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Hexane recovery Unit

HEXANE TANK FARM AND CATALYST STORAGE


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.

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