-1403 is metered by 7W-1412 & fed to 7ME-1406. liquid stabilizer & Wstabilizer are fed into 7ME-1406 by the liquid stabilizer feed pump 7P1402A/B & W-stabilizer feed pump 7P-1403A/B respectively.

PELLETIZING SYSTEM
Polyethylene powder & stabilizers are fed to 7EX-1425. The pelletizer is a twin screw type continuous mixture with gear pump where PE powder & stabilizers are mixed & kneaded. Molten polymer are pushed towards the dye by gear pump system, then the molten polymer is extruded through the dye hole into the cutter box through which pellet cooling water is circulated. The extrudate is cut into pellets by revolving cutters. The resin in the pellet form is transferred to the pellet separator 7SE-1404 with circulated PCW. For protection of 7SE-1404 a grid PW strainer 7SE-1427 is provided, to remove any fused blocks of pellets. The pellets which pass the grade are sent to 7SE-1404 after they are drained on the perforated plate screen. Product pellets are classified by the pellet-vibrating screen 7SE-1428, into

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oversized, normal & undersized products. Normal sized pellets which flow in the pellet separator hopper 7BN-1404 are pneumatically conveyed to the specified silo through the pellet rotary valve 7ME-1431 by the pellet transfer blower 7B-1451A/B.

PELLET BLENDING & TRANSFER SYSTEM

Pellet silos 7BN-1451A/B/C/D/E have a capacity of 500 each. In order to rectify such fluctuations of quality due to possible variance in operating conditions of process control, the pellet blending is carried out through transferring the pellet to the bagging hopper.

PACKING
Each plant is supplied with two bagging lines, 7X-901, fed from independent silos 7BN-1901A/B. Each bagging line includes the bagging matching 7ME-1901A/B-X, the check weighers 7W-901A/B/C/D-X, the metal detectors 7W-903A/B/C/D-X and bag rejecter devices 7ME904A/B/C/D-X.

HEXANE RECOVERY SECTION

CAUSTIC SODA WASHING
Mother liquor is transferred to HE and NAOH separator V-721 through HE and NAOH contactor 7M-721 together with 20% (weight) caustic soda,demineralised water and low pressure steam which is fed in to the system to maintain its temperature at 60 degree C. the pH of the fluid circulated through 7M-721 is more than 12. Then caustic washed crude hexane is transferred to HE and water separator 7V-722 through HE and water contactor 7M-722, where processes water is fed to wash out caustic soda. The PH of the fluid circulating through 7M-722 is approximately 7~8.

HEXANE STRIPPING

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Hexane containing low polymer and coming from crude hexane feed drum 7V-701 is fed to 7C-703 by the crude hexane feed pump P702A/B.Hexane vapor generated in 7C-703 is depressurized to 0.2 kg/cm2 g,condenced and cooled in hexane overhead condenser 7E704. molten low polymer in hexane concentrated in the bottom of 7C-703 is pressurized to 22kg/cm2g by the flash drum feed pump 7P-711A/B and heated from 120 degree C to 220 degree C in the flash preheated 7E-711. The heated solution gets its pressure reduced to 3kg/cm2g as it enters in the flash drum 7V-711.The solution is cooled to approximately 160 degree C,while hexane vapor so generated is recycled to 7C-703.The low polymer solution in 7V-711 is kept from cooling of, from the steam coil provided in it and is fed to the low polymer preheater,7E-712,where the solution is heated up to 180 degree C. the solution then flows in to the second flash drum 7V-712 whose is kept at 300 mm Hg,by the LP vacuum pump 7B-701.Hexane vapor generated in 7V-712 is condensed in the vent gas cooler 7E-713 and stored in the 7V-713 bottom ,then transferred to 7V-701. the LP solution ,from which hexane is removed in 7V-712 is transferred to LP holding drum ,7V-717 by low polymer transfer pump 7P-713A/B .

LOW POLYMER FLAKING

Molten low polymer of LP holding drum 7V-717 is transferred by LP storage bottom pump 7P-717 to the drum flaker, 7X-701 LP is cooled and solidified on the drum of 7X-701, which is cooled with a circulating water system .Flaked LP is collected in the flaker hopper ,7BN-704 and manually packed

HEXANE PURIFICATION
Hexane vapour from 7C-703 is condensed and cooled in 7E-704 ,then flows into the stripper receiver 7V-702 by gravity ,during which DM water can be added . The mixture flows into 7V-702, provided with rectifying plates for enhancing separation of water drops in hexane, in which it is caused to undergo phase separation into hexane and water layers . The water layer in 7V-702 is discharged by LC. The hexane layer, saturated with water up to approximately 250 weight ppm, is fed by the dehydrator feed pump 7P-706A/B to the top of the hexane dehydrator 7C704 . Low press steam is supplied to the dehydrator reboiler 7E-705 installed in the 7C-704 bottom .The bottoms of 7C-704, water content and temp of which are 10wt ppm or less and about 80 degree C respectively, is forwarded by the dehydrated bottom pump 7P-707 A/B to the
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dehydrator bottom cooler 7E-706 where the liquid is cooled to 40 degree C or lower & then transferred to the pure hexane drum 7V-772 .

PURE HEXANE DISTRIBUTION

Purified hexane with a water content of 10wt ppm or less is pressurized to 12 kg/cm2 or higher by the HP hexane pump 7P-708A/B , dehydrated to less than 5wt ppm water content by hexane dryer 7V703A/B containing molecular sieves, and then forwarded to various process sections through the hexane strainer 7Z-704A/B.

Processing Additives and Product Quality:

Additives are essential ingredients added to the polymers to stabilize it and to obtain an optimum combination of the desired properties and in the final product in most economical way. The output from the processing equipment and the quality of the product are determined by the resistances of the polymer to thermal degrading, the speed with which a solid feed can be converted into melt and the fractional behavior of the melt on the surface of the processing equipment. High thermal stability in polymers enables processing to be carried out at high temps and to achieve a higher output through a reduction in melt viscosity. It also improves the product quality as a result of elimination of the deleterious effect of degradation on physical properties and appearance. Fast fusion of the particles is essentially to ensure that a homogeneous melt is produced before it is resolidified into the required shape. Finally the frictional behavior of the polymer melt on the metal surfaces determines the residence time of the polymer molecules in the processing equipments. Primary stabilizers or antioxidants: This interrupt the chain reaction by combining directly with the propagating free radicals itself, typical examples of antioxidants are hindered phenols and aromatic amines.

Secondary stabilizers or peroxide decomposer:

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These functions by reacting with hydro peroxide as soon as they are formed and converting them into non-radical species. The most common type of additives that acts as peroxide decomposer is organic thioesters, phosphides and metal thio carbamates. Chelating agents/ Metal deactivators: These protect the polymer against degradation (particularly where there is a danger of contamination of a hydrocarbon polymer with metal ions like Ni, Cu, Mn, Fe, Co that take catalyses the oxidation reaction) by immobilizing the metal ions through coordination reactions. Infact they produce a cage effect around the metal ions so that they cant react with the peroxides and dont allow the O2 to interact with the active free radicals. The most important chelating agents are compound based on organic phosphates, ox amides and hydrazides.some times di methyl glyoxime also acts as a very good chelating agents. Different stabilizers used for HDPE virgin polymer in the form of antioxidants are:
1.

Phenolic antioxidant for processing and long-term thermal stabilization.

IRGANOX 1010:

Characterization: IRGANOX 1010- a sterically hindered phenolic antioxidant is a highly effective, non-staining stabilizer for organic substrate such as plastics, synthetic fibers, elsatomers etc. it protects these substrates against thermo oxidative degradation. Chemical name: Pentaerythritol Tetrakis (3, 5-di-tert-butyl-4hydroxyphenyl) propionate.
2. IRGANOX 1076: phenolic primary antioxidant for

processing and long-term thermal stabilization. Characterization: IRGANOX 1076, a sterically hindered phenolic antioxidant, is highly efficient, non-staining stabilizer for substances such as plastics, synthetic fibers, elastomers etc. it protects these substrates against thermo-oxidative degradation. It is odorless, stable to light and has excellent color retention. It has good compatibility with most substrates, low volatility and high resistance to extraction. Chemical name: Ocadecyl-3- (3, 5-di-tert.butyl-4-hydroxy phenyl)propionate. 3. P-EPQ: A high performance phosphonite processing stabilizer

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Characterization: IRGAFOS P-EPQ is a hydrolytically stable phosphonite-processing stabilizer. As a secondary antioxidant, IRGAFOS P-EPQ reacts during processing with hyroperoxides formed by auto oxidation of polymers preventing process induced degradation and extending the performance of primary antioxidants. Chemical Name: Tetrakis (2, 4-di-tert-butylphenyl) [1, 1-biphenyl]-4, 4diylbisphosphonite

Lubricant & flow promoters: There are three major friction problems encountered in polymer processing------Inter particle friction between the polymer powders, or granules, which impair their free flowing characteristics and hence creating difficulties in conveying operation such as feeding into the processing equipment and advancement within it. 1. Friction between the polymer melt and the metal surfaces of thee processing equipment, which can seriously impair the flow of the melt and produce undesirable effect such as low output and poor surface quality of the finished product. 2. Friction during finishing operations and in conveys e.g. printing, packaging and transportation. External lubricants used to aid processing are high molecular weight fatty acids, alcohols, and amines having 12-18 carbon atoms in their backbone. In solid layer lubrication the surfaces of the rubbing members (polymer granules) are coated with lamellar solids e.g. graphite, MoS, CoS etc, and are normally used under extremely high friction conditions where by very high temperatures are developed and which would render both fluid and bonding lubrication sometimes ineffective. Different lubricants and flow promoters used for HDPE are Calcium Stearate, Glycerol Mono Stearate, and Oil etc.

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Surface Property Modifier: Anti static agent:

Anti-static agents normally consist of one N-compound such as long chain amines, amides, or quaternary ammonium slats E.g. 1.Stearamide-propyl dimethyl 2-hydroxyl ethyl ammonium nitrate. 2. Sulphonic acid and alkyl aryl sulphonates. 3. Polyhydric alcohols and derivatives.
Acid Scavengers:

The inclusion of an acid scavenger is necessary because of the catalyst resides. Even though the amount of catalyst residues is in the low ppm range, the need to neutralize acid residues persists. The potential for the corrosion of a mold surface or die tip can be a very costly proposition. By adding the appropriate antacid, any acidic species will be neutralized or scavenged, eliminating or reducing the potential for corrosion. Antacids include metallic stearate, including sodium, calcium, and zinc. The use of metal stearate will give a resin a certain amount of lubricity, which has the potential for providing small amount of mold release or slip properties. Calcium-stearate is used as acid scavenger.

HDPE- GRADES
Grade F5400 MFI 0.06 Density 0.954 Product attributes Easy processability, Good strength and Sealability. High strength and Impact strength. Easy processability, High tenacity. Very easy processability, High tenacity. Applications Thin films

F5600 R5801 P5300

0.04 0.66 0.55

0.956 0.958 0.954

Tissue films and Liners. Raffia for woven sacks and Tarpaulin. Monofilament yarn for Nets, Twines and Ropes.

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HDT6 B5500

0.5 0.35

0.960 0.955

. Easy processability, High tenacity Easy processability, High stiffness and Impact resistance Easy processability, Excellent Impact/Stiffness ratio Easy processability, Excellent Impact/Stiffness ratio Easy processability, Excellent Impact/Stiffness ratio

for woven sacks and Tarpaulin. Blow molded parts and Containers, Large Containers and Chemicals. Blow molded parts and Containers. Blow molded parts and Containers Blow molded parts and Containers

B6401

0.3

0.964

E5201

0.36

0.952

E5201(S)

0.36

0.952

COOLING PROCEDURES
1. Overhead condenser. 2. Slurry cooler. 3. Jacket cooling. Here the reactor is fitted with 3-stage turbine agitator where ethylene, comonomer & recycle gas are fed to the reactor bottom by eight injector system. Here the reactor used is following type: Designed by: Design Pressure: Design Tempr: Capacity: Operating Fluid: Test Pressure: Sinko-Pantech Co.Ltd. 143/107 psig. 221/212 F. 89.9/3.63 m3. Polyethylene. 220/165 psig. Shell/Jacket.
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 OVERHEAD CONDENSER: Heat generated during polymerization reaction is taken by the solvent hexane which comes out from top of the reactor & this hexane is cooled in overhead condenser by cooling water system. The operating fluid is come to the accumulator & then recycle back to the reactor by a centrifugal blower. During this operation theoretically 60% of total heat generated is removed. SLURRY COOLER: Here slurry cooler is used to remove heat upto 30% of total heat. Here slurry & water is passed counter currently to cool the slurry & recycle back to the reactor. JACKET COOLING: Reactor is jacketed by a cooling system in which cooling water is circulated to remove heat upto 10% of total heat.

Pumps :
The pump section is the most important section of the workshop. The refinery requires so much movement of different materials, starting from crude oil to the final processed diesel and gasoline, from cooling water to the reactor effluents, across the length and breadth of the plant that pumps are inevitably of the greatest importance. As in the valve section, the pumps, as and when reported to be malfunctioning are brought to the workshop and are repaired accordingly. The different kinds of pumps used in the industry are : Centrifugal pumps Positive displacement pumps Screw pumps

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 Sundyne pumps Gear pumps

Positive displacement pump : A positive displacement pump causes a fluid to move by trapping a fixed amount of it then forcing (displacing) that trapped volume into the discharge pipe. The periodic fluid displacement results in a direct increase in pressure.

Positive displacement pump

Liquid flow path centrifugal pump

inside a

Working Mechanism of a Centrifugal A centrifugal pump the simplest pieces equipment in any plant. Its purpose is convert energy of a mover (a electric or turbine) first into velocity or energy and then into pressure energy of a fluid that is being

Pump is one of of process to prime motor

kinetic

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pumped. The energy changes occur by virtue of two main parts of the pump, the impeller and the volute or diffuser. The impeller is the rotating part that converts driver energy into the kinetic energy. The volute or diffuser is the stationary part that converts the kinetic energy into pressure energy. Note: All of the forms of energy involved in a liquid flow system are expressed in terms of feet of liquid i.e. head .
General components of Centrifugal Pump

SU N D Y N E PU M P

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Flow in this pumps is self limiting by the diffuser venturi when the velocity through the throat produces static pressure equal to or less than the vapor pressure of the liquid. At this point, capacity cannot be further increased because of the vaporization of the fluid in the diffuser throat.

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Various Valves :
Various types of valves used in this plant are given below.
1. Gate valve : With rotation of the hand wheel of the valve the bush

attached to it also rotates. Accordingly, the threaded portion of the spindle moves either upwards or downwards with the wheel. The spindle is slotted to the gate and the gates moves according to the spindle. Here min pr. drop and bi-directional on-off service is required. Some of the valves are rejected here due to pitting in the valve seats and body seats.

Gate valve 2. Globe valve : Unlike the gate valve the globe valve can obstruct the fluid fully. Here the spindle rises along with the wheel. Thus by rotation of the hand wheel and observing the movement of the spindle we can differentiate globe valve and gate valve.

. Globe Valve

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3.

Ball valves : In this valve there is a spherical part with a hole called the ball. The upper stem is precision-keyed to the ball. Through this hole the fluid enters.

Ball valves

4. Butterfly Valve: These valves occupy less space in the line than
any other valve installed mostly in the large diameter pipes. Pressure drop is quite high compared to gate valves. These are recommended for large diameter pipes when isolation is not required. Besides these a number of check valves ,needle valves, three way valves, safety valves, different types of the control valves, cylindrical type on-off valves, solenoid valves, etc are used in the plant. COMPRESSOR There are various types of compressors in LLDPE plant : 1) Centrifugal compressor: It is used for fluidization of 1st & 2nd gas phase reactors. 2) Reciprocating compressors: It is used for the recycle of the gas from 1st & 2nd bag filter. It is a 2 stage double acting reciprocating compressor. There is also a Hydrogen compressor, an Ethylene

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compressor, an instrument air compressor. They are single acting reciprocating compressors. 3) Screw compressors: It is used for a) 4 - pneumatic transport of polymer powder from the intermediate silo to the polymer surge silo. b) 2- refrigeration unit. c) 8- pellets conveying.

BLOWER 1. CENTRIFUGAL: Low discharge head Discharge pressure is less 2. ROOT: High discharge head Discharge pressure is high

HEAT EXCHANGERS Shell & Tube Heat Exchanger Ex: Polymeriser feed cooler Shell side fluid: Refrigerated water Tube side fluid: Hydrocarbon Heat load: 73500 Kcal/hr Plate Type Heat Exchanger Ex: 9R-202 reactor jacket water cooler 9E-208 Side-1 fluid: Jacket water Side-2 fluid: Cooling water Heat load: 9.16 106 Kcal/hr Fin Type Heat Exchanger Ex: 9B-901/2 X discharge cooler 9E-901 A-X Type: Fin tube horizontal Shell side fluid: Air Tube side fluid: cooling water Heat load: 1 106 Kcal/hr
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DESIGN OF HEAT EXCHANGER

Shell & Tube Heat Exchanger
Type: AEL Tag: E2304N Ex: Polymeriser feed cooler Shell side fluid: Refrigerated water Tube side fluid: Hydrocarbon Heat load: 73500 Kcal/hr

Design problem:
Steam is cooled in 2-4 heat exchanger (E-2304N) whose heat duty (Q) is 432504 kcal/hr.Shell and Tube specification are given below - Properties Shell tube Fluid LP steam Cooling water Flow rate 26000 kg/hr 21280 kg/hr o o Temperature in=143 C out=110 C in=33 oC out=35 oC Density 0.82 kg/m3 994 kg/m3 Viscosity 0.0135 cP 0.728 cP I.D. 400 mm inch=19mm Length 1.5 m Specific heat 1 j/kg 0c 0.99 j/kg 0c Thermal conductivity 0.024 w/m 0c 0.53 w/m 0c Calculate the following: 1.LMTD 2.corrected LMTD 3.no of tube(n),A,UD 4.hi , ho 5. clean overall co-efficient(UD) 6.fouling factor(RD)

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Ans.
LMTD = (T1- T2)/ ln (T1/T2) = (108- 77)/ ln (108/77) = 91.63 For LMTD correction : Z=(143- 110)/(35- 33) =16.5

=(35-33)/(143-33)
=0.01818 Correction factor (FG)= (z^2+1)(1/2) ln (1-/1- z .) (z-1) ln (2-(z+1)-(z^2+1)(1/2)) (2 - (z+1)+(z^2+1)(1/2)) =0.9986 Corrected LMTD=0.9986 x 91.63 =91.502 Let, UDO=600 btu/hr oF ft2
=43.2 kcal/hr oc m2 For 3/4 OD tubes on 1 inch triangular pitch Shell dia 15.25 has 122 no. tubes (from Kern 842 page). No of tube (N) =122 + (122 x 10%) = 132 Surface area (A) = 0.1963ft2/ft = 0.0597 m2/m x 1.5m = 0.0896 m2 1/5 x shell dia.<B.S.<shell dia. 3.15<B.S<15.75 Let, B.S.=15 inch Tube side: Flow area = 0.302 in2/tube Flow area per pass = 0.302 x132/4 = 6.43x10-3 m2 (B.S.=baffle space)

Volumetric flow rate of tube =(23280/994)=23.44 m3/hr Velocity(u)=(23.44/6.43 x10-3 x 3600)=1.013 m/sec

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Re=d . u./ =(0.62 x2.54 x10-2 x1.013x994)/0.728 x10-3 =2.716 x104 Pr = Cp /k =0.728 x10-3 x 0.99 x 3600/0.53 = 4.893 Nu = (hi di)/k = 0.023 x (Re)0.8 x (Pr)0.33 hi = 3679.73 kcal/ m2 hr oC hio=hi .OD/ID = 4451.28 kcal/hr oC m2 Shell side: C=Pt - O.D.=2.54- (3/4) x 2.54 [C=clearance ; Pt= pitch] =0.00635 m D=400 mm=0.4 m B.S.=15 inch =0.381 m Flow area(as)=C * B.S.* D/Pt = (0.00635 x 0.381 x 0.4)/0.0254 =0.0381 m2 Gs=w/as=26000/0.0381=6.82 x104 kg/ hr m2 Do=3/4 inch =0.01905 m DH =4{(0.5 x 0.0254 x0.86 x0.254) ( x 0.019052 /8) }/( x 0.01905/2) =1.803 x10-2 m Re=DH Gs / =(1.803 x10-2 x 6.82 x104)/(0.0135 x10-3 x 3600) =25.306 x103 Pr = Cp /k = (0.0135 x10-3 x1 x3600)/0.024 = 2.024 From Ditus _Bolter equation: ho DH/k = 0.023 x Re0.8 x Pr0.33 ho = 134.082 kcal/ hr oc m2 Clean overall co_efficient : 1/UDO =1/ho + 1/hio =(1/134.082) +(1/4451.28) =7.683 x10-3 (UDO)c=130.16 kcal/hr oC m2 Fouling factor : Rdo=(1/Udo,dirt) (1/Udo,clean) =(1/43.2) - (1/130.16) = 0.01546 hr oC m2 /kcal =0.01325 m2 oc /w

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STUDY OF P & ID :
Piping and instrumentation (P & ID) diagram is a diagram which shows the interconnection of process equipments and the instrumentation used to control the process. In the process industry, a standard set of symbols is used to prepare drawings of the processes. The instrument symbols used in these drawings are generally based on International Society of Automation(ISA) standard S5.1. P & IDs play a significant role in the maintenance and modification of the process that it describes. It is critical to demonstrate the physical sequence of equipment and systems, as well as how these systems connect. During the design stage, the diagram also provides the basis for the development of system control schemes, allowing for further safety and operational investigations, such as the hazard and operability study(HAZOP). A list of important instruments and equipments very commonly used in P & IDs along with their diagrams is given below:
VALVE DIAGRAM INSTRUMENT DIAGRAM EQUIPMENT DIAGRAM

Gate valve Globe valve Needle valve Butterfly valve

Venturi tube Orifice meter Rotameter ( )

Electrical motor Shell & tube heat ex. Centrifugal pump Gear pump

Ball valve

SAFETY
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INCIDENT: ACCIDENT:

Freedom from any accident is called an incident. Any unwanted incident which cannot be foreseen.

THE BASIC DIFFERENCE BETWEEN ACCIDENT AND INCIDENT: Accident is mainly loss. Incident is mainly near miss. THE MAIN DIFFERENCE BETWEEN HAZARD AND RISK: Source or situation with a potential to harm human health, property or environment is termed hazard. Risk is a combination of hazard along with probability. CAUSE IS MAINLY OF TWO TYPES:
UNSAFE CONDITION: In human life the percentage of unsafe

condition is very less of about 2%.

UNSAFE ACT: In human life the percentage of unsafe activity is

very high of about 98%.

FIRE:
It is a chemical reaction commonly known as fire. To create fire three materials are very much important. If anybody suppresses one of them fire will not be created. These three and terms for lack of each one of them are given below. 1. 2.
3.

If we remove fuel called=>Starvation. If we remove heat called=>Cooling. If we remove O2 called=>Smothering. The classification of fire:1. CLASS A FIRE:-cloth, plastic. 2. CLASS B FIRE:-chemical fire 3. CLASS C FIRE:-Gas fire 4. CLASS D FIRE:-Metal fire 5. CLASS E FIRE:-Electrical fire.

FIRE FIGHTING SYSTEM: Fire extinguisher(different for different fires).

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 Fire brigade. PERSONAL PROTECTIVE EQUIPMENT: H G elmet oggle s H and S gloves afety

HEALTH
OCCUPATIONAL HEALTH CENTER:
1. 2. 3. 4. 5. 6. 7. 8. Pre Employment Health check up. Periodic Health check up. Treatment of occupational induced illness. General Medical care. Immunization. Referral Service. First Aid training programme. Research Analysis.

FACILITIES IN OCCUPATIONAL HEALTH CENTER:

1. Availability of upgraded medicines and drawing materials. 2. Equipped with necessary resuscitation equipments.

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ENVIRONMENT
Several measures were induced during the design stage itself to prevent waste generation . The environmental management philosophy in HPL centers on Resource Conservation& Waste Minimisation by optimal utilization of resources . The waste minimization approach works on the 5-R concept . Reduce Replace Reuse Recover Recycle Treatment

Various steps of environmental management strategy in Haldia Petrochemical Limited can be summarized as follows: Prevention of waste generation by adopting cleaner technology. Process control measure to prevent process upsets. State of the art treatment facilities to handle waste in approprote manner. 100% statutory compliance.

Regular measurement and monitoring of environmental parameters.

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 Adoption of continual improvement tools like ISO 1401:204. Green belt development , community awareness & other community development activities.

CONCLUSION
The Summer Training carried out at Haldia Petrochemicals Ltd., has provided us a much-needed exposure into the industrial world of Chemical Engineering. During the course of the training, we gained an insight into the overall manufacturing process of Polypropylene (HDPE). From this training we have got an idea about manufacturing, processing, testing and molding of HDPE. At the same time, it also provided us with a chance to observe the various equipments used in the plants such pumps,
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compressors, valves, blower, heat exchangers, condensers, reboilers, dryers, loop reactors, bag filters, cyclone etc in operation. We are sure that the experience gained here will help us in future.

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