Basically ,the tank farm section comprises the following two major subunits: 1 Hexane tank farm (Unit 410) 2 Al-alkyl / TIC unloading station and storage (Unit 410) The tank farm and catalyst storage contains large amounts of potentially hazardous raw materials.
Mother liquor and hexane receiver Unit 410
For furthur treatment, the following hexane streams from different operational units are collected in the mother liquor tank 41-T-4102 : 1 Hexane from the mother liquor collecting vessel 41-V-2101 via pump 41-P-2101A/B installed in the hexane separation, Unit 210. 2 Hexane from the wax evaporator 41-V-3101 feed line via valve 41XV31102B, Unit 310. 3 Hexane from butene recovery unit (41-C-3201) in unit 320. 4 Hexane from battery limit (OSBL). 5 Hexane from adsorption towers 41-C-3102A/B/C outlet, Unit 310. 6 Hexane from nitrogen scrubber pumps 41-P-2201A/B via valve 41H/Y22203, Unit 220. 7 Hexane from liquid analyzers discharges. 8 Hexane from Al-alkyl and TIC pumps 41-P-4103A/B/4105/4106A/B discharge line (drains), Unit 410. 9 Hexane from Al-alkyl storage tank 41-V-4103/4106 and from TEAL/IPRA cylinder via valve 41HV41403, Unit 410. The contents of mother liquor vessel 41-T-4102 are pumped for Hexane evaporation/distillation; by means of mother liquor feed pump 41-P-4102A/B. After evaporation, distillation and purification (by adsorption), it is fed to the vessel for distilled hexane 41-T-4101. Via hexane feed pump 41-P-4101A/B, the contents of the vessel for distilled hexane 41-T-4101 are fed to the Powder Production. Both vessels are nitrogen-blanketed; a constant blanketing pressure is maintained by means of a pressure controller. The waste gas obtained in both vessels is fed to condensers 41-E-3401 charged with cold hexane, where hexane is trapped. Liquefied hexane goes to 41-V-3401. Non-condensed waste gas passes to waste gas system .
Check lists Hexane tank farm Check the following points: - level of tanks 41-T-4101/41-T-4102 level 41LI41101 of vessel for distilled hexane 41-T-4101 should amount to about 50 60 % - level 41LI41104 of vessel for mother liquor 41-T-4102 should not exceed some 15 25 % else increase distillation throughput - nitrogen blanketing system and pressure control 41PIC41103 / 41PIC41105. - proper function of hexane and mother liquor feed pumps: 41-P-4101 A/B and 41-P-4102 A/B.
Hexane and Al-alkyl unloading station Inspect the unloading station regularly. Control safety systems. Look for any irregularities. Repairs, if necessary, should be completed before the next unloading procedure.
Butene feed tank Unit 410: Butene storage tank receives butene from B.L. The pressure in the vessel is maintained by split control (41PIC41201) by regulating make-up nitrogen or the amount of gas discharged to 41-V-3502. The butene necessary for polymerisation as make-up to the recycle butene stream from 41-C-3201 is sent to the reactors by 41-P-4107A/B.
General This section comprises the following units: - Hexane evaporation, distillation and purification (Unit 310) - Butene recovery (Unit 320) - Wax recovery (Unit 330) - Waste water pretreatment (Unit 340) - Off gas system (Unit 350) The units are primarily designed for the purpose of: - hexane evaporation, distillation, purification and recycling - co-monomer recycling - mother liquor treatment for wax removal - waste material treatment - hydrocarbons rich off gas recovery to OSBL and waste gas treatment
Hexane evaporation, distillation and purification
Unit 310 Hexane coming from the process and from hexane tank farm, which is needed as make-up / or for start-up for the plant, are collected in the mother liquor tank 41-T-4102. The hexane in the mother liquor tank contains polar impurities, light hydrocarbons and wax components, which needs to be separated before it can be sent back to the process as distilled hexane The hexane treatment comprises three unit operations: - Evaporation (41-E-3102) for wax removal sent to wax recovery section - Distillation (41-C-3101) in order to remove light components from hexane - Purification (of hexane from 41-C-3101 bottom) to let polar components being adsorped in towers 41-C-3102A/B Wax are then sent to hexane tank farm for processing The unit includes: 41-C-3101 Hexane Distillation Column 41-C-3102A/B/C Adsorption Tower 41-C-3103A/B Adsorption Tower 41-E-3101 Mother Liquor Preheater 41-E-3102 Hexane Evaporator 41-E-3103 41-V-3102 Condenser 41-E-3104 41-C-3101 Reboiler 41-E-3105 Hexane Cooler 41-E-3106 41-C-3101 Head Condenser 41-E-3107 Regeneration Gas Heater 41-E-3108 Regeneration Condenser 41-P-3101A/B 41-C-3101 Column Feed Pump 41-P-3102A/B 41-C-3101 Column Discharge Pump 41-P-3103A/B 41-C-3101 Column Reflux Pump 41-P-3104 Waste Hexane Pump 41-V-3101 Liquid- Vapour Separator 41-V-3102 Hexane Feed Vessel 41-V-3103 Collecting Vessel 41-V-3104 Water- Hexane Separation Vessel Hexane evaporation The mother liquor from the mother liquor tank 41-T-4102 pumped through 41-P-4102A/B and from the mother liquor collecting vessel 41-V-2101 through 41-P-2101A/B are sent to the distillation unit, where light hydrocarbons and wax components are separated. Mother liquor is pumped with the mother liquor feed pump 41-P-4102A/B via flow control 41FIC31101 to the pre-heater 41-E-3101 and then transferred to separator 41-V-3101. Wax is enriched in the evaporator 41-E-3102 which is heated up by medium pressure steam. The mother liquor is partly evaporated. The heavy components (wax components) are enriched in the liquid phase and are continuously discharged to the wax recovery unit. The lighter components are discharged to the separator vessel 41-V-3101. The boiling rate is controlled by the level in 41-V-3101 (41LIC31101). The excess amount of vapour is condensed in the condenser 41-E-3103. The light components (non condensable components), which can not be condensed in 41-E-3103, which is cooled by jacket water, is sent to the adsorption towers 41-C-3103A/B and finally to the butene recovery unit for further treatment. Venting to 41-C-3201 is performed via pressure controller 41PIC31103 mounted on 41-C-3101. The heavy components (mainly hexane) in the vapour leaving 41-V-3101 are collected in the hexane feed vessel 41-V-3102 and pumped by the centrifugal feed pump 41P3101A/B to the distillation column 41-T-3101 where light ends such as butene, ethylene and ethane are separated from hexane. Hexane distillation The hexane column 41-C-3101 is equipped with reboiler 41-E-3104 heated by means of hexane vapour from 41-V-3101. The heat given by the reboiler is controlled via the level in reflux-collecting vessel 41-V-3103 (41LIC31105). The light ends are withdrawn from the top of 41-T-3101 and are partly condensed in the head condenser 41-E-3106 which is cooled by jacket water. The condensate is collected in the collecting vessel 41-V-3103 which provides the reflux for 41-C-3101. The reflux is pumped through flow control 41-FIC-31102 back to 41-C-3101 by means of pump 41-P-3103A/B. Thus pressure is controlled by venting non-condensables from 41-E-3106 or by nitrogen injection system. The distillate is withdrawn from the collecting vessel by the level controller 41LIC31104 if water is collected at the bottom of the collecting vessel. Otherwise the valve 41LV31104 is closed. The water distillate is dumped to the waste water pre-treatment unit. The column pressure is controlled by split range controller 41PIC31103 and the light hydrocarbons are sent to butene recovery unit through adsorption town 41-C-3103A/B. Hexane purification The continuous hexane flow from the distillation is purified in the three adsorption towers 41-C-3102A/B/C. The towers are operated alternately and subjected to regeneration at certain intervals. Adsorptive purification of hexane is effected by means of improved amorphous alumino-silicate gel in the form of hard beads (KC Pearls), which removes dissolved impurities formed during polymerization as well as H2O and O2. This process takes place in three adsorption towers 41-C-3102A/B/C through which hexane passes from bottom to top. The non-condensables from 41-E-3103 and 41-E-3106 are sent to butene recovery units through 41-C-3103A/B, operated alternately and subjected to regeneration at certain intervals. The purified hexane from the distillation leaving the adsorption columns overhead is transferred to the vessel for distilled hexane 41-T-4101 of Unit 410.
As the purification efficiency of the adsorption tower decreases ,the respective adsorption tower is subjected to regeneration. For this purpose, hexane contained in the adsorption tower is drained into separating vessel 41-V-3401 of the waste water pretreatment. The tower is then heated with steam, which is electrically overheated by gas heater 41-E-3107. The outlet temperature is monitored and shall not be lower than 250C. The steam flow rate is set by a controller for a period of app. 100 hours. Most of the catalyst poisons are removed from the adsorption tower in this regeneration step and are condensed in regeneration condenser 41-E-3108 and sent to 41-V-3104. In separation vessel 41-V-3104 water and hexane are separated. The hexane is rich in impurities. It is pumped by 41-P-3104 to waste hexane tank 41-T-4109 and then unloaded by 41-P-4109 into tanker for further treatment. In the second phase of regeneration the adsorption tower is treated with an air/nitrogen mixture. In this step remaining catalyst poisons are oxidatively degraded. This exothermic reaction creates a remarkable temperature increase which may reach >250C. In case the outlet CO/CO2 content or temperature increases over a preset value. the air feed is automatically interrupted and a further steaming has to be performed. Finally, in the third step, the tower is cooled down by nitrogen and is flushed with hexane. The plant equipment steam / nitrogen / air heater 41-E-3107, nitrogen/steam and air flow controllers, regeneration condenser 41-E-3108 as well as separation vessel 41-V-3104 and the waste gas monitoring system are also used for regeneration of the adsorption towers 41-C-3103A/B.
Butene recovery Unit 320 In the scrubbing tower 41-C-3201 butene-rich waste gases from different sources as well as very pure hexane vapors are treated to recover butene/hexane and feed them back to the process. Vent gasses from the polymerization section (decanter feed vessel 41-V-1301) and noncondensables from vent gas condenser 41-E-1303 and non condensed gases from hexane distillation through 41-C-3103A/B are fed to vent gas cooler 41-E-3203, which is cooled by cold hexane. From vent gas cooler 41-E-3203 condensed liquid fraction is fed to scrubbing tower 41-C-3201 at the bottom. Non condensed gases from vent gas cooler 41-E-3203 are fed to scrubbing tower 41-C-3201 as main feed. Feed gas is treated in counter current flow with pure hexane fed from the top of the scrubbing tower 41-C-3201. For this purpose, distilled hexane from the distilled hexane tank 41-T-4101 is fed through feed pumps 41-P-4101 A/B to the top of scrubbing tower 41-C-3201 after being cooled in the hexane cooler 41-E-3202 with cold hexane. The butene-enriched hexane is collected in the bottom of the column. The off-gas stream leaving the scrubber on top is nearly free of butene and contains mainly ethylene, ethane, hydrogen and only little quantity of hexane. It is sent to cracker gas compressor 41-PK-3501. The bottom product of scrubbing tower 41-C-3201 is discharged to first reactor 41-R-1201,second reactor 41-R-1202 via 41LIC32101 which acts on 41FIC12112 (feed controller for 41-R-1201), 41FIC12212 (feed controller for 41-R-1202). Optionally the bottom product can be discharged to the mother liquor tank 41-T-4102 as well (via flow orifice 41FO32105).
Wax recovery Unit 330 During hexane distillation wax components will be enriched during the partial evaporation of mother liquor in the evaporator 41-E-3102. The liquid phase (wax / hexane solution) in the evaporator 41-E-3102 is continuously discharged by the wax treatment feed pump 41-P-3301 (controlled by 41FIC33101) to the wax flash vessel 41-V-3301 through the wax evaporator 41-E-3301. The wax evaporator 41-E-3301 is heated with medium pressure steam. The pump housing of wax treatment feed pump 41-P-3301 and the discharge lines of 41-P-3301 are heated with low pressure steam as well as the outlet line of wax evaporator 41-E-3301 to the wax flash vessel 41-V-3301 to prevent blocking of the pumps respectively of the lines. Hexane is evaporated in 41-E-3301. The mixture of hexane vapour and wax is sent to the flash vessel 41-V-3301. The temperature in the flash vessel 41-V-3301 is controlled by 41TIC33101 which controls the pressure of medium pressure steam used for heating up the hexane / wax mixture in the wax evaporator 41-E-3301. The pressure in the flash vessel 41-V-3301 is controlled by 41PIC33102 acting on nitrogen. The flash vessel 41-V-3301, which is jacketed, is heated with medium pressure steam. The wax is continuously withdrawn by the wax discharge pump 41-P-3302 via 41LIC33101. For removal of residue content of hexane in the wax low pressure steam is injected in the flash vessel. Steam also is used to deactivate the co-catalyst. The wax is discharged to movable bins where it cools / freezes at ambient condition or sent to OSBL for further treatment. The hexane vapour and steam are withdrawn at the top of the flash vessel 41-V-3301and are condensed in the condenser 41-E-3302, which is cooled with jacket water. As the steam contains chloride acid from the deactivation of the co-catalyst, slightly caustic aqueous water from the separation drum 41-V-3401 in the waste water pre-treatment unit is added In order to neutralise. The hexane (liquid) / water and vapour are sent from the condenser 41-E-3302 to the waste water pre-treatment unit (41-V-3401) and finally to mother liquor tank 41-T-4102. The unit includes the following equipment: 41-J-3301 Steam Injector 41-E-3301 Wax Evaporator 41-V-3301 Wax Flash Vessel 41-P-3301 Wax Treatment Feed Pump 41-P-3302 Wax Discharge Pump
Drying Unit 210 / 240 After mechanical separation of the hexane and HDPE powder in decanter centrifuges 41-S-2101 A/B/C operated in parallel, the screw conveyors 41-SF-2101 A / B / C supply the hexane-moist HDPE powder to a 2-stage fluid bed drier 41-DR-2201 for thermal separation of the dispersing agent. Here, the residual hexane contained in the HDPE powder is evaporated by means of hot nitrogen to a residual content < 1%(wt) By means of screw conveyors 41-SF-2101 A / B / C the hexane-moist HDPE powder is fed to the first drier chamber, where the product is fluidized with hot nitrogen causing to evaporate the major part of the residual hexane. In the second chamber the rest of the hexane is separated and the powder heated up to ~102C. The drier is equipped with internal heating surfaces charged with low pressure steam of 0.7 kg/cm2g supplying the heat required for drying. The dried HDPE powder is passed through vibrating screen 41-S-2203 to separate oversize and then fed to rotary feeder 41-ME-2205 from where it is pneumatically (nitrogen) conveyed to the powder purification. The nitrogen used for powder drying is circulated. The hexane-containing nitrogen stream leaving the drier passes through the N2 scrubbing tower 41-C-2201 to remove the hexane before being used again in the drier. The nitrogen leaving the N2 scrubbing tower with a reduced hexane content is compressed by fan 41-K-2201A/B heated in nitrogen heater 41-E-2201 and fed back to the second chamber of the fluid bed drier for drying and fluidizing the HDPE powder. Flow of nitrogen through the drier is controlled by control valve at suction side of 41-K-2201A/B. In the shell side of 41-E-2201 excess hexane vapors from the evaporator 41-E-3102 of the hexane distillation are used for heating the N2 circuit of the fluid bed drier 41-DR-2201 up to the required value of approximately 102 C.The condensed hexane is returned to feed vessel 41-V-3102 of the hexane distillation.
Drying nitrogen circuit Hexane contained in the moist HDPE powder leaving the decanter centrifuge is evaporated in the drier and absorbed by the drier nitrogen. In the N2 scrubbing tower 41-C-2201 hexane is removed by scrubbing in countercurrent with cold hexane and recovered as mother liquor. The nitrogen from the N2 scrubber is conveyed to the nitrogen heater 41-E-2201 by means of the recycle gas blower 41-K-2201A/B, where it is heated to the drying temperature required (102 C). The nitrogen is then transferred to the second chamber of the drier. Here, it absorbs the hexane remaining from the first stage to a level of 1% (wt). After passing the second stage the nitrogen passes through cyclone separator 41-S-2202 where entrained fines are separated and returned to the drier outlet by rotary feeder (41-ME-2202). The cleaned nitrogen is then compressed by 41-K-2202A/B and transferred to the first drier stage. Here it will absorb most of the hexane entrained in the feed. The nitrogen leaving the first stage is passing cyclone separator 41-S-2201 and is subsequently returned to the N2 scrubbing tower 41-C-2201. Fines separated in the cyclone are transferred via rotary feeder (41-ME-2201) to the drier second stage. The nitrogen leaves the head of the scrubbing tower in purified condition and is compressed by fan 41-K-2201A/B and flow controlled transferred to the second stage of the drier. The suction side of fan 41-K-2201A/B is pressure-controlled, i.e. nitrogen is discharged at overpressure, and at low pressure make-up nitrogen is fed in (split range loop). In any case vacuum condition has to be avoided. This is achieved by vacuum relief valve 41PSV22201 located on line coming from 41-E-2401 to scrubbing tower. For vacuum relief, nitrogen from 41-E-2401outlet line is used. The nitrogen discharged is fed to the off-gas system via waste gas header. The dip pot 41-V-3401 serves as safety installation against overpressure. For safety reasons, analyzers monitor the circulated drying nitrogen. Online analyzers measure the water content (dew point) in the pressurized line to the scrubber and trigger an alarm if the limit values are reached. In order to measure the oxygen content, a small stream is sampled on the pressure side of the fan 41-K-2201A/B for the drying nitrogen circuit and analyzed in the analyzer room. An alarm is triggered in case the oxygen content exceeds the limit value. N2 scrubbing tower:
The hexane-containing nitrogen from drier 41-DR-2201 is subjected to scrubbing in counter-current with cold hexane in the N2 scrubbing tower 41-C-2201, i.e. by low temperature condensation. The hexane-lean nitrogen leaving the head of the scrubbing tower is fed back to drier 41-DR-2201 after having been heated in the nitrogen heater 41-E-2201. The hexane removed from the nitrogen by condensation may contain small portions of HDPE-fines. Therefore, by means of the scrubber circulation pump 41-P-2201A/B via level controller a side stream can be sent to the mother liquor collecting vessel 41-V-2101 or mother liquor tank (41-T-4102). Hexane from the bottom of the scrubbing tower is pumped through the hexane cooler 41-E-2206 and post-cooler 41-E2207 by means of scrubber circulation pump 41-P-2201A/B and injected into the head of the scrubbing tower in countercurrent to the nitrogen. The hexane flow rate is controlled. In addition, a small not cooled portion of hexane from the bottom of the scrubbing tower is used for preliminary scrubbing of the nitrogen entering the scrubbing tower. The hexane required for low-temperature condensation is cooled in the hexane cooler 41-E-2206 cooled by jacket water followed by post cooler 41-E-2207, coolant being tempered hexane At a temperature of approx. 40 C, the nitrogen leaves the head of the scrubbing tower.
Discharge and conveying of HDPE powder From the weir at the outlet of the fluid bed drier 41-DR-2201, the HDPE powder is transferred to the vibration screen 41-S-2203. Here, coarse-grained material and agglomerates are removed and collected in buffer vessel 41-V-2205. The HDPE powder is pneumatically (by nitrogen) conveyed for powder purification. Nitrogen circulated in a closed circuit is used for pneumatic conveying. Pneumatic powder transport system 41-PK-2205
Unit 220 The nitrogen used to transfer the HDPE powder from the drier to the powder purification is circulated in a closed system. The pressure is kept by a split range on nitrogen make-up and connection to off gas system (41PIC22305). The transport nitrogen is compressed in compressor 41-K-2203A/B, cooled in 41-E-2204 by jacket water and supplied to rotary feeder 41-ME-2205 by which the HDPE powder is pneumatically conveyed to the powder purification (Unit 230). 41-G-2302 separates HDPE powder from the transport nitrogen. Nitrogen is then passed through 41-G-2202 and cooled in transport nitrogen cooler 41-E-2203. The oxygen, water and hexane contents of the recycled nitrogen are monitored. The oxygen, water and hexane content are determined by separate analyzers in the analyzer room in Unit 120. Powder purification
Unit 230 Powder treatment vessel
In order to improve the quality of the HDPE, the powder is to be subjected to a post-treatment for further reduction of the hexane level and to destroy catalyst residues. The HDPE powder leaving fluid bed drier 41-DR-2201 is pneumatically transferred to the powder purification stage as described above. The hot powder is blown into filter 41-G-2302 which removes fine particles and Nitrogen is fed back to the transport nitrogen circuit. Via the pressure-proof rotary feeder 41-ME-2301, the HDPE powder is fed to the powder treatment vessel 41-V-2301. The rotary feeder serves as gas lock. The nitrogen used for flushing the bearings of the inlet rotary feeders serves as sealing gas. Additional nitrogen can be added manually. The powder passes the vessel in a plug flow with a residence time of ~one hour. In a counter-current flow, nitrogen is send through the bed to remove the solvent which is still present in the powder. The inlet temperature should be greater than 100C to avoid condensation of slightly superheated steam injected to the nitrogen By this steam catalyst residues are destroyed. This destruction leads to the formation of hydrochloric acid which will be removed from the vessel by nitrogen which is injected in the lower part of the bed. Steam and nitrogen feed are flow controlled. The filling level of the powder treatment vessel is measured by a contact-free radioactive level meter. In order to maintain the plug flow in the vessel the speed rates of the discharge rotary feeders 41-ME-2302 and 41-ME-2303 are controlled depending on the powder level. Powder discharge and transport
The purified HDPE powder is discharged by pressure-proof rotary feeder 41-ME-2302 and transferred to Rotary feeder 41-ME-2303 where it is pneumatically conveyed to the powder silos of Unit 240 or directly to the pelletising units (Units 510). For pneumatic conveying, nitrogen from transport nitrogen circuit 1 (41-PK-2401) of Unit 240 is used. Rotary feeders 41-ME-2302 and 41-ME-2303 serve also as gas lock between powder treatment vessel and the conveying system. Treatment of waste gas from powder purification
The waste gas from 41-V-2301, consisting of steam / nitrogen mixture enriched with hexane and HDPE dust, is transferred to the Membrane Separation Unit 41-PK-2301 via nitrogen filters 41-G-2301 and 41-G-2304. The gas leaving the filters 41-G-2301 and 41-G-2304, contains traces of HCl. Therefore diluted NaOH (20% by weight) is added to a stream water for neutralization purpose in the Membrane Separation Unit 41-PK-2301. For hexane separation, the uncondensed gas phase consisting of hexane and nitrogen is fed to the membrane separation unit 41-PK-2301. The dried nitrogen leaving the membrane separation unit 41-PK-2301, is heated in the nitrogen heater 41-E-2301 and is then reused as stripping gas in 41-V-2301. The nitrogen is heated with low pressure steam. A temperature controller sets the temperature at the gas outlet. Pressure and flow rate of the nitrogen in the circuit is maintained by the liquid ring compressor of the membrane separation unit. Variations in flow are compensated by the pressure controller of the liquid ring compressor on the recycle line. In the case of overpressure, excess nitrogen is discharged via a pressure-controller. The condensate from the membrane separation unit 41-PK-2301 contains hexane and water: hexane rich drain is transferred to separation vessel 41-V-3401, while waste water to the waste water treatment (Unit 340). Pneumatic powder transport system 41-PK-2401
Unit 240 The nitrogen used to convey the HDPE powder from the powder purification Unit 230 to the powder silos 41-V-2401A/B or 41-V-5101 (SYSTEM 1), from the powder silos to the pelletizing powder bin 41-V-5101 (SYSTEM 2); one powder silos bottom cone fluidization unit (SYSTEM 3) is circulated in a closed system. Three compressors (41-K-2402A/B/C) have been provided to transport the powder from the Powder Treatment Vessel to the pelletizing powder bin 41-V-5101; this configuration is based on the assumption to provide one compressor (41-K-2402A) dedicated to transport the powder from 41-V-2301 to the powder silos 41-V-2401A/B or directly to the pelletizing powder bin 41-V-5101 (SYSTEM 1) and one compressor (41-K-2402B) to transport the powder to the pelletizing powder bin (SYSTEM 2); compressor 41-K-2402C has been considered as spare for both transports. Three coolers (41-E-2401, 41-E-2402A/B) are provided in order to avoid products heating and to remove the blower compressions heat (no product temperature increasing according to a product feeding temperature of 100 C). A fluidization unit (SYSTEM 3) has been designed to fluidize the silos bottom cone. Nitrogen pressure control shall be realized with a pressure control by means of a dedicated make up and discharge valves. Compressors 41-K-2402 B / C supply transport nitrogen for conveying a max. of 42 t/h powder from powder silos 41-V-2401 A/B to the pelletising unit Unit 510 via Rotary feeders 41-ME-2401A/B. SYSTEM 1 41-ME-2303 discharges the polymer from the rotary feeder 41-ME-2302 in the pneumatic haulage; the powder is then sent to the powder storage silos 41-V-2401A/B, while the gas is cleaned in the silos top filter 41-G-2401A/B and recycled from silos top to cooler 41-E-2401 through filter 41-G-2402, and finally back to blowers suction. As alternative, a diverter valve is provided in order to feed directly the pelletizing powder bin 41-V-5101 from the PTV, bypassing the powder storage silos. The leak gas from the conveying station 41-ME-2303 is cleaned by 41-G-2303 (directly installed on the rotary feeder) and recycled to the return gas circuit. SYSTEM 2 Polymer is discharged from the silos 41-V-2401A/B by the rotary feeders 41-ME-2401A (silo A) and 41-ME-2401B (silo B) in the pneumatic haulage; the powder is then sent to the pelletizing powder bin , while the gas is cleaned in the silos top filter 41-G_5101 and recycled from silos top to blowers suction. FLUIDIZATION UNIT (SYSTEM 3) The HDPE powder that is stored in the 41-V-2401A/B silos has to be fluidized to avoid arching and because of that, problems with the discharge of the powder out of the silos. Therefore nitrogen is fed under flow rate control to the bottom cone of the powder storage silos. The transport nitrogen, the leaking nitrogen from flushing the Rotary feeder bearings as well as the nitrogen from filter cleaning is fed to the suction side of transport nitrogen compressors 41-K-2402 A / B / C.Hexane and oxygen content of the conveying nitrogen are determined online. Powder Storage
Unit 240 Powder is supplied to the powder silos at random, i.e. there is no fixed charging sequence. Furthermore the silos serve as buffer during shut down of the pelletizing lines and as a buffer while operating compounders. Powder silos 41-V-2401A/B in Unit 240 are operated as buffer silos during normal operation, during startup and shutdown of polymerization and for taking up the so-called transition product obtained when changing over to a different product grade. From the powder silos, the HDPE powder can be supplied to the product pelletizing line (Unit 510) at different discharge rates based on the speed of the rotary feeder.
Powder Separation and mother liquor system Unit 210 Centrifugal Pumps 41-P-1302A/B transfers the polyethylene product to the decanter centrifuges 41-S-2101A / B / C operated in parallel. In the centrifuges the major portion of the hexane is separated from the solid polyethylene by means of centrifuging. After decanting, the residual moisture content of the polyethylene is approx. 35% (as compared to the dry substance). The hexane-moist HDPE powder is discharged from the decanter centrifuges and reaches the screw conveyors 41-SF-2101A / B / C by gravity, which transfer the moist product to fluid bed drier 41-DR-2201. The screw conveyors serve to convey HDPE powder to fluid bed drier 41-DR-2201 and to form a product plug acting as a seal towards the hot nitrogen atmosphere of the drier. The hexane (mother liquor) separated reaches the mother liquor collecting vessel 41-V-2101 by gravity, from where mother liquor pumps 41-P-2101A/B recycle the mother liquor to the reactors depending on the recipe. A part-stream is withdrawn from mother liquor collecting vessel 41-V-2101 via a level control device for being treated in the hexane purification. It can be fed to mother liquor tank 41-T-4102 in Unit 410 which serves as a buffer and then to the hexane purification (Unit 310) or directly to the preheater 41-E-3101 of the hexane purification. The distilled hexane is collected in the tank for distilled hexane 41-T-4101 in Unit 410 and is supplied to the polymerization process as fresh hexane.