Crash Course For Basic Process

Crash Course for Basic Process
Petchem Plants
1. P11 - Ethylene Oxide Ethylene Glycol (EOEG)
2. P6A - Linear Low Density Polyethylene (LLDPE)
3. P7 - Polypropylene (PP)
4. P27 - High Density Polyethylene (HDPE)
© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)
All rights reserved. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical,
photocopying, recording or otherwise) without the permission of the copyright owner.
©Petroliam Nasional Berhad (PETRONAS) 2017 1

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P11 - Ethylene Oxide Ethylene Glycol (EOEG)
Process Unit Familiarization

UNIT 3220: EO UNIT
UNIT 3230: EG UNIT
All rights reserved. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical,

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Unit Introduction
Purpose • In the Ethylene Oxide Unit (EOU), the direct oxidation of ethylene
over a silver containing catalysts at high temperature will produce
Ethylene Oxide (EO).
• In the Ethylene Glycol Unit (EGU), a liquid-phase thermal hydrolysis
reaction of EO in the presence of excess water takes place to
produce MEG, DEG, TEG, and subsequent higher glycols.
Licensor Shell MASTER
Capacity 740 kta MEG (584 kta EOE)
Feedstock • Ethylene
• Oxygen
• Methane
• Demin Water
Products 1. Monoethylene Glycol (MEG)
2. Diethylene Glycol (DEG)
3. Triethylene Glycol (TEG)
4. Heavy Glycols

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Plot Plan
EOEG SCC SCC complex

TF
complex
EOEG SCC complex
Centralized Petchem Unit

CT CT Polymer TF C4 Complex
East West
Future
Sub
FDPE unit LLD PP unit station
Future
Polymer WH

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Plot Plan
Area 100 Area 200

EO Reactor EO
Recovery
and CO2
removal
Area 200
EO Recovery and
CO2 removal
Area 300 LE Area 500

Removable
Glycol Electrical
Purification Substation
Area 400
Glycol Reactor and
Recovery
Area 400
Area 600
Utilities ACC Pit

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Simplified Flow Scheme with Product Yields
SOC EOC
CO2 vent Process Deaerator
vent vent
Ethylene 413.78 446.88
Oxygen 354.3 467.31
Methane 2.54 3.21
Ethylene HP steam 1067.8 562.88
import
MEG
DMW 0 309.32
Oxygen EOU
MEG 740.1 740.07
(unit 3220)
DEG DEG 64.22 64.22
Methane &
TEG 3.77 3.77
EGU
HP steam Heavy Glycols 3.07 3.07
(unit 3230) TEG
import
Condensate 68.54 0
export
DMW Condensate
export CO2 vent 138.21 248.8
Process Vent 2.58 3.29
Waste Heavy Deaerator vent 18.46 8.41

water Glycols
Waste water 798.9 717.2
*All unit in kta

*Based on Case 5 Heat & Material balance

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Simplified Block Flow Diagram

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EO/EG Overview
Unit 100 Unit 300
Unit 200
Unit 400 Unit 500

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3220 – EOU
Thermal Residual Gas
Oxidizer Absorber
CO2
CO2 Stripper
Vent
Absorber Absorber
Residual Gas
Oxygen Compressor
Mixing
Nozzle EO
Stripper
Recycle Gas
Compressor
Light Ends
EO Column
Absorber
EO Quench Stripper
Reactor
Quench Flasher
Water Buffer
Vessel
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3230 – EGU
Glycol Bleed
Concentrator 1
Flasher
Concentrator 2
Glycol
Reactor Dehydrator MEG RecycleColumn
Vacuum
System
Condensate
Vessel
MEG
Column
Concentrator 3
Concentrator 4
DEG TEG
Column Column
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Utilities Consumption Summary
Unit 3220/3230
Power Load (MW) 20.96
HP Steam (T/h) 137.3
LP Steam (T/h)
Service Water (T/h) 20.0 (max)
Potable Water (T/h) 20.0 (max)
Demin Water (T/h) 68.6
Cooling Water (T/h) 22,288.3
Fuel gas (T/h) 0.475
Instrument Air (Nm3/h) 578.0
Plant Air (Nm3/h) 2,000 (max)
HP N2 (Nm3/h) 400 (max)
LP N2 (Nm3/h) 4,162.0 (peak)

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P6A - LINEAR LOW DENSITY POLYETHYLENE
PROCESS (LLDPE)
Prepared:
AHMAD RABBANI BIN AB RASHID
(Executive Process Tech. Polyethylene)
Credit: All rights reserved. No part of this document may be reproduced, stored in a retrieval
1. Shaiful Nizam Iskandar Mad Dali (Polymer Specialist) system or transmitted in any form or by any means (electronic, mechanical,

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Polyethylene

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What is Polymerization ?
Polymerization is the process of connecting monomers together to
become a long chain of molecules (called POLYMER) with the use of a
catalyst/initiator
POLYMERIZATION is an important process for making plastics
Catalyst
speed up rate of a chemical reactions use in
making LLDPE, HDPE, PP
Initiator
A chemical substance decompose by heat
to produce free radicals to initiate Pressure Heat
polymerization, use in making LDPE, PVC

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Polyethylene can be classified as LDPE, LLDPE,
MDPE and HDPE
Properties LDPE LLDPE MDPE HDPE
Molecular structure
morphology
Density (g/cm3) 0.917 – 0.925 0.917 – 0.930 0.930 – 0.940 >0.940

Melting temp oC 115 125 128 134

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What is LLDPE and How it is made?
LLDPE is a Polymer of ethylene. Polymerization is performed with selected catalysts
and under controlled conditions to yield Polymers with low density.
1. Fluidised Bed Gas Phase Process : 3. Slurry Loop Process: Chevron Phillips,
Unipol by Univation, Innovene G by INEOS Innovene S by INEOS
2. Slurry CSTR : MITSUI CX, HOSTALEN by 4. Solution CSTR Process : DOW DOWLEX,
BASELL NOVA SCLAIRTECH

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LLDPE Classification
1. Catalyst type: 4. MWD: Refer catalyst type
Zeigler Natta Metallocene
2. Co-monomer: ESCR
- C4 – Low
- C6 – Moderate
- C8 – High HDP LLDPE

Hard,Estrong, Soft, flexible,
3. Melt Index : hazy clarity
Easy flow
1 kg
Unit : g/10min Low viscosity 1kg
Test load condition: 2.16kg
Hard flow Less volume High volume
190oC 5.0kg
21.6kg High viscosity
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Uses of LLDPE
Film Bottles
Roto-Moulding product
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LLDPE Characteristics
 Parts become more flexible
 In general impact strength is high
 Films has high clarity
 lower melting temperature
 In general environmental stress cracking resistance (ESCR) increases

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PRPC’s LLDPE Polyethylene Plant
TECHNOLOGY
• Fluidised Bed Gas Phase Process
Innovene G by INEOS
CAPACITY • 350 KTPA

- 300 Ziegler-Natta base product
- 50 KTPA Metallocene base product
FEEDSTOCK • Ethylene
• Butene-1 / Hexene-1 (Co-monomer)
- C4 Film 64%
PRODUCT - Metallocene Film 24%
- Roto-Moulding 12%

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Plot Plan
EOEG SCC SCC complex

TF
complex
EOEG SCC complex
Centralized Petchem Unit

CT CT Polymer TF C4 Complex
East West
Future
Sub
FDPE unit LLD PP unit station
Future
Polymer WH

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Process Flow Block Diagram
Hydrogen
Separator
FPU -
Hydrogen Flare Flare KO RFH
Drum
HCD Storage
Clean HC OSBL
Recovery unit
Cyclone
Liquid
Pentane Recycle Gas
FPU - compressor
Separator
Pentane
KO Drum
Butene/Hexene
FPU -
Comonomer Polymerization
Reactor
De-gasser
Ethylene
FPU -
Ethylene
TEAL
TEAL
Liquid Additive (B1)
Main Loop Purge

Compressor Column
Additive
Liquid Additive (S1)
Hopper
Catalyst
Catalyst
Injection Unit
Pellet Blender
Product to OSBL
Extruder Drier
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P7 - POLYPROPYLENE PROCESS (PP)
3305 – PP Spheripol
3315 - PP Spherizone
Prepared:
Rashidah Samsuri & Nazeerah M Puaat
(Executive Process Tech. Polypropylene)

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Polypropylene

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Polypropylene
PP is a thermoplastic addition Polymer of polypropylene. PP is made from polymerization
of propylene gas in presence of a catalyst system.
The main properties that distinguish PP from other

thermoplastic are:
• Low density (0.90 g/cm3) Bulk density: 450 to 600 kg/m3
• High hardness, abrasion resistance and rigidity.
• High melting point, it is used for many microwave
containers.
• Tough without being brittle, it is used for many automotive
parts
• High resistance to cracking even when flexed, it is used in
lots of hinges
• Chemically inert, doesn’t react with acid or bases.
• CHEAP to MAKE, produce more number of parts per kg
weight. ©Petroliam Nasional Berhad (PETRONAS) 2017 25
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Uses of PP
Yarn TWIM Household
Automotive Interior & Exterior

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Example of PP Products
Homo polymer
stiffness
Impact/block copolymer
Random copolymer
Terpolymer
toughness
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PRPC’s Polypropylene Plant
TECHNOLOGY & • 3305 - Slurry Loop • 3315 - Gas Loop
Spheripol by Spherizone by
LICENSOR
LyondellBasell LyondellBasell

- 450 KTPA for Spheripol
- 450 KTPA for Spherizone
• Propylene • Propylene
FEEDSTOCK • Ethylene • Ethylene
• Butene-1 • Butene-1
• Hydrogen • Hydrogen
• Homopolymers
• Homopolymers
• Random Copolymers
• Random Copolymers (C2-)
(C2-)
PRODUCT • Random Copolymers
• Random Copolymers (C4-)
• Random Terpolymers (C2-
(C4-)
/C4-)
• Random
• Heterophasic Impact
Terpolymers (C2-
Copolymers
/C4-)
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PetChem Plot Plan
FUTURE
TTLR
6810-SUB-
STATION
SUB –
301
FUTURE
TANK FARM
ASU EXPANSION
SCC
AREA:
FUTURE
EOEG
EXPANSION POLYMERS
GLYCOL
INA
UTILITIES (UF)
PETCHEM OTHERS
WATER (W)
WATER (E)
COOLING
COOLING
CENTRALIZED TANK
FUTURE UTILITIES
FAR INA
EXPANSION
M LANDMARK:
OSB
6810-SUB-
STATION
SUB –
FDP LLD
302
PP
E PE
FUTURE FUTURE
EXPANSION EXPANSION
MCB
2
PRODUCT WAREHOUSE
*AFTER DELETION OF PHENOLICS & LDPE (JULY 2015)

+ RELOCATION OF PETCHEM PLANT TOWARDS EAST
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PP Plant Plot Plan

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3D Model View
Pellet Unit 3305 –

Homogenization SPH Plant Unit 3315 –
& Storage
SPZ Plant
Common &
Utilities
Extrusion Area
Monomer
Purification
Substation
Rack Room

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Internal
Polypropylene Process Flow
1st Reactor 2nd Reactor
Hydrogen
Hydrogen
Propylene Ethylene
Ethylene Propylene
Butene-1
Gas Phase
Reactor Reactor
Catalyst
Co-Catalyst &
External Donor
Powder Gas or
Polymer
Powder Liquid
Powder Bagging Line
Separation
Only in impact
copolymer
production:
• Two reactors are
used in tandem
Additives Extrusion Pelletizing Homo silos,

bagging
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PP SPZ & SPH Process Section
Area 100 • Catalyst and Cocatalyst storage and metering
Area 200 • Prepolymerization, and Polymerization
Area 300 • Polymer degassing and monomer recovery
Area 400 • High impact copolymerization (SPZ)
Area 500 • Polymer steaming and drying
• Blow down system -Process facilities - Waste oil

Area 600
treating
Area 700 • Monomers treating unit (SPZ)
Area 800 • PP polymer transport, Additivation and Extrusion
Area 900 • PP pellets homogenization and transport.

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Block Flow Diagram
Propylene Area 700 3315 - Area 300
from RCC Common Monomer Purge
and SCU Recovery Gas to
C3 purification 3315 - Area 300 Steam
C3 Storage Cracker
Hydrogen Unit
from H2 3315 - Area 500
Distribution H2 purification Steaming
3315 - Area 300 3315 - Area 300 Drying
HP Degassing LP Degassing
3315 – Area
Butene-1 200
from Tank C4 purification MZCR
Farm 3315 - Area
Polymerization 3315 - Area 400 800
Ethylene Copolymerisation Extruder &
C2 purification Unit
from SCU Additivation
Purge
liquid to
Steam
3315 – Area 3305 – Area 3305 – Area 3315 - Area 900 Cracker
200 300 300 Blending Silos Unit
Prepolymerisa- Monomer LP
Atmer Conveying
Area 100 tion Recovery Degassing Bagging Silos PP
Common
Bagging Product
Oil Cocatalyst to Export
Machine
& Additive Warehouse
Storage/ 3305 – Area
Donor 3305 - Area 300
Metering 300
3315-Area 100 C3 Storage
Catalyst HP Degassing
TEAL Preparation
3305 – Area
900
3305 – Area Blending Silos
500
Steamer & Conveying
3305 – Area
Dryer Bagging Silos
200
Loops Reactor Bagging
Grease
Polymerization Machine
3305-Area 100
3305 – Area Warehouse
Catalyst
800
Catalyst Preparation
Extruder &
Additivation
3305 – Area 200
Prepolymerization
Reactor
Additives /
Peroxide 3315 - Area 600 Waste water
Waste Water To Effluent
Collection Treatment
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Internal
P27 - FLEXI POLYETHYLENE PROCESS (HDPE)
Multimodal HDPE Product
Prepared:
Radin Nashri Bin Radin Yahya Alem Sah
(Executive Process Tech. Polyethylene)
2. Chintakindi Venkata Suryanarayana (Process Specialist)
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Uses of HDPE
Film Bottles Jerry Can & L-Ring Drum
Cap & Closure Black Pipe

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HDPE Characteristics
 Parts become more rigid
 In general impact strength is reduced
 Films become more hazy
 Parts weight can be reduced due to thinner walls
 Higher melting temperature
 In general environmental stress cracking resistance (ESCR) reduces
 Chemical resistance increases

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PRPC’s Flexi Polyethylene Plant
TECHNOLOGY • Hostalen Advanced Cascade Process
(Hostalen ACP) by LyondellBasell, Germany
• A low-pressure slurry process technology

- 300 KTPA Natural
- 100 KTPA Black
• Ethylene
FEEDSTOCK • Butene-1 (Co-monomer)
• Hydrogen
• Hexane
• Multimodal HDPE
PRODUCT - Film 35%
- Blow Molding 35%
- Pipe 25%
- Injection Molding 5%
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Process flow block diagram
Ethylene from SCC
Unit 200
Powder Separation
Hydrogen from SCC
Unit 100
Z501, Z509 Catalyst Catalyst Unit 200
Additives & Carbon
(Drum) Preparation and Powder Drying
Black Master Batch
Dosage
Unit 100 Unit 200 Unit 500

Logistic center at
Polymerization Reactors Powder Extrusion and
Unit 5550
Purification Blending Black
Al-Alkyl (cylinder)
Unit 200
Mother Liquor
Tank
Butene from PTF
Unit 300
Steam Cracker
Butene-1
Complex
Recovery
Unit 300
Unit 400
Hexane (Iso-tank) Hexane Recovery
Hexane/Mother Liquor Tankfarm
& Purification
Wax In Big Bag
Feed Unit 700

Feed Purification
ETP
Utilities from CUF Unit 600
Utilities
Propylene from SCC Waste hexane

Unit 600 Cold hexane to Unit 100-300
disposal
Mechanical Chiller Tempered hexane to Unit 100-200
and Cold/Tempered Cold hexane from Unit 100-300

Hexane Supply Tempered hexane from Unit 100-200

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Package units in HDPE Plant
1. Transport Nitrogen package
There are two packages: one transporting the powder from the FBD to
Powder treatment vessel and the second from Powder treatment vessel to
Intermediate silos.
2. Membrane separation package
3. Pneumatic transport package for transferring pellets to Blending silos

4. Propylene refrigeration package.
5. Ethylene purification package
6. Nitrogen purification package
7. Additives dosage package( Two numbers one for natural one for
black)
8. Extruder package( Two numbers)
9. Powder dryer package
10. Cracker Gas compressor package
11. Recycle gas compressor package
12. Waste gas compressor package

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Thank you

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Crash Course For Basic Process - Petchem Plants

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© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

©Petroliam Nasional Berhad (PETRONAS) 2017 1

Process Unit Familiarization

© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

©Petroliam Nasional Berhad (PETRONAS) 2017 2

©Petroliam Nasional Berhad (PETRONAS) 2017 3

EOEG SCC SCC complex

EOEG SCC complex

Centralized Petchem Unit

©Petroliam Nasional Berhad (PETRONAS) 2017 4

Area 100 Area 200

Area 300 LE Area 500

©Petroliam Nasional Berhad (PETRONAS) 2017 5

Waste Heavy Deaerator vent 18.46 8.41

*All unit in kta

©Petroliam Nasional Berhad (PETRONAS) 2017 6

©Petroliam Nasional Berhad (PETRONAS) 2017 7

©Petroliam Nasional Berhad (PETRONAS) 2017 8

©Petroliam Nasional Berhad (PETRONAS) 2017 11

©Petroliam Nasional Berhad (PETRONAS) 2017 12

©Petroliam Nasional Berhad (PETRONAS) 2017 13

POLYMERIZATION is an important process for making plastics

©Petroliam Nasional Berhad (PETRONAS) 2017 14

Density (g/cm3) 0.917 – 0.925 0.917 – 0.930 0.930 – 0.940 >0.940

©Petroliam Nasional Berhad (PETRONAS) 2017 15

©Petroliam Nasional Berhad (PETRONAS) 2017 16

- C8 – High HDP LLDPE

 Parts become more flexible

 In general impact strength is high

 Films has high clarity

 lower melting temperature

 In general environmental stress cracking resistance (ESCR) increases

©Petroliam Nasional Berhad (PETRONAS) 2017 19

CAPACITY • 350 KTPA

©Petroliam Nasional Berhad (PETRONAS) 2017 20

EOEG SCC SCC complex

EOEG SCC complex

Centralized Petchem Unit

©Petroliam Nasional Berhad (PETRONAS) 2017 21

Main Loop Purge

©Petroliam Nasional Berhad (PETRONAS) 2017 23

©Petroliam Nasional Berhad (PETRONAS) 2017 24

The main properties that distinguish PP from other

Yarn TWIM Household

Automotive Interior & Exterior

©Petroliam Nasional Berhad (PETRONAS) 2017 26

CAPACITY • 900 KTPA

*AFTER DELETION OF PHENOLICS & LDPE (JULY 2015)

©Petroliam Nasional Berhad (PETRONAS) 2017 30

Pellet Unit 3305 –

©Petroliam Nasional Berhad (PETRONAS) 2017 31

Additives Extrusion Pelletizing Homo silos,

Area 200 • Prepolymerization, and Polymerization

Area 300 • Polymer degassing and monomer recovery

Area 400 • High impact copolymerization (SPZ)

Area 500 • Polymer steaming and drying

• Blow down system -Process facilities - Waste oil

Area 700 • Monomers treating unit (SPZ)

Area 800 • PP polymer transport, Additivation and Extrusion

Area 900 • PP pellets homogenization and transport.

©Petroliam Nasional Berhad (PETRONAS) 2017 33

Film Bottles Jerry Can & L-Ring Drum