1.

1 GENERAL
The plant comprises following section:
Section 1100/2100 Catalyst Feeding
1200/2200 Polymerization
1300/2300 Separation and Drying
1400/2400 Palletizing and Storage
1700 Hexane Reo!ery
1"00 Proess #$xiliary
1%00/2%00 &agging and Palletizing
1.2 CATALYST EE!"NG SECT"#N
1.2.1 $% & Catal'st preparation

P'(Catalyst is )arged into P' Feed Dr$m 7*(1110# or &+7!(2110# or &, -it)
)as .een /illed -it) a spei/ied 0$antity o/ )exane meas$red .y F12P' atalyst is
dissol!ed in )exane .y means /eed dr$m agitator
Prior to )arging o/ P' atalyst2 3)e /lexi.le onnetion t$.e to onnet t)e P'
ontainer to 7*(1101# or & +7*(2110# or &,4 -)i) is dried4 s)all .e p$rged -it)
nitrogen a/ter it is onneted2 Preparation o/ P' atalyst is arried o$t approximately
e!ery t)ree days2 3)e /re0$eny depends on t)e at$al rate o/ atalyst ons$mption2
3)e -)ole atalyst o/ t-o P' ontainers are $sed /or e!ery .at) o/ P' atalyst
preparation2 5ormally4 sl$rry onentration in 7*(1101# 6 & +7*(2110# or &, is
ad7$sted at 8 mmol 9 3i/1(Hexane2
:n t)e meantime P' atalyst is )arged into 7*(1110# or &+7*(2210# or &,2 Speial
are s)o$ld .e exerised2 3o pre!ent t)e system /rom imp$rities s$) as oxygen/
S$l/$r ompo$nds et2 3)e entire parts o/ P'( Catalyst preparation system is
operated $nder nitrogen press$re .et-een 021 and 023 ;g/m
2
<2 *ent gas at t)e time
o/ press$ring or depress ring is passed t)ro$g) !ent Condenser 7=(1104 +7=(2104,
and dis)arged to t)e /lare system2
1. !ESCR"$T"#N # AC"L"T"ES.
=ntrainment o/ )exane -it) t)e !ent gas is ondensed as it goes t)ro$g) 7=(1104
+7=(2104, and is olletion in Drain Pot 7*(1127 +7*(2127,2
P' Catalyst is treated in 7*(110" &y #D(Catalyst /or prod$tion o/ >100&
#nd >30>= and .y #3( Catalyst -it) ?H(Catalyst /or prod$tion o/ >>00S2
1.2.2 TE(CATALYST $RE$ARAT"#N
3=(atalyst is )arged into 3= 3reatment Dr$m 7*(110" and dil$ted -it)
)exane .y t)e same manner as P'( Catalyst2 3=(Catalyst is pretreated .y #3(
Catalyst -it) ?H(Catalyst or #3(Catalyst at am.ient temperat$re in 7*(110" .e/ore
/eeding to t)e reator t)ro$g) 7*(1110# or &2
#3( Catalyst trans/erred .y nitrogen press$re /rom #3
ontainer to #3 /eed dr$m 7*(1111 +7*(2111,@ a/ter4 a spei/ied 0$antity o/ )exane
meas$red .y F1 )as .een )arged into 7*(1111 +7*(2111,2 #3 atalyst sol$tion is
t)$s dil$ted to a spei/ied #: onentration -)i) is normally 200 mmol( #:/:
()exane .y nitrogen .$..ling
Aean-)ile4 !ent gas oming /rom #3 9 Catalyst ontainer and /eed system is
dis)arged into /lare system2
1.2.) A"(CATALYST $RE$ARAT"#N
#:(Catalyst is trans/erred .y nitrogen press$re /rom #: ontainer to #: Feed dr$m
7*(1113 a/ter a spei/ied 0$antity o/ )exane meas$red .y F1 )as .een )arged into
7*(11132 #:(Catalyst sol$tion is t)$s dil$ted to a spei/ied #: Conentration -)ile is
normally 200 mmol(#:/:(Hexane .y nitrogen .$..ling2
Aean-)ile4 !ent gas oming /rom #:(Catalyst ontainer and /eed system dis)arged
into /lare system2
1.2.* #G & Catal'st preparation.
#G & Catal'st is trans/erred .y o-n press$re /rom a ylinder to ?<C Feed dr$m
7*(1114 a/ter a spei/ied 0$antity o/ )exane meas$red .y F1 )as .een )arged into
7*(11142 ?<( Catalyst sol$tion is t)$s dil$ted to a spei/ied onentration2
1.2.+ Catal'st ee,
$E(Catal'st -)ile )as .een dil$ted to a spei/ied onentration in 7*(1110#
or &+7*(2110# or &, is /ed to ea) polymerize .y P' /eed p$mp 7P(110>#4& and
/or C +7P(210>#4& and/or C,2 3)e $nites ser!ed .y t)ese p$mps are as /ollo-s2
-$(11.*A or / -R(12.1
-$(11.*/ or C -R(1221
-$(21.*A or / -R(22.1
-$(21.*/ or C -R(2221
1.2.- AT(Catal'st fee,
#3(Catalyst -)i) .een dil$ted to a spei/ied onentration in 7*(111 +7*(
2111, is /ed to ea) polymerize t)ro$g) #3 Feed s$. dr$m 7*(1112 +7*(2112, .y
#3 /eed p$mp 7P(1108#2& and/or C +7P(2108#2& and/or C,2
3)e $nited ser!ed .y t)ese p$mps are as /ollo-s2
-$(11.+A or / -R(12.1
-$(11.+/ or C -R(1221
-$(12.+A or / -R(22.1
-$(12.+/ or C -R(2221
1.2.0 AT(Catal'st fee,
A"(Catal'st -)i) )as .een dil$ted to a spei/ied onentration in 7*(1113 is /ed
to ea) polymerize .y #: /eed p$mp 7P(111#4 & and/or C2 3)e $nites ser!ed .y
t)ese p$mps are as /ollo-s2
-$(1111A or / -R(12.1
-$(1111/ or C -R(1221
1.2.1 #G(Catal'st ,ee,
#G(Catal'st -)i) )as .een dil$ted to a spei/ied onentration in 7*(1114 is /ed
to ea) polymerize .y ?<C /eed p$mp 7P(1112#4 & and/or C2
3)e $nites ser!ed .y t)ese p$mps are as /ollo-s2
-$1112 A or / -R(12.1
-$(1112 / or C -R(1221
1.2 $#LY3ER"%AT"#N SECT"#N
For t)e polymerization reation4 a lo- press$re +.elo- 10 ;g/m <, )exane sl$rry
proess is employed4 $sing Polymerize 7R(1201 and 7R(1221 +7R(2201 and 7R(
2221, lined $p in parallel or series2
=t)ylene monomer -)i) is t)e main ra- material de)ydrated )exane ad7$sting
sl$rry onentration and Hydrogen are ontin$o$sly /ed at spei/ied /eed rate to t)e
polymerizes2 Hydrogen as mole$lar -eig)t ontroller and eit)er propylene or
.$tene(1 /or ad7$sting t)e density are ontin$o$sly premixed -it) et)ylene gas2
S$) mixt$re is /ed into t)e reyle gas line leading to t)e polymerizes2 3)e )eat o/
reation is remo!ed .y latent )eat o/ )exane2 Sl$rry ooling system and .y t)e
polymerizes 7a;ets ooling2 Control o/ polymer properties2 Aelt /lo- rate +AFR,2
Density +D, and mole$lar -eig)t distri.$tion +55:, o/ polymer in t)e polymerizes2
:s arried o$t .y ad7$sting polymerization ondition2
1.2.1 Raw materials an, he4ane fee, to pol'meri5es.
16 Eth'lene
=t)ylene gas is ontroller at 12 ;g/m
2
< .y P:C and /ed to t)e reyle gas
line leading to ea) polymerize $nder #C or FC ontrol to .e premixed -it)
et)ylene2
26 7',rogen
Hydrogen is ontrolled at 12 ;g/m
2
<4 and /ed et)ylene gas line to t)e
polymerizes $nder #C or FC ontrol to .e premixed -it) et)ylene2
26 $rop'lene
Hig) p$rity and li0$e/ied propylene is /ed to propylene *aporizer 7*(232
$nder BC ontrol2 3)e propylene so /ed is )eated .y lo- press$re steam in 7*(232
to .eome propylene gas )a!ing a press$re o/ 14 ;g/m2 <4 S$) gas is premixed
-it) et)ylene gas at a gi!en $nder FC2
)6 /8tene(1
Bi0$e/ied .$tene(1 is /ed to &$tene *aporizer 7*(233 /rom &$tene Holder
7*(2344 in -)i) it is )eated .y lo- press$re steam to .eome .$tene(1 gas )a!ing
a press$re o/ 12 ;g/m
2
<2 &$tene(1 in t)e gaseo$s state is premixed at a gi!en rate
-it) et)ylene gas .y t)e FC2
*6 7e4ane
Hexane press$rized $p to 12;g/m
2
< .y H2P Hexane p8mp -$(-.0 A #r /
is de)ydrated in )exane Drying 7*(703# or & to .eome de)ydrated )ig)(press$re
)exane )a!ing a > ppm or less -ater ontent4 t)en /ed to ea) polymerize $nder FC
ontrol -it) t)e p$rpose o/ ontrolling t)e sl$rry onentration in it2 :n t)e
meantime4 ea) atalyst /eed line to t)e polymerize is onneted to t)e )exane inlet
nozzle so t)at t)e /ed atalyst is -as)ed -it) t)e )exane stream all t)e time in t)is
-ay it pre!ents logging d$e to partial polymerization2 Part o/ t)e mot)er li0$or
/rom entri/$ge is reyled to polymerize2
1.2.2 $ol'meri5e rec'cle gas
=t)ylene4 )ydrogen4 and eit)er propylene or .$tene(1 are mixed -it) polymerize
reyle gas4 and /ed 1
st
polymerize 7R(1201 +7R(2201, and 2
nd
polymerize 7R(1221
+7R(2221, t)ro$g) t)e gas in7etion pipes2 3)e /ed ra- material gases are
t)oro$g)ly dispersed .y t)e 3stage t$r.ine agitator to .e dissol!ed in )exane4 and
t)e et)ylene gas is polymerized in t)e presene o/ atalyst and /orms polymer sl$rry
)a!ing a spei/ied onentration2 #t t)is time4 t)e polymerization press$re in
maintained .y )ydrogen partial press$re2
Reyle gas omprising et)ylene and )ydrogen is .lo-n into t)e .ottom o/ t)e
polymerize and et)ylene is polymerize d$ring its passage t)ro$g) t)e ade0$ately
agitated )exane p)ase2 Aore t)at a )al/ o/ t)e )eat generated .y polymerization is
remo!ed .y t)e latent )eat o/ )exane2
3)e reyle gas ontaining plenty o/ )exane !apor is trans/erred to 1
st
o!er)ead
ondenser 7=(1201 +7=(2201, and t)e 2
nd
o!er)ead ondenser 7=(1221 +7=(2221, 4
ondensed and ooled4 and /$rt)er trans/erred to t)e 1
st
)exane #$m$lator 7*(
120> +7*(220>, and t)e 2
nd
Hexane #$m$lator7*(122> +7*(222>, to .e separated
into ondensate )exane and reyle <as2 3)e reyle gas so separated is press$rized
in t)e 1
st
reyle gas .lo-er 7&(1201 +7&(2201, and t)e 2
nd
reyle gas .lo-er 7&(
1221 +7&(2221, and .lo-n into t)e .ottom o/ t)e polymerization -)ile its /lo- rate
is ontrolled $nder 3C in order to maintained t)e polymerization temperat$re at a
spei/ied !al!e2
Condenser )exane separated in 7*(120> +7*(220>, and 7*(122> +7*(222>, is
reyle to t)e polymerize t)ro$g) t)e 1
st
ondensate reyle p$mp 7P(1202# or &
+7P(2202# or &, and t)e 2
nd
ondensate reyle p$mp 7P(1222# or & +7P(2222# or
&,2 Part o/ t)e ondensate )exane is $sed /or /l$s)ing at a spei/ied rate $nder FC in
t)e gas o$tlet piping /or 7R(1201 +7R(2201, and 7R(1221 +7P(2221,2
1.2.2 Sl8rr' Cooler
Polyet)ylene sl$rry in 7R(1201 +7R(2201, and 7R(1221 +7R(1221, is
ir$lated t)ro$g) t)e 1
st
ooler 7=(1204 +7=(2204, and t)e 2
nd
sl$rry ooler 7=(
1224 +7=(2224, .y t)e 1
st
sl$rry ooler P$mp 7P(1203 +7P(2203, and t)e 2
nd
sl$rry
ooler p$mp 7P(1223 +7P(2223, to remo!e polymerization )eat toget)er -it)
reyle gas and reator 7a;et ooling system2
1.2.) #9erflow sl8rr' han,ling
Sine t)e o!er/lo- sl$rry ontains .$..les o/ mixed gas in t)e polymerize4 t)e
sl$rry is separated in t)e 1
st
sl$rry Dil$tion dr$m 7*(1202 +7*(2202, and t)e
separate gas is sent .a; to t)e polymerize t)ro$g) t)e gas .alane lines .et-een
7R(1221 +7R(2221, and 7*(1202 +7*(2202,and .et-een 7R(1221 +7R(2221, and
7*(1222 +7*(2222,2 3)e polymer sl$rry is /l$s)ed into t)e 1
st
Flas) Dr$m 7!(1203
+7!(2203, and t)e 2
nd
/las) dr$m 7!(1223 +7*(2223, and t)e temperat$re .eomes
a.o$t 8>
0
2 3)e 1
st
/l$s) gas /rom t)e Flas) Dr$m is ooled to 0
0
.y t)e 1
st
Flas) gas
ondenser 7=(1202 +7=(2202, and t)e 2
nd
/las) gas ondenser 7=(1222 +7=(2222,
and t)e /las) gas ooler 7=(1223 +7=(2223,2
Compressor s$tion Dr$m 7*(228 and press$rized to 42> ;g/m
2
< .y t)e /las) gas
ompressor 7C(222 to send it to 5ap)t)a Cra;er2 :n t)e meantime2 3)e press$res o/
7*(1203 +7'(2203, and 7*( 1223 +7*(2203, and 7*(1223 +7*(2223, system are
ontrolled at spei/ied le!els .y PC2 3)e polymer sl$rry in 7*(1223 +7*(2223, is
trans/erred to t)e entri/$ge 7S=(1301 +7S=(2301,( t)ro$g) t)e 2
nd
sl$rry 3rans/er
p$mp 7P(1221 & +7P(2221 # or &,2 :n ase -)ere t)e polymerizes are lined $p in
series4 polymer sl$rry in 7*(1203 +7*D2201# or &, to 7!(1221 +7!(2221,2
1.2. Controlling of pol'mer properties in pol'meri5ation.
3)ere are t)ree 0$ality parameters o/ ma7or importane t)at go!ern polymer
properties2 3)ese are melt /lo- rate +AFR,2 Polymer density +D,2 and mole$lar
-eig)t distri.$tion +55:,2
16 3" Control
AF: is determined .y t)e )ydrogen et)ylene molar ratio o/ t)e gas p)ase in
t)e polymerize2 AF: rises as t)e )ydrogen(et)ylene molar o/ t)e gas p)ase in
polymerize inreases
Note : 1, 3)e a$ses t)at inrease t)e )ydrogen(et)ylene molar ratio o/ t)e gas
p)ase in polymerize are .ro$g)t .y t)e inreasing o/ )ydrogen /eed
rate2

2,
Hig)(speed gas )romatograp) om.ined -it) distri.$ted ontrol
system in $sed to ontrol t)e )ydrogen(et)ylene molar ratio o/ t)e gas
p)ase in t)e polymerize at t)e spei/ied !al!e2
26 !ensit' control 3)e density o/ t)e prod$t pellets in ad7$sted .y
ontrolling t)e /eed rate o/ monomer i2e24 propylene or .$tene(1 !s2 t)at o/
et)ylene2 3)e
density also !aries -it) t)e AFR !al!e2
26 3olec8lar weight ,istri:8tion control ;NN"6
:n ase -)ere polymer )a!ing .road mole$lar -eig)t distri.$tion s$) as
.lo- molding grade and HAE /ilm grade are prod$ed4 t)e ontrol o/ mole$lar
-eig)t distri.$tion is a)ie!ed .y !arying operation onditions o/ t)e t-o
polymerize mainly AFR o/ 1
st
polymerize 7R(1201 +7R(2201,4 aording to t)e
spei/ied 55: /or ea) type o/ polymer2
124 SE$ARAT"#N AN! !RY"NG SECT"#N
1.).1 Separation
3)e prod$t sl$rry is ontin$o$sly /eed t)ro$g) t)e 2
nd
sl$rry 3rans/er p$mp
7P(1221# or & +7P(2221# o/ &, to t)e )orizontal type Centri/$ge 7S=(1301 +7S=(
2301, re!ol!ing at a )ig) rotating speed4 in -)i) polymer is separated .y
entri/$gal /ore2
3)e prod$t sl$rry /ed to t)e rotation .o-l o/ 7S=(1301 +7S=(23001, is pressed to
t)e inside -all o/ rotation .o-l $nder entri/$ged /ore and separation into prod$t
and )exane sol!ent2 3)e polymer is dis)arge /rom t)e entri/$ge .y t)e sre-
on!eyor pro!ided in t)e .o-l in t)e /orm o/ -et a;e ontaining )exane .y
approximately 30 -tF4 and /ed to t)e Dryer 7S=(1302 +7S=(2302, !ia t)e Eet a;e
sre- Feeder 7A=(1301 +7A=(2301,
Aean-)ile4 )exane o!er/lo-s t)e -eir pro!ided in t)e .o-l and /lo-s into t)e
Aot)er li0$or 7*(1301 +7*(2301 # or &, so t)at part o/ it -ill .e sent .a; to
polymerization setion and t)e reminder -ill .e /ed to )exane reo!ery setion2
3)e piping to trans/er )exane separated in 7S=(1301 +7S=(2301, is pro!ided -it)
7a;et or steam traing to pre!ent t)e lo- polymer dissol!ed in t)e )exane /rom
getting rystallized2
1.).2 !r'ing
16 Steam t8:e rotar' ,r'er
Aixed gas onsisting o/ nitrogen and )exane !apor /lo-s t)ro$g) t)e
Dryer 7S=(1302 +7S=(2302, o$nter $rrently -it) t)e prod$t2 E)en t)e
prod$t po-der lea!es 7S=(1302 +7S=(2302, a/ter a.o$t 30 min$tes )olding time2 :t
ontains less t)at 022F !olatile matter +as )exane, and its temperat$re is
approximately 100
o
2 Bo- press$re steam is s$pplied to t)e steam t$.e in 7S=(1302
+7S=(2303, as t)e )eat so$re a/ter its press$re and temperat$re )a!e .een red$ed
to 022 to 023> ;g/Cm
2
< and approximately 107
o
t)ro$g) t)e steam ooler 7=(1304
+7=(2304,2 3)e operating press$re o/ t)is system is a.o$t 400mm#02
26 !r'er gas circ8lation s'stem
3)e mixed reyle gas /rom 7=(1302 +7=(2302, ontaining a small
amo$nt o/ /ine polymer partiles goes into t)e dryer gas Sr$..er 7*(1302 +7*(
2302,2 3)e /ine polymer entrained -it) t)e mixed gas is olleted .y t)e ir$lation
li0$id in t)e dryer gas sr$..er p$mp 7P(1302# or & +7P(2302# or &,2 3)e
olleted polymer is reo!ered t)ro$g) 7P(1302# or & +7P(2302# or &, into
7!(1223 +7!(2223,4 -)ile t)e li0$id le!el o/ 7*(1302 +7*(2301, is ontrolled
.y BC2 3)e mixed reyle gas ooler in 7=(1301+7=(2301, is press$rized .y t)e
dryer gas .lo-er 7&(1301# or & +7&(2301# or &, and is ooled to approximately
30o .y t)e dryer gas ooler 7=(1307 +7=(2307, -it) .rine to derease )exane
ontent in it2 3)e reyle gas /rom 7=(1307 +7=(2307, is )eated to approximately
100o .y t)e dryer gas Header 7=(1302 +7=(2302, -it) lo- press$re steam $nder
3C ontrol2 3)e nonondensi.le gas -)i) la!es t)e o$tlet o/ t)e p$rge gas
ondenser 7=(1303 +7=(2303, is press$rized to 3;g/m2 < .y t)e o// gas
ompressor 7C(302 and part o/ it is s$pplied to t)e gland o/ 7S=(1302 +7S=(2303,
/or /l$s)ing -)ile s$rpl$s is dis)arge to t)e /lare system2
1.* $ELLET"NG ST#RAGE AN! $AC<"NG SECT"#N
1.*.1 $ow,er hopper
3)e prod$t po-der -)i) )as le/t 7S=(1302 +7S=(2302, is trans/erred to t)e
nitrogen gas pne$mati po-der on!eying system t)ro$g) t)e po-der Rotary !al!e
7A=(1303 +7S=(2303,2 3)e prod$t -)i) is /or-arded .y t)e po-der trans/er
.lo-er 7&(1401# or & +7&(2401# or &, is ontin$o$sly separated in t)e po-der
ylone 7S=(1401 +7S=(2402, /rom nitrogen and dropped in to t)e po-der )opper
7&5(1402 +7S=(2402,2 5itrogen gas is /iltered t)ro$g) t)e .ag /ilter 7S=(1402
+7S=(2402, to .e re ir$lated2 3)e !ery /ine po-der entrained -it) nitrogen gas in
7S=(1402 +7S=(2402, is ontin$o$sly reo!ered 7&5(1402 +7&5(2402,2
Powder bulk loading
From t)e po-der )opper 7&5(1402 t)e polymer po-der an .e trans/erred4 .y
means o/ t)e pne$mati transport 7G(14034 to t)e po-der .$l; loading silo 7&5(
140>2
&elo- t)is silo4 a tr$; .$l; loading is pro!ided 2
3)is /aility is a!aila.le only line(1
1.*.2 Sta:ili5er meas8ring s'stem
=le!en ;inds o/ solid sta.ilizer +#&4#=4#H4#B4H#4HD4HF4SF4IC and ID,
and nine ;inds o/ li0$id sta.ilizer +##4#D4#F4#H4=&4=D4=H4H& and E, are
a$tomatially -eig)ed and dis)arge in aordane -it) t)e .lending ratios /or
indi!id$al types2
16 Soli, sta:ili5er
Solid sta.ilizer are )arged in spei/ied 0$antities into sta.ilizer Aixer 7A=(
140% +7A=(240%, -)ere t)ey are mixed /or a spei/ied period o/ time2 3)em t)e
mixt$re is trans/erred to t)e sta.ilizer )opper 7&5(1403 +7&5(2403, in -)ile it is
stored in nitrogen atmosp)ere -it) gently stirring2 # spei/ied amo$nt o/ s$)
mixt$re is a$tomatially dis)arge into t)e sta.ilizer Aeas$ring Feeder 7E(1412
+7E(2412,2
26 Li=8i, sta:ili5er
a. Bi0$id sta.ilizer ot)er t)an E(sta.ilizer are )arged in a spei/ied
0$antity in nitrogen atmosp)ere into t)e sta.ilizer melting dr$m 7*(1401 +7*(2401,2
3)e sta.ilizer are melted -it) agitation .y means o/ lo- press$re red$ing t)ro$g)
PC*2 Sta.ilizer sol$tion -)ose temperat$re is approximately 100
o
4 is trans/erred to
t)e Aelt sta.ilizer Holding dr$m 7*(1402 and & +7*(2402 # and &, t)ro$g) t)e
li0$id sta.ilizer trans/er p$mp 7P(14012 3)en a spei/ied amo$nt o/ li0$id sta.ilizer
/ed to t)e palletized 7=G(142> +7=G(242>, t)ro$g) li0$id sta.ilizer /eed p$mp 7P(
1402# or & +7P(2402# or &,2
:. >(Sta:ili5er
Dematerialized -ater +DAE, is )arged .at) -ise to E sta. storage dr$m
7*(1403 +7*(2403,2 3)en t)e E(sta.ilizer is a$tomatially in7etion to t)e
Homogenizer 7A=(1408 +7A=(2408, at a normally ratio o/ 70 o/ DAE t 1000
;g P= po-der t)ro$g) t)e E(Sta.ilizer /eed p$mp 7P(1403 or & +7P(2403,2
1.*.2 $ow,er an, sta:ili5er fee, s'stem
3)e po-der stream -)i) )as le/t t)e o$tlet o/ 7&5(1402 +7&5(2402, is
metered .y t)e po-der meas$ring /eeder 7E(140> +7E(240>, and is /ed to 7=G(
142> +7=G(242>, t)ro$g) 7A=(1408 +7A=(2408,2
Solid sta.ilizer mixt$re in aordane -it) t)e sta.ilizer reipe predetermined /or
prod$t type is prepared in 7A=(140% +7&5(240%, and dis)arged .at) -ise into
7&5(1403 +7&5(2403, is metered .y 7-(1412 +7-(1412, and /ed 7A=(1408 +7A=(
2408,2
Bi0$id sta.ilizer and E(Sta.ilizer are /ed into 7A=(1408 +7A=(2408, .y t)e li0$id
sta.ilizer /eed p$mp 7P(1402 +7P(2402# or &, and t)e E(Sta.ilizer /eed p$mp 7P(
1403# or & +7P(2403# or &, respeti!ely2
1.*.) $elleti5ing S'stem
Polyet)ylene po-der4 Silo sta.ilizer and E(sta.ilizer are /ed to 7=G(142>
+7=G(242>,2 3)e Pelletier is a t-in(sre- type ontin$o$s mixer -it) gear p$mp4
-)ere P= po-der and sta.ilizer are mixed and ;neaded2 Aolten polymer is p$s)ed
to-ard t)e die(.y t)e gear p$mp system@ t)en t)e molten polymer is extr$der
t)ro$g) t)e die()old into t)e $tter .ox t)ro$g) -)i) pellet ooling -ater is
ir$lated2 3)e extr$der is $t into pellet .y t)e re!ol!ing $tter2
3)e resin in t)e pellet /rom is trans/erred to t)e Pellet Separated 7S=(1404 +7S=(
2404, -it) ir$lated PE +pellet ooling -ater,2
For protetion o/ 7S=(1404 +7S=(2404,4 a gird PE strainer 7S=(1427 +7S=(2427, is
pro!ided4 to remo!e any /$sed .lo;s o/ pellet2 3)e pellets -)i) passed t)e grid are
sent to 7S=(1404 +7S=(2404, a/ter t)ey are drained on t)e per/orated plant sreen2
3)e pellet ooling -ater separated .y 7S=(1427 +7S=(2427, and 7S=(1404 +7S=(
2404, /lo- into PE dr$m 7*(1404 +7*(2404,4 /rom -)i) it is reir$lated to t)e
$tter .ox o/ 7ex(142> +7=G(242>, a/ter press$rized .y t)e PE ir$lation p$mp
7P(1404# or & +7P(2404# or &,4 t)en ooled 70o .y PE ooler 7=(1401 +7=(
2401,2
Po-dery matter s$spended in t)e pellet ooling -ater is dis)arge o$t o/ t)e system
t)ro$g) t)e o!er/lo- o$tlet o/ 7*(1404 +7*(2404, .y ontin$o$sly /eeding
demineralized -ater +DAE, to 7*(1404 +7*(2404, t)ro$g) t)e BC2 Sine t)is
-asted -ater ontains solid partiles and sta.ilizer s$spended or dissol!ed in it4 it is
trans/erred to po-der separator 4 -)ere Prod$t pellet are lassi/ied .y t)e pellet
*i.ration sreen 7S=(142" +7S=(242", into o!ersized4 normal and $ndersized
Prod$ts2
5ormal size pellets -)i) /lo- in t)e pellet separator Hopper 7&5(1404 +7&5(
2404, are pne$matially on!eyed to t)e spei/ied silo t)ro$g) t)e pellet Rotary
*al!e 7A=(1431+7A=(2431, .y t)e pellet trans/erred &lo-er 7&(14>1# or &
+7&(24>1# or &,2
1.*.* $ellet :len,ing ? transfer s'stem.
Pellet silos 7&5(14>1#4&4C4D and = +7&5(24>1#44&4C4D and =,4 )a!e
a apaity o/ >00m3 ea) one2 :n order reti/y s$) /l$t$ation o/ 0$ality d$e to
possi.le !ariane in t)e operating onditions at proess ontrol4 t)e pellet .lending is
arried o$t t)ro$g) trans/erring t)e pellet to t)e &agging Hopper2
Prod$t pellet are pne$matially on!eyed .lending to &agging Hopper .y t)e
&lending Pellet 3rans/er &lo-er 7&(14>3# and & +7&(24>3# and &, o/ -)i)
on!eying apaity is 372> ton/)r2
1.*.+ Repelleting S'stem
3)is is a system in -)i) spei/ied o//(spe material prod$ed at t)e
time o/ plat start($p and grade transition is mixed in a spei/ied 0$antity -it) on(
spe po-der at t)e time o/ its prod$tion and repelleted2 3)e spei/ied o//(spe
pellet are ta;en into Repellet silo 7&5(1481 +2481, or ?// pellet silo 7&5(14>3
+7&5(24>3,and a/ter passing t)ro$g) rotary !al!e 7A=(1442 +7A=(2442, or 7A=(
1473 +7A=(2473,4 3)ey are trans/erred to re(pellet Hopper 7&5(1482 +7&5(2482,
-)ose pellet le!el is ontrolled a$tomatially +or trans/erred to &agging Feeding
Silos diretly,2 3)e rotating speed o/ Rotary !al!e 7A=(1444 +7A=(2444, $nder
7&5(1482 +7&5(2482, is ad7$sted so t)at t)e spei/ied o//(spe pellet are mixed
-it) on(spe po-der in a proportion o/ less t)en 10 -tF and t)e pellet are /ed to
7A=(1408 +7A=(2408,2
1.*.- $ac@ing
=a) plant is s$pplied -it) t-o .agging lines4 7G(%014 /ed /rom
independent silo 7&5(1%01 #/& +7&5(2%01 #/&,2 =a) .agging line inl$des t)e
.agging ma)ine 7A=(1%01 #/&(G +A=(2%01 #/&(G,4 t)e )e; -eat)ers 7E(
%01#/&/C/D(G +C/D $nits are /or t)e 2
nd
line,4 t)e metal detetors 7E(%03 #/&/C/D(
G +CD $nits are /or t)e 2
nd
line,4 re7etors de!ies 7A=(%04 #/&/C/D(G +CD $nits
are /or t)e 2
nd
line,4 Do-nstream ea) .agging $nit2 3)ree are t)e palletizing $nits
7G(%024 inl$ding t)e /eeding .elt on!eyors 7A=(%0> #/&/C/D(G4 t)e palletization
ma)ines 7A=(%08 #/&/C/D(G and t)e roller on!eyors 7A=(%04 #/&/C/D(G +C
and D $nits /or t)e 2
nd
line2,
?ne stret)ing $nit 7G(%034installed do-nstream t)e 1
st
.agging line o/ t)e 1
st
line4
in s$pplied /or t)e /o$r .agging $nits2 3)e stret)ing $nit is omposed o/ a
stret)ing ma)ine 7A=(%0" #(G4 o/ a stret)ed pallets roller a$m$lator
7A=(%0%#(G and o/ a roller on!eyor 7A=(%10(G2 #lternati!ely to t)e .agging
$nits4 a /$t$re pro!ision /or t-o .ig .ags loading $nits+one /or ea) plant,4 /ed /rom
t)e silo 7&5(1%01/& +7&5(2%01/&, is en!isaged2
1.*.0 $ellets :8l@ loa,ing
:nstead o/ .eing trans/erred to t)e .agging $nits t)e pellet an .e .$l;
loaded on tr$;s2
3)e same pne$mati transport 7G(14>3 +7G(24>3,4 -)i) /eeds .agging $nits an
/eed4 /rom t)e pellet silo 7&5(14>1 #J=+7&5(24>1#J=,4 t)e .$l; loading silo
7&5(1%02 +7&5(2%02,2
&elo- t)is silo4 a tr$; .$l; loading station is pro!ided2
128 H=G#5= R=C?*=RK S=C3:?5
1.+.1 Ca8stic so,a washing
Aot)er li0$or )as .een separated .y 7S=(1301 +7S=(2301, is -as)ed -it)
a$sti soda and proess -ater to derease as) and )loride ontents .e/ore .eing
sent to lo- polymer separation system2
Aot)er li0$or +r$de )exane, is trans/erred to H= 6 5a?H separator 7*(721
t)ro$g) H= 6 5a?H Contator 7A(721 toget)er -it) 20-tF a$sti soda4
demineralized -ater and lo- press$re steam4 -)i) is /ed into ir$lated t)ro$g)
7A(721 is more t)an 122 Easte -ater is ontin$o$sly dis)arged /rom 7*(721 !ia
BC*2
3)en a$sti -as)ed r$de )exane is trans/erred to H= 6 Eater separator 7*(722
t)ro$g) H= 6 Eater ontator 7A(7224 -)ere proess -ater is /ed to -as) o$t
a$sti soda2 3)e P) o/ t)e /l$id ir$lation t)ro$g) 7A(722 is approximately 7 to "2
Easte -ater /rom 7*(722 is ontin$o$sly ret$rned to 7A(721 s$tion !ia BC* on
7*(2222
3)e system operates at 022 ;g/m
2
< and 80
0
C2
1.+.2 7e4ane stripping
Hexane ontaining lo- polymer +r$de )exane, and oming /rom Cr$de
Hexane /eed Dr$m 7*(701 is /ed to 7C(703 .y t)e r$de Hexane Feed
P$mp 7P(702#/&2 Aedi$m press$re steam is s$pplied to t)e s)ell side o/ r$de
Hexane Re.oiler 7=(703# and & and 7C(703 operates at t)e ondition o/ a .ottom
temperat$re o/ 120
0
and total press$re o/ 3;g/m2 < Hexane !apor generated : 7C(
703 is depress$rized to 022;g/m2 < .y PC4 ondensed and ooled in Hexane
o!er)ead Condenser 7=(70># and & /or /ored ir$lation o/ Hexane2
Aolten lo- polymer in )exane onentrated in t)e .ottom o/ 7C(703 is press$rized
to 22;g/m2 < .y t)e Flas) dr$m /eed p$mp 7P(711# and & and )eated /rom 120
0
C in t)e /las) Pre )eater 7=(7112 E)ose s)all side is s$pplied -it) )ig) press$re
steam $nder 3enimont S2p2# 2 ontrol2 3)is )eated sol$tion gets its press$re
red$ed to 3;g/m
2
< .y as it enter in t)e 1
st
/las) dr$m 7*(7112 3)e sol$tion is
ooled to approximately 180
0
4 -)ile )exane !apor so generated is reyled to 7C(
7032
3)e lo- polymer sol$tion in7*(711 is ;ept /rom ooling o// .y t)e steam oil
pro!ided in it and is /ed to t)e lo- polymer pre)eater 7=(7124 E)ere t)e sol$tion is
)eated $p to 1"0
0
2 3)e sol$tion t)en /lo-s into t)e 2
nd
/las) dr$m 7&(712 -)ose
press$re is ;ept at (300mmHg .y t)e BP !a$$m P$mp 7&(7012
Hexane !apor generated in 7*(712 is ondensed in t)e *ent <as ooler 7=(713 and
stored in t)e
7=(713 .ottom4 t)en trans/erred to 7*(701 or ?SH&B .y t)e Condensate Hexane
P$mp 7P(714# or &2
3)e lo- polymer sol$tion4 -)i) remo!ed )exane in 7*(7124 is trans/erred to t)e BP
Holding Dr$m 7*(717 .y t)e Bo- polymer 3rans/er P$mp 7P(713# or &2
1.+.) Low $ol'mer fla@ing
Aolten lo- polymer o/ BP Holding Dr$m 7*(717 is trans/erred .y BP storage
&ottom p$mp 7P(717 t)e Dr$m Fla;er 7G(7012 Bo- polymer is ooled and
solidi/ied on t)e dr$m o/ 7G(7014 -)i) is ooled -it) ir$lating -ater system2
Fla;er lo- polymer is olleted in t)e Fla;er Hopper 7&5(704 and man$ally
pa;ed2 *ent gas /rom dr$m Fla;er is ex)a$sted -it) *entilator 7&(702 to
atmosp)ere2
1.+.* 7e4ane p8rification
Hexane !apor /rom 7C(703 is ondensed and ooled in 7=(7044 t)en /lo-s
into t)e Stripper Reei!er 7*(702 .y gra!ity4 D$ring -)i) demineralized -ater an
.e added !ia FC -it) t)e p$rpose o/ )a!ing imp$rities ontained in s$) )exane
a.sor.ed into -ater as needed +5ormally2 DAE is not /ed to t)is system,2
3)e mixt$re /lo-s into 7*(7022 pro!ided -it) reti/ying plates /or en)aning
separation o/ -ater drops in )exane4 in -)i) it is a$sed to $ndergo p)ase
separation into )exane and -ater layers2 3)e -ater layer in 7*(702 is dis)arged .y
BC2 3)e )exane layer2 Sat$rated -it) -ater $p to approximately 2>0 -t ppm4 is /ed
.y t)e De)ydrator Feed p$mp 7P(708# or &4 -)ile t)e le!el o/ 7*(702 is .eing
ontrolled .y BC4 to t)e top o/ t)e Hexane De)ydrator 7C(7042 Bo- press$re steam
is s$pplied $nder FC ontrol to t)e De)ydrator Re.oiler 7=(70> installed in t)e
7C(704 .ottom2 3)e .ottom o/ 7C(7044 -ater ontent and temperat$re o/ -)i) are
10 -t ppm or less and a.o$t "0
0
respeti!ely4 is /or-arded .y t)e De)ydrator
.ottom p$mp o/ 7C(704# or & to t)e De)ydrator .ottom ooler 7=(7084 -)ere t)e
li0$id is ooled to 40
0
or lo-er4 and t)en trans/erred to t)e p$re Hexane dr$m 7*(
7224 -)ile t)e le!el o/ 7C(704 .ottom is ontrolled .y BC2 Aean-)ile4 t)e 7C(704
system is operates at a press$re le!el o/ 022;g/m
2
< $nder ontrol .y nitrogen PC
mo$nted on 7*(7022
1.+.+ $8re 7e4ane !istri:8tion
P$ri/ied )exane -it) a -ater ontent o/ 10 -t ppm or less is press$rized
to 12;g/m2 < or )ig)er .y t)e H2P )exane p$mp 7P(70"# or & de)ydrated to a less
t)en > -t ppm -ater ontent .y t)e )exane Dryer 7*(703S or & Containing
mole$lar sie!e4 and t)en /or-arded to !ario$s proess setions t)ro$g) t)e Hexane
Strainer
7'(704 # or &2
1.+.- Slop he4ane reco9er'
3)e slop )exane reo!ery system is /or disposal o/ )exane ontaining
polymer and -aste li0$ids dis)arged o$t o/ t)e proess system4 as a res$lt o/
sampling4 maintenane -or;4 disposition o/ atalyst4 et2 Sampled li0$ids $sed /or
t)e proess ontrol analysis are a$m$lated in t)e Drainage dr$m 7*(17>1 +7*(
27>1, or 7*(7>22 E)en t)e a$m$lated li0$id )as rea)ed a ertain le!el2 :t is
trans/erred to t)e Hexane stripper 7*(7>32 :n ases -)ere t)e li0$ids in P' Feed
dr$m 7*(1110# 6 & +7*(2210# 6 &, and at Feed dr$m 7*(1111 +7*(2111, and 7*(
1112 +7*(2112, in t)e Catalyst Feeding setion are to .e remo!ed4 t)ey are diretly
trans/erred .y nitrogen press$re to 7*(7>32 3)e li0$ids trans/erred o/ 7*(7>3 are
ompletely ne$tralized .y a$sti soda2 E)i) )as already .een /ed t)is dr$m2
3)en in order t)at )exane may .e reo!ered steam stripping is arried o$t in 7*(7>3
at approximately %0
0
.y means o/ lo- press$re steam s$pplied $nder FC2
*aporized )exane and -ater are ooled to 40
0
.y t)e )exane ondenser 7=(7>14
ondensed and a$m$lated in Hexane reo!ery 7*(7>42 3)e )exane and -ater so
reo!ered are trans/erred .y t)e )exane trans/er p$mp 7P(7>1 to t)e Aa;e $p
)exane dr$m 7*(773 or 7*(7012 3)e agitator o/ 7*(7>3 is stopped and t)e ontent
t)erein is allo-ed to stand and ool o//2 3)en4 s$) polymer is separated2
:n ase t)e li0$id oming /rom 3= treatment dr$m 7*(110"4 -)i) ontains ?H
Catalyst is trans/erred to t)e draining dr$m 7*(7>> Diretly4 )exane is reo!ered to
7*(7>4 .y operating ?H $t 3o-er 7C(7>12 ?H Catalyst onentrated Hexane is
sent to t)e drain pot 7*(71" t)ro$g) t)e ?H/H= 3rans/er p$mp 7P(7>34 and
dis)arged to ?SH&B .y t)e -ater ?il p$mp 7P(71"2
1.- $R#CESS AAB"L"ARY SECT"#N
12721 Ca$sti soda and mole$lar sie!e regenerating gas system
16 Ca8stic so,a
20-tF a0$eo$s sol$tion o/ a$sti soda is s$pplied /rom o$tside o/
&attery Bimits and is reei!ed into t)e Ca$sti soda reei!ing dr$m
7*("01 as re0$ired2
2, Aole$lar sie!e regenerating gas system
3)is system is designed to regenerate mole$lar sie!es $sed in Hexane
dryer 7*(703# and & .y means o/ nitrogen2
1.-.2 Seal oil S'stem
3)e seal oil is s$pplied to t)e /ollo-ing $sersL
1, 3o t)e s)a/t seals /or reator agitators4 /las) dr$m agitators and
.lo-ers in Polymerization Setion2
2, 3o t)e s)a/t seals /or agitators in Catalyst Feeding Setion2
3, 3o t)e s)a/t seals /or dr$m agitator in Separation and drying
Setion2
3)e press$re o/ seal oil entering t)e Ae)anial seal on t)e s)a/t needs to .e al-ays
maintained )ig)er t)an t)at on t)e proess side2 For t)e seal oil press$ring system
adopted /or t)is plant4 )ig) press$re nitrogen $sed2
Seal oil dr$m 7*(1"11 +7*(2"11, is onstantly ;ept in a press$rized ondition -it)
nitrogen press$red ontrolled .y PC at 10 ;g/m
2
<2
Seal oil is press$rized .y seal oil p$mp 7=(1"11# or & +7*(2"11# or &,4 ooled .y
seal oil ooler 7=(1"11 +7=(2"11,4 t)en distri.$ted to ea) $ser e0$ipment and
ret$rned to 7*(1"11 +7*(2"11,2
1.-.2 /rine s'stem
3)e .rine omprising 3> -tF =t)ylene <lyol ooled to (10
0
is
s$pplied /or t)e p$rpose o/ reo!ering )exane ontain in t)e nonondensi.le gas
a/ter ooling it to 10
0
.y !ent ondensers2 3)e /lo- rate o/ .rine s$pplied to ea)
!ent ondenser is reg$lated man$ally2 So as as to .ring t)e proess /l$id temperat$re
to 0
0
2 &rine4 -)ose temperat$re )as .een raised to approximately (>
0
.y )eat
ex)anger in t)e !ent ondenser4 et2 is sent to t)e .rine dr$m 7*("212
1.-.) >ater s'stem
16 Cooling >ater
:ndiret ooling -ater is s$pplied /rom o$tside o/ &attery Bimits t)ro$g) a
pipe line and distri.$ted to ea) ex)anger2
26 !eminerali5e, water
!3> -)i) is s$pplied /rom o$tside o/ &attery Bimits4 is $sed /or pellet
on!eying -ater .arrel ooling -ater )exane -as)ing et2
1.-.* Steam s'stem
Steam $sed /or t)e proess is lassi/ied into t)ree typsL )ig) +HS,4 medi$m
+AS, and lo- +BS, press$re2 Prinipal $sed inl$de t)e /ollo-ing
HS Bo- polymer treatment4 regeneration o/ mole$lar sie!es4 et2
AS Hexane stripping4 et2
BS Dryer4 )exane de)ydrator4 et
Steam ondensate reo!ery is arried o$t .y t)e /ollo-ing t-o systemsL
#2 Condensate o/ lo- press$re steam is reo!ered /rom Dryer 7S=(1302 +7S=(
2302, /lo-s into steam ondensate Dr$m 7*(">2 !ia 7*(1">3 +7*(2">3,2
&2 Condensate o/ medi$m press$re steam /rom Cr$de Hexane Re.oiler 7=(703#
and & /rom lo- polymer )anding system and ondensate o/ )ig) press$re steam
system /rom Fl$s) Pre)eater 7=(7114 lo- polymer pre)eater 7=(7124 lo- polymer
)andling setion et2 #re /las)ed in steam ondensate dr$m 7*(">1 to generate lo-
Press$re steam -)i) is reo!ered into t)e lo- press$re steam )eader2 3)e steam
-)i) : 7*(">1 /lo-s o$t to t)e Steam Condensate Dr$m 7*(">2 !ia BC2
3)e -)ole o/ t)e steam ondensate /lo-s into 7*(">2 to .e p$mped ?S&B .y t)e
ondensate 3rans/er P$mp 7P(">1# or &2
1.-.+ Nitrogen S'stem
5itrogen is $sed /or t)e /ollo-ing p$rposesL
1, 3o red$e t)e oxygen onentration in proess e0$ipment -)erein s$)
/lamma.le s$.stanes as )exane4 et)ylene4 propylene4 )ydrogen4 .$tene(14 al;yl
al$min$m4 P'(Catalyst4 Polyet)ylene po-der4 et2 are introd$ed and Stored2
2, 3o pre!ent entry o/ imp$rities so as to maintain t)e atalyst ati!ity2
3, 3o pre!ent polymer )eated to a )ig) temperat$re in t)e pelletizer $nit
/rom s$//ering t)ermal degradation2
5itrogen is distri.$ted at t)ree di//erent press$re le!els )ig) +H5<,4 medi$m
+A5<, and lo- +B5<,2 3)e )ig) press$re nitrogen ser!es to maintain t)e spei/ied
press$re o/ 7*(1"11 +7*(2"11, d$ring normal operation2
1.-.- Air s'stem
#ir system t)e /ollo-ing man p$rposesL
16 $lant air ;SA6
S# is $sed mainly as ooling air pre!ent melting /or polymer po-der at
t)e gland o/ Dryer 7S=(1302 +7S=(2302, and also as t)e ser!ie air /or air !i.rator
in Catalyst preparation setion2
26 "nstr8ment Air ;"A6
:# is s$pplied /rom o$tside o/ .attery limits t)ro$g) a pipe line2 3)e
main portion is $sed /or proess ontrol instr$ments2
1.-.0 lare s'stem
3)e gas dis)arge system t)ro$g) -)i) s$) gas is !ented t)ro$g) sa/ety
!al!es installed on t)e proess e0$ipment2 ?r released .ea$se o/ press$ring or de
press$ring o/ proess e0$ipment2 #re lassi/ied into t)e /ollo-ing ma7or gro$ps2
16 #pen to atmosphere s'stem
#, *ent gas /rom palletizing setion
&, *ent gas /rom separation and drying setion is dis)arge is
t)ro$g) !ent sta; in ase o/ emergeny -)en press$re ontrol !al!e or r$pt$re dis;
pro!ided on t)e proess e0$ipment in t)is setion .lo- o// and protet t)e
e0$ipment -)ose design press$re is extremely lo-2
26 Cent gas to Naphtha Crac@er
*ent gases /rom polymerization setion +/rom 7=(1223 and 7=(2223,4
-)i) are olleted into 7*(228 and press$rized 7C(2224 are sent to 5ap)t)a ra;er
+?S&B, /or ra;ing2
26 lare s'stem
1, *ent gas ot)er t)an a.o!e and 2, is dis)arged to /lare system !ia /lare ;no;(o$t
dr$m 7*(""12 *ent gas /rom Catalyst Feeding setion4 and Hexane Reo!ery setion
is olleted into /lare ompressor s$tion dr$m 7*(""2 and press$rized .y /lare gas
ompressor 7C(""1 to dis)arge it to /lare system !ia 7*(""12
*ent gas /rom .ot) Drying 6 separation setion press$rized .y o// <as ompressor
7C(302 is dis)arge to /lare system !ia 7*(""12