Volume 1 - General - V1-CH03-Basis of Design

OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°
Technologies RAPID L20 INE PRO DES 3200 0001

LICENSOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
350 kta LLDPE PLANT 61070F 3200 JDS - 002 0 1
PROJECT PROCEDURE
BASIS OF DESIGN
VOLUME 1
CHAPTER 3
BASIS OF DESIGN
0 05-NOV-12 ISSUE FOR PDP M. GUEYE F. BETTON F. BETTON

DATE WRITTEN BY CHECKED BY APPROVED BY
REV. STATUS – REVISION MEMO
DD-MMM-YY (name & visa) (name & visa) (name & visa)
Document revisions.
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and
images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial
Services UK Limited.
OWNER REFERENCE

350 kta LLDPE PLANT 61070F 3200 JSD - 002 0 2
BASIS OF DESIGN
CONTENTS
1. PLANT DEFINITION
1.1 FUNCTIONS OF UNITS
2. PLANT CAPACITY, OPERATING FACTOR AND PRODUCT MIX
2.1 PLANT CAPACITY AND OPERATING FACTOR
2.2 DESIGN GRADE SLATE
3. DEFINITION OF TERMS
3.1 TEMPERATURE AND PRESSURE
3.2 FLOW
4. UTILITIES & RAW MATERIAL SPECIFICATIONS
4.1 UTILITIES & RAW MATERIAL
4.2 ELECTRICITY
5. SPECIFICATION OF CHEMICALS
5.1 GENERAL
5.2 TEAL
5.3 LIQUID ADDITIVE
5.4 PRODUCT ADDITIVES
5.5 CATALYSTS
5.6 MISCELLANEOUS CHEMICALS
6. PRODUCT CHARACTERISTICS
7. ENVIRONMENTAL CONDITIONS
7.1 CLIMATIC CHARACTERISTICS
7.2 TEMPERATURE
7.3 HUMIDITY
7.4 WIND DIRECTION AND VELOCITY
7.5 AIR PRESSURE
7.6 SEISMIC DESIGN
7.7 RAINFALL
7.8 SNOWFALL
7.9 FROZEN SOIL DEPTH
7.10 WINTERISATION
7.11 PERSONNEL PROTECTION
8. SPACING OF EQUIPMENT
9. ENVIRONMENT REQUIREMENT
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and
the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the
express permission of INEOS Commercial Services UK Limited.
OWNER REFERENCE

BASIS OF DESIGN
ATTACHMENTS
ATTACHMENT A RAW MATERIAL CONDITIONS AT LLPDE BATTERY LIMIT
ATTACHMENT B RAW MATERIAL COMPOSITIONS AT LLPDE BATTERY LIMIT AND

CORE PLANT
ATTACHMENT C UTILITY CONDITIONS AT LLPDE BATTERY LIMIT & AT USERS
ATTACHMENT D UTILITY COMPOSITIONS AT LLPDE LIMIT
ATTACHMENT E PLOT LAYOUT SPACING OF EQUIPMENT RP44-7
OWNER REFERENCE

BASIS OF DESIGN
1. PLANT DEFINITION
1.1 FUNCTIONS OF UNITS
Feedstock Preparation Unit
The raw materials, ethylene, butene-1, hexene-1, octene-1, pentane and hydrogen are
metered, treated in order to achieve required reaction quality and transferred to
the polymerisation unit. All feeds are fed to the core plant by pipeline. Nitrogen is treated
to generate the various required quality levels.
Catalyst Feeding
The Ziegler catalyst or the Metallocene catalyst (one transfer and one injection system per
catalyst type) is transferred batchwise via tote bins to the injection system. Continuous
Catalyst Injection process is used.
Polymerisation
Ethylene, comonomer (butene-1, hexene-1, octene-1), hydrogen, pentane, TEAl, liquid

additives and catalyst are introduced into the fluidised bed reactor where the continuous
polymerisation reaction takes place.
The fluidising process gas is circulated in a reaction loop where entrained powder is
removed by cyclones, the gas cooled, condensate separated and the gas compressed and
recycled to the reactor. The condensate is pumped back to the reactor through injection
nozzles.
Reagents (TEAI and liquid additives S1 and B1) are directly injected into reactor from
dedicated containers.
Powder degassing and Powder conveying
Polymer product (powder) is removed by lateral withdrawal systems. Residual

hydrocarbons are stripped from the powder in multistage degassing process and residual
catalyst is deactivated before the powder is directed to the Extrusion feeding and
Pelletisation unit.
Pentane and comonomer extracted from the powder are recovered and recycled to
the reaction loop. Nitrogen from degasser outlet gas is separated from heavy hydrocarbons
and recycled to the degasser.
The capacity of the purge column provides up to 4h storage at powder design rate
to accommodate stoppages in the upstream or downstream sections of the plant.
OWNER REFERENCE

BASIS OF DESIGN
Extrusion feeding and Pelletisation
Powder from the Polymerisation and pure powder additives, supplied from Flexible
Intermediate Bulk Containers (FIBCs 1 and 2 m3), are fed into the extruder via an extruder
feed screw. A facility for addition of powder from 25 kgs bags is also provided with
each FIBC unloading station. The product pellets are carried away and cooled by a pellet
water circuit, dried, screened, metered and conveyed via a pneumatic air system to the
Pellet conveying and Blending unit.
Pellet conveying and Blending
Pellets from the Extrusion feeding and Pelletisation are transferred to one of 2 continuous
pellet blenders. Under level control the pellets are simultaneously transferred to OSBL via
an elutriation system to ensure pellet quality in the final storage bins. In normal operation,
only one pellet blender is required with a second blender being used for transitions.
One additional pellet blender is installed for flexibility.
Liquid recovery Unit
Liquid purges during normal and transition operation with Ziegler grades are distilled in
the LRU column in order to remove traces of TEAL prior sending the purge stream to
OSBL. TEAL and heavy components are recycled to the main loop. The LRU may be
bypassed if necessary.
Utilities
Vents & Flare

It consists of the facilities for primary gaseous effluent treatment, including the flare drum.
Utilities battery limits

It consists of metering and distribution of steam, steam condensate recovery, cooling water,
other waters (demineralised and service), instrument air and standard quality nitrogen.
Utilities required for common Ethylene and Hydrogen treatment are segregated from
LLDPE networks.
Nitrogen
Nitrogen is purified and letdown to generate the various required pressure levels of
nitrogen.
Primary aqueous treatment facilities

The water effluents, potentially containing powder, pellets and extruder start-up materials
are recovered and treated if required, before being sent OSBL to oily water or
contaminated rain water system.
OWNER REFERENCE

BASIS OF DESIGN
1.2 SCOPE OF THE PROCESS DESIGN PACKAGE
The Process Block Diagram, in chapter 4 of this volume, shows the scope of the LLDPE
plant and indicates the ISBL and OSBL facilities which are necessary to support it.
This PDP defines the units of the Gas Phase LLDPE Plant, which are described in general
terms in Section 1.1 above.
The Units for the Plant are:
Feedstock Preparation Unit (200)
Catalyst Injection Unit (300)
Polymerisation Unit (400)
Degassing and recycle Unit (600)
Vent Recovery Unit (600)
Liquid Recovery Unit (700)
Additive and Pelletising Unit (800)
Pellet Blending Unit (800)
Reagents and Utilities Unit, including:

• Utilities distribution, including (100):
o Nitrogen letdown and distribution,
o Steam distribution,
o Steam condensate recovery,
o Cooling water distribution,
o Other waters distribution (demineralised, service, potable),
o Instrument air distribution,
o Plant air distribution,
o Fuel gas distribution.
• Flare KO Drum and Flare Header (100)
• Process vents (100)
• Nitrogen treatment (200),
• Waste water treatment (100).
OWNER REFERENCE

BASIS OF DESIGN
2. PLANT CAPACITY, OPERATING FACTOR AND PRODUCT MIX
2.1 PLANT CAPACITY AND OPERATING FACTOR
The gas phase polyethylene plant will be designed to produce 350 KTPA of low and high
density polyethylene using Ziegler or Metallocene catalysts with C6 or C8 comonomers.
The plant will also have the capability to produce LL and HD polyethylene using Ziegler catalyst
with butene comonomer.
OWNER REFERENCE

BASIS OF DESIGN
2.2 DESIGN GRADE SLATE
The design grades for the Polymerisation loop are:
Innovene PEG Rate kT/a

Segment Comonomer Catalyst
Grade Name (t/h) (1)
LL6209AA Film LL C6 Hexene-1 Ziegler 44 88
PF6212AA Film mLL C6 Hexene-1 Metallocene 44 70
HD3850UA Rotomolding Hexene-1 Ziegler 44 17
LL8409AA Film LL C8 Octene-1 Ziegler 44 -
PF8212AA Film mLL C8 Octene-1 Metallocene 40 -
HD8850UA Rotomolding Octene-1 Ziegler 44 -
TOTAL 350
Note 1: Used for additive storage sizing only.
OWNER REFERENCE

BASIS OF DESIGN
The plant shall have the capability of producing the following Butene-1 grades.
Innovene PEG Rate

Segment Comonomer Catalyst
Grade Name (t/h)
LL0209KJ Film LL C4 Butene-1 Ziegler 44
LL0220AA Film LL C4 Butene-1 Ziegler 44
HD3840UA Rotomolding Butene-1 Ziegler 44
OWNER REFERENCE

BASIS OF DESIGN
3. DEFINITION OF TERMS
3.1 TEMPERATURE AND PRESSURE
3.1.1 Design Temperature or Pressure
The maximum temperature or pressure that the system could be subjected to reach under
any emergency condition. This forms the basis for the mechanical design (e.g. relief valve
setting).
3.1.2 Maximum Temperature or Pressure
The maximum temperature or pressure that the system could attain under normal operating
conditions (used to determine limits of instrument operation and equipment sizing where
appropriate).
3.1.3 Normal Temperature and Pressure
The normal temperature or pressure at which the system operates under steady state
conditions.
3.1.4 Minimum Temperature and Pressure
The minimum temperature or pressure that the system might attain under any conditions. This
is also used as a basis for the mechanical design where applicable (e.g. vacuum conditions, or
Joule-Thomson temperature effects).
3.2 FLOW
3.2.1 Maximum Flow
The maximum available flow on either a short term or continuous basis. If the former is entered
the acceptable duration should be indicated.
3.2.2 Normal Flow

The normal process flow corresponding to the grade with the highest continuous requirements.
3.2.3 Minimum Flow
The minimum flow required on a continuous basis (used for process design).
OWNER REFERENCE

BASIS OF DESIGN
4. UTILITIES & RAW MATERIAL SPECIFICATIONS
4.1 UTILITIES & RAW MATERIAL
This section contains information defining the raw materials required by the process which are
available to the Plant from the Licensee’s facilities and is the basis upon which the PDP is
prepared.
Refer to:
Attachment A: Raw material conditions at LLDPE battery limit
Attachment B: Raw material compositions at LLDPE battery limit and core plant
Attachment C: Utility conditions at LLDPE battery limit & at users.
Attachment D: Utility compositions at LLDPE battery limit
NB: LLDPE battery limit = PDP Scope
4.2 ELECTRICITY
The power supply conditions at battery limits are assumed as follows:
Nominal voltage Motor size range Phase Frequency

11 or 33 kV Medium Voltage Motors 3 50 Hz
6.6 kV P > 185 kW 3 50 Hz
400 V P ≤ 185 kW 3 50 Hz
230 V AC Lighting, plugs and others 1+N 50 Hz
The requirement for a high integrity electrical supply, with “voltage dip” protection should be
noted. A DC back-up electrical supply is not required for the plant.
An uninterruptible power supply of 30 minutes duration must be specified for the DCS.
Monitoring, control and safety instrumented systems and field instrument equipment must be
powered via an uninterrupted power source (UPS) continuously operating in on-line mode. The
UPS must provide the battery back-up over a period of time sufficient for accident-free
shutdown of a facility.
There is no requirement for battery power back-up of motors.
OWNER REFERENCE

BASIS OF DESIGN
5. SPECIFICATION OF CHEMICALS
5.1 GENERAL
The catalyst reagents required by the Innovene G process are shown below.
Name Chemical Name Generic Description
TEAl Tri-Ethyl-Aluminium Cocatalyst
Liquid additive B1 (n-BuCl) Butylchloride Catalyst activity booster
Liquid additive S1 (Stadis) Antistatic agent
5.2 TEAl
INEOS Technologies uses and recommends Tri-Ethyl-Aluminium that meets the following
specification:
Al content greater than 22 % wt.
N-butyl group content less than 7.0 % wt.
Hydride content less than 0.6 % wt.
TEAl used in the design is undiluted.
5.3 LIQUID ADDITIVE
5.3.1 Liquid additive : B1
n-BuCl (B1): ButylChloride (pure liquid)
5.3.2 Liquid additive : S1
Stadis (S1): INNOSPEC additive type STATSAFE 6000 or equivalent.
OWNER REFERENCE

BASIS OF DESIGN
5.4 PRODUCT ADDITIVES
The basis of design of the powder additive system results from the formulation of commercial
Innovene grades as given in Table 3.1 in chapter 10 of this volume.
Properties of the additives are given in datasheet Typical 3, in Volume 2, chapter 2.
5.5 CATALYSTS
Catalyst will be supplied in a ready-to-use form, under nitrogen, by INEOS.
5.5.1 Ziegler SDx Catalyst
Physical Properties:
Bulk Density 310 - 340 kg/m3

Average Particle Size 33 - 47 µm
Typical Specifications:
Titanium Content 3.1 - 3.7 % wt

Hydrocarbons Content < 5 % wt
5.5.2 Ziegler NOVACAT T Catalyst

Titanium Content 0.38 – 0.52 % wt

5.5.3 Metallocene Catalyst

OWNER REFERENCE

BASIS OF DESIGN
Titanium Content 0.20 – 0.30 % wt

5.6 MISCELLANEOUS CHEMICALS
The following chemicals are also required:
1. Bottled carbon monoxide for use in termination of the polymerisation reaction in the event of
an emergency.
2. The extruder pellet water circuit and the Recycle Gas Compressor cooling water circuit may
require chemicals, depending on the water quality and operating temperature. The details
are to be developed during detailed engineering.
3. TEAl deactivating agents e.g. carbon dioxide.
4. Seal pot mineral oil e.g. ISOPAR.
6. PRODUCT CHARACTERISTICS
Typical powder, pellet and extrusion additives physical properties for the design grades are
given in data sheets, Typical 1, Typical 2 and Typical 3 included in Volume 2 Chapter 2.
7. ENVIRONMENTAL CONDITIONS
7.1 CLIMATIC CHARACTERISTICS
The Plant will be located in a new complex at Johor Baru in Malaysia.
7.2 TEMPERATURE
7.2.1 Average Temperature
Coastal environment with tropical/monsoon location.
OWNER REFERENCE

BASIS OF DESIGN
Maximum recorded ambient temperature 36 °C
Minimum recorded ambient temperature 20.2 °C
7.2.2 High and Low Ambient Design Temperatures
Maximum air temperature for design 36.5 °C
Annual average air temperature. 27.5 °C
Minimum air temperature for design (used as MDMT) 20 °C
Design Web bulb for cooling tower design 30 °C
7.3 HUMIDITY
Average relative humidity 83.4 %
Maximum relative humidity 98.9 %
7.4 WIND DIRECTION AND VELOCITY
Prevailing wind direction From NNE (13%) and from S (10%)
Design wind velocity 32.5 m/s
7.5 AIR PRESSURE
Min Atmospheric Pressure 1002 mbar abs.
Average Atmospheric Pressure 1010 mbar abs.
7.6 SEISMIC DESIGN
The effects of earthquake shall be taken into account. The design shall be based on design
conditions indicated below, and be in full accordance with the latest revision of Uniform Building
Code (UBC 1997). For load and design factors reference is made to the UBC section 1624
through 1633.
Design Condition One: “Operating Basis Earthquake” (OBE).
OWNER REFERENCE

BASIS OF DESIGN
All equipment, structures and buildings shall be designed for OBE. The OBE shall be based on
the following factors:
a) Seismic Zone 1 shall be applied for all equipment (Z= 0.075).
b) Importance factor 1 shall be applied for all equipment (I = 1).
c) Site Amplification factor 1.5 shall be applied (S3 =1.5).
d) For vertical ground acceleration a factor of 0.05 g shall be applied.
Tsunami may occur.
7.7 RAINFALL
Maximum 24-hour rainfall 240 mm (10mm/h during 24h)
Maximum hourly rainfall 45 mm (180mm/h during 15min)
Design must consider occasional lightning and thunderstorm.
7.8 SNOWFALL
Not applicable.
7.9 FROZEN SOIL DEPTH
Not applicable.
7.10 WINTERISATION
Not applicable.
7.11 PERSONNEL PROTECTION
Personnel protection will be applied on all lines and equipment with Operating temperature
≥ 70°C
or
Minimum temperature to avoid ice.
OWNER REFERENCE

BASIS OF DESIGN
8. SPACING OF EQUIPMENT
Equipment Spacings used for the development of the layout drawings of this PDP follow the
most constraining rule between the “Plot Layout Spacing of Equipment” table from INEOS
standard: RP 44-7 (extract in attachment E) and GAP, for inter-unit spacing.
9. ENVIRONMENT REQUIREMENT
Emission levels; Licensor standard will be applied:
- Allowable hydrocarbons to atmosphere (deliberate discharge only) : 15 mg/Nm3 (*)
- Powder to atmosphere (maximum after filtration or treatment) : 10 mg/Nm3 (*)
(*) Standard value to be confirmed by Client.
OWNER REFERENCE

BASIS OF DESIGN
ATTACHMENT A
RAW MATERIAL CONDITIONS AT LLDPE BATTERY LIMIT
TABLE 61070F-3200-JSD-0000-02A
Project N° - Unit Code Type doc. Serial N° Rev. Index
BASIS OF DESIGN - ATTACHMENT A 61070F-3200 JSD - 02A 0
Technologies
CLIENT PETRONAS Rev. Date Made by Chk by Page

PROJECT RAPID XA JUN 12 BGO FBN
LOCATION JOHOR, MALAYSIA 0 NOV 12 MGU FBN
RAW MATERIAL CONDITIONS SUMMARY TABLE
1/1
UNIT 350 KTA LLDPE PLANT
PRESSURE AT LLDPE BL TEMPERATURE AT LLDPE BL

FLOWING FLUID
REMARKS
bar g - REF. TO GRADE °C
CODE NAME OF FLUID G OR L MINI NORMAL MAXI DESIGN MINI NORMAL MAXI DESIGN
ET Ethylene Import G 32.0 32.0 34.0 42.0 10 20 AMB (36) 80/-45
1BTN Butene-1 L 6.0 7.0 8.0 12.0 AMB (20) AMB (27) AMB (36) 80/ -7
iPENT Pentane L 6.0 7.0 8.0 12.0 AMB (20) AMB (27) AMB (36) 80
1HEX Hexene-1 L 6.0 7.0 8.0 12.0 AMB (20) AMB (27) AMB (36) 80
1OCT Octene-1 L 6.0 7.0 8.0 12.0 AMB (20) AMB (27) AMB (36) 80
HG Hydrogen Import G 23.0 25.0 26.0 30.0 AMB (20) AMB (27) 45 80
OWNER REFERENCE

BASIS OF DESIGN
ATTACHMENT B
RAW MATERIAL COMPOSITIONS AT LLDPE BATTERY LIMIT AND CORE PLANT
Please note that the Innovene Specification = Reactor Requirement
ETHYLENE
SCU
Innovene™G
Component Units Specification at B.L
Specification
Note 1
Ethylene vol % min. 99.95 min 99.95
Methane + Ethane 500 max

vol ppm max 550 max
(Ethane) (450 max)
N2 vol ppm max 5 -
Total Hydrocarbons C3 and higher vol ppm max 10 20
Acetylene vol ppm max 2 (Note 1) 1
Sulfur as H2S, Total vol ppm max 1 1
Water vol ppm max 5 (Note 1) 0.1
Oxygen vol ppm max 1 (Note 1) 0.1
CO vol ppm max 1 (Note 1) 0.1
CO2 vol ppm max 5 (Note 1) 0.1
H2 vol ppm max 5 5
Alcohol as Methanol vol ppm max 4 (Notes1) 0.5
Nitrogen compound (NO+NO2) vol ppm max 0.2 0.2
Oxygenated compounds (as ketone) vol ppm max 1 1
Ammonia vol ppm max 0.2 0.2
Chloride(as Cl or Cl²) vol ppm max 1 0.8
N2O Vol ppm max 0.2
Note 1: It is assumed the feed quality available at battery limit will match the Innovene™ G except
for the following impurities for which treatment is required:
• O2, CO and C2H2 removal (copper oxide/zinc oxide based catalyst)
• CO2, water,alcohol (Molecular sieve for water, and activated alumina beds)
• Layout and PIDs to allow for future installation of Chloride guard.
OWNER REFERENCE

BASIS OF DESIGN
HYDROGEN
Innovene™G
Component Units Specification at B.L
Specification
(TBC)
Hydrogen vol. % min. 99.7 98
N2 vol. % max. 0.3 (*) 2
Methane vol. % max. (*) 0.1
Acetylene vol. ppm max. - 10
Other hydrocarbons vol. ppm max. 20 (NOTE1) 20
Carbon Monoxide vol. ppm max. 1 (NOTE1) 1
Carbon Dioxide vol. ppm max. 20 (NOTE1) 0.5
Oxygen vol. ppm max. 0.1 1
Water vol. ppm max. 2 (NOTE1) 0.5
Total Sulfur wt ppm max. 1 5
Total combined Nitrogen wt ppm max. 0.5 (NH3) 1
He vol ppm max. 150 (tbc)
Total chlorine Wt ppm max. 1
(*) Total CH4 + N2 at B.L : 0.3% vol max.
Note 1: It is assumed the feed quality available at battery limit will match the Innovene™ G except
for the following impurities for which treatment is required:
• CO2 and water removal (activated alumina beds)
• Treatment for C2H2 and CO is not required.
OWNER REFERENCE

BASIS OF DESIGN
HEXENE-1
Specification at B.L Innovene ™ G

Component
Note 1 specification
Hexene-1 99% wt min 99% wt min
Lighter than C6 0.5% wt max 0.5% wt max
Heavier than C6 0.5% wt max 0.5% wt max
Other C6 0.5% wt max 0.5% wt max
Olefins (Internal & Branched) 2% wt max 2.0% wt max(with

paraffin)
Carbon monoxide 1 ppm wt max 1 ppm wt max
Carbon dioxide 1 ppm wt max 1 ppm wt max
Carbonyls (as =O) 10 ppm wt max 0.5 ppm wt max
Alcohols (as -OH) 5 ppm wt max 1 ppm wt max
Benzene 1 ppm wt max 1 ppm wt max
THF 5 ppm wt max 5 ppm wt max
Oxygen (liquid phase) 1 ppm wt max 1 ppm wt max
Water 25 ppm wt max 0.6 ppm wt max
1,3 Hexadiene 10 ppm wt max as total diene 10 ppm wt max as total

diene
Total Combined Sulphur 1 ppm wt max 1 ppm wt max
Peroxide(as active O) 2 ppm wt max 0.5 ppm wt max
Note 1: Data based on INEOS experience.
INEOS will add treatment facilities in anticipation of commercial available specifications, based on
their experience. Guard treatment is typically provided for water and oxygenated compounds
removal. Activated Alumina Treatment is recommended to remove oxygenated compounds,
regardless of supply specification. This treatment will be foreseen within the ISBL Plant facilities.
OWNER REFERENCE

BASIS OF DESIGN
OCTENE-1
Spec at BL Note 1 Innovene™ G

Component Units
Specification
C8 hydrocarbons wt. % min. 99 99
Lighter than C8 wt. % max. 0.5 0.5
Heavier than C8 wt. % max. 0.5 0.5
Octene-1 wt. % min. 99 99
Olefins (Internal & Branched) wt. % max. 1 1
Paraffins wt ppm max. 0.5 0.5
Carbon monoxide wt ppm max. 1.0 1.0
Carbon dioxide wt ppm max. 1.0 1.0
Carbonyls (as MEK) wt ppm max. 10 0.5
Alcohols (as -OH) wt ppm max. 3 1.0
Benzene wt ppm max. 1.0 1.0
Oxygen (liquid phase) wt ppm max. 1.0 1.0
Water wt ppm max. 50 0.6
Total Combined Sulphur wt ppm max. 1 1
Peroxide(as active O) wt ppm max. 2 1
Note 1: Data based on INEOS experience.
INEOS will add treatment facilities in anticipation of commercial available specifications, based on
their experience. Guard treatments are typically provided for water and oxygenated compounds
removal. Activated Alumina Treatment is recommended to remove oxygenated compounds,
regardless of supply specification. This treatment will be foreseen within the ISBL Plant facilities.
OWNER REFERENCE

BASIS OF DESIGN
BUTENE-1
Battery Limit Specification Innovene G Specification

COMPONENT
Note (2) to Reactor
Butene-1 99% wt min 99% wt min
Butene-2 (cis and trans isomer) 1% wt max

1% wt max
Other butenes and butane 1% wt max
1% wt max
Acetylene
10 ppm wt max
10 ppm wt max
Propyne (methyl acetylene)
5 ppm wt max
1,3 Butadiene (including
50 ppm wt max
propadiene) 50 ppm wt max
1,2 Butadiene 5 ppm wt max
5 ppm wt max
C5 and heavier 500 ppm wt
500 ppm wt
Carbonyls (as MEK) 0.5 ppm wt max
5 ppm wt max
Alcohols (as methanol) 1 ppm wt max
5 ppm wt max
MTBE 5 ppm wt max
5 ppm wt max
Carbon Monoxide 2 ppm wt max
2 ppm wt max
Carbon Dioxide 2 ppm wt max
2 ppm wt max
No spec. No spec.
Ammonia
(not normally present) (not normally present)
No spec.
Nitrogen compounds (NO+NO2) No spec. (normally not present) (1)
(normally not present) (1)
Oxygen (liquid phase) 1 ppm wt max
1 ppm wt max
Water 0.6 ppm wt max
20 ppm wt max
Total combined Sulphur (as
3 ppm wt max
H2S) 3 ppm wt max
Peroxides
0.5 ppm wt max
(as active O2) 3 ppm wt max
Total Chloride 1 ppm wt max
1 ppm wt max
Note 1: Excludes dissolved nitrogen
Note 2: Data based on INEOS experience
OWNER REFERENCE

BASIS OF DESIGN
INEOS will add treatment facilities in anticipation of commercial available specifications, based on their
experience. Guard treatments are typically provided for water and oxygenated compounds removal.
Activated Alumina Treatment is recommended to remove oxygenated compounds, regardless of supply
specification. This treatment will be foreseen within the ISBL Plant facilities
OWNER REFERENCE

BASIS OF DESIGN
PENTANE
Battery Limit Specification

COMPONENT INNOVENE™ G SPECIFICATION
Note 1
n-pentane 50% wt (min) (2) No specific requirement. Licensee

to advise (NOTE1)
i-pentane 50% wt (max) (2)
C5 Content 99% wt min 99 % wt min
Carbon Monoxide 1 ppm wt max 1 ppm wt max
Carbon Dioxide 1 ppm wt max 1 ppm wt max
Water (to reactor) 50 ppm wt max 1 ppm wt max
Oxygen (in liquid phase) 0.5 ppm wt max 1 ppm wt max
Total oxygenated compounds (as C=O) 5 ppm wt max 0.5 ppm wt max
Total aromatics as Benzene 20 ppm wt max 20 ppm wt max

Total Combined Sulphur
2 ppm wt max 2 ppm wt max
Bromine Index
50 mg Br/100g 50 mg Br/100g
Compounds not shown may not be present.
Supply of pentane needs to meet the Innovene™ G specification.
However, guard treatment is typically provided ISBL for water removal. Activated alumina is
recommended to remove also oxygenated compounds, regardless of supply specification.
Note 1: Data based on INEOS experience
Note 2: Other supplies acceptable in the range of 60-80% n-pentane and balance i-pentane.
INEOS will add treatment facilities in anticipation of commercial available specifications, based on their
experience. Guard treatments are typically provided for water and oxygenated compounds removal.
Activated Alumina Treatment is recommended to remove oxygenated compounds, regardless of supply
specification. This treatment will be foreseen within the ISBL Plant facilities
OWNER REFERENCE

BASIS OF DESIGN
ATTACHMENT C
UTILITY CONDITIONS AT LLDPE BATTERY LIMIT & AT USERS
TABLE 61070F-3200-JSD-0000-02B
Project Nr - Unit Code Type doc Serial Nr Rev index
Technologies
BASIS OF DESIGN - ATTACHMENT C 61070F-3200 JSD - 02B 0
CLIENT PETRONAS Rev Date Made by Chk by Page

PROJECT RAPID XA JUN 12 BGO FBN
LOCATION JOHOR, MALAYSIA XB SEP 12 MGU FBN
UTILITIES AND EFFLUENTS CONDITIONS SUMMARY TABLE 1/1
0 NOV 12 MGU FBN
UNIT 350 KTA LLDPE PLANT
PRESSURE AT BL PRESSURE AT USERS TEMPERATURE AT BL TEMPERATURE AT USERS

FLOWING FLUID
REMARKS
bar g - REF. TO GRADE bar g - REF. TO GRADE °C °C
CODE NAME OF FLUID G OR L MINI NORMAL MAXI DESIGN MINI NORMAL MAXI DESIGN MINI NORMAL MAXI DESIGN MINI NORMAL MAXI DESIGN
SH High Pressure Steam G 52.5 53.0 53.5 62 / FV 48.7 49.2 52.5 62 / FV 430 435 440 455 265 425 440 455
SL Low Pressure Steam G 6.5 7.0 7.5 9.0 / FV 4.7 5.2 6.0 9.0 / FV 180 185 190 295 160 170 190 295
SCL Low Pressure Condensate not returned OSBL 0.0 1.0 2.0 9.0/FV not returned OSBL 100 120 133 295
PCC Low Pressure Condensate (to OSBL) L/G 9.0 9.0 9.0 15.0 NO USERS Amb (20) 100 105 150 NO USERS
IA Instrument air G 6.0 (7) 7.0 9.0 12.0 6.0 (7) 6.7 9.0 12.0 25 Amb (27) 45 75 Amb (20) Amb (27) 45 80 Dew point: -40°C
PA Plant air G 6.0 8.0 9.0 12.0 5.7 7.7 9.0 12.0 25 Amb (27) 45 75 Amb (20) Amb (27) 45 80 Dew point: -40°C
LLN Very Low Pressure Nitrogen G generated ISBL 0.05 0.06 0.07 0.10 generated ISBL Amb (20) Amb (27) 45 80 OSBL quality.
LN Low Pressure Nitrogen G generated ISBL 3.0 3.0 3.4 4.4 generated ISBL Amb (20) Amb (27) 40 80 Normal quality.
LNP High Purity LP Nitrogen G generated ISBL 2.0 2.2 2.4 2.8 generated ISBL Amb (20) Amb (40) 40 80 High purity
LNS Standard LP Nitrogen G generated ISBL 3.0 3.0 3.4 4.4 generated ISBL Amb (20) Amb (40) 45 80 OSBL quality.
MN Medium Pressure Nitrogen G generated ISBL 7.0 7.5 8.0 10.5 generated ISBL Amb (20) Amb (40) 40 80 Normal quality.
MNP High Purity MP Nitrogen G generated ISBL 7.0 7.5 8.0 10.5 generated ISBL Amb (20) Amb (40) 40 80 High purity.
LPN Raw LP Nitrogen G 7.0 7.0 9.0 12.0 NO USERS Amb (20) Amb (27) 45 80 NO USERS OSBL quality.
MPN MP Nitrogen G generated ISBL 6.8 7.0 9.0 12.0 generated ISBL Amb (20) Amb (27) 45 80 OSBL quality.
HPN Raw High Pressure Nitrogen G 32.0 32.0 34.0 40.0 NO USERS Amb (20) Amb (27) 45 80 NO USERS OSBL quality.
HN High Pressure Nitrogen G generated ISBL 28.7 31.4 34.0 40.0 generated ISBL Amb (20) 40 40 80 Normal quality.
PHN Priority HN G generated ISBL 29.2 31.4 34.0 40.0 generated ISBL Amb (20) 40 40 80 Normal quality / High priority.
HNP High Purity HN G generated ISBL 28.7 31.4 34.0 40.0 generated ISBL Amb (20) 40 40 80 High purity.
PHNP Priority HNP G generated ISBL 29.2 31.4 34.0 40.0 generated ISBL Amb (20) 40 40 80 High purity / High priority.
CWS Cooling Water Supply L 6.0 6.0 7.0 13 (6) 5.5 5.5 7.0 13 (6) 30 34 34 80 30 34 34 80
CWR Cooling Water Return L 3.0 3.0 4.0 13.0 (6) 3.0 3.5 4.5 13.0 (6) 44 44 80 44 44 80 Note 1.
DMW Demineralised Water L 7.0 7.0 8.0 13.0 6.5 6.5 8.0 13.0 25 Amb (27) 35 80 25 Amb (27) 35 80
RFH High Pressure Flare G - 0.2 (2) 1.6 (3) 3.5 - 0.2 (2) 2.5 (4) 3.5 Amb (20) Amb (27) Amb (36) 200 / -29 Amb (20) Amb (27) Amb (36) 200 / -29 (5)
PRV Powder Relief Vent G not returned OSBL 0.0 0.2 (5) 2.5 (4) 3.5 not returned OSBL Amb (20) Amb (27) Amb (36) 200 (5) To flare
Powder Vent
PV G not returned OSBL 0.1 0.2 0.5 4.4 not returned OSBL Amb (20) Amb (27) Amb (36) 130 To flare via purge column
operational
CRV Catalyst Relief Vent G not returned OSBL 0.0 0.0 1.0 (4) 1.0 not returned OSBL Amb (20) Amb (27) Amb (36) 80 Atmospheric system.
CV Catalyst Vent operational G not returned OSBL 0.05 0.05 0.2 3.1 not returned OSBL Amb (20) Amb (27) Amb (36) 80 Atmospheric system with oil guard.
FG Fuel Gas G 4.0 4.5 5.0 7.0 3.2 3.7 4.5 7.0 35 40 50 80 35 40 50 80
DC Clean hydrocarbon liquid drain L 6.0 tbc 6.6 12.0 0.2 1.0 2.0 3.5 tbc 45 45 80 -24 45 45 80 / -29 Export to OSBL
HCD Hydrocarbon Liquid Drain L not returned OSBL 0.2 1.0 2.0 3.5 not returned OSBL -24 45 45 80 / -29
TD TEAL drain L not returned OSBL 0.2 1.0 2.0 3.5 not returned OSBL -24 45 45 80 / -29
OWS Oily water L Atm Atm Atm Atm Atm Atm Atm Atm Amb (20) Amb (27) Amb (36) 80 Amb (20) Amb (27) Amb (36) 80
STW Storm water L Atm Atm Atm Atm Atm Atm Atm Atm Amb (20) Amb (27) Amb (36) 80 Amb (20) Amb (27) Amb (36) 80
PWS Polymer water L not returned OSBL Atm Atm Atm Atm not returned OSBL Amb (20) Amb (27) 60 100
NOTES: (6) FV to be specified on elevated equipment and piping (above 5 meters)

(1) Available ΔP at BL: 2 bar min. Available ΔP for design: 1 bar for all users. (7) 4 barg for pneumatic actuators design
(2) Superimposed backpressure
(3) Maximum BL Main Header Backpressure 1.6 barg.
(4) Maximum allowable backpressure at safety valve discharge. To be confirmed during D.E.
(5) For main header. May be locally higher as specified in PDP.
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited,
and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without
the express permission of INEOS Commercial Services UK Limited.
OWNER REFERENCE

BASIS OF DESIGN
ATTACHMENT D
UTILITY COMPOSITIONS AT LLDPE LIMIT
NITROGEN Two qualities are required. In addition, raw OSBL nitrogen

(“standard quality”) is suitable for treater regeneration and use in the finishing
area. Normal and high purity nitrogen are generated ISBL from OSBL nitrogen.
INNOVENE™ G
B.L SPECIFICATION
COMPONENT UNITS
specifications
High purity Normal purity
Purity % mol (min) 99.99 99.99 99.99
Oxygen ppm mol (max) 5 0.1 1

Carbon dioxide ppm mol (max) 20 0.1 1
Carbon monoxide ppm mol (max) 20 0.1 1
Water ppm mol (max) 5 0.1 1
HC 5
ppm mol (max)
Chlorine 1 - -
ppm mol (max)
DEMINERALISED WATER: From OSBL.
Parameters Value
Silica < 0.02 mg/L (max)
Iron < 0.01 mg/L (max)
Copper < 0.003 mg/L (max)

Na < 0.01 mg/L
Oil and grease < 0.2 mg/L
Conductivity < 0.2 μs/cm (max) @ 25°C
pH 6 to 7.5
OWNER REFERENCE

BASIS OF DESIGN
HP & LP STEAM : From OSBL. Fouling factor: 0.00017 m2.°C / W
INSTRUMENT AIR : From OSBL. Quality: dust free, oil free and free from
other contaminants. Dew point -40°C at operating
pressure
PLANT AIR From OSBL. Quality: Oil free.
COOLING WATER. : From OSBL Atmospheric Cooling Tower system

Fouling factor: 0.00029 m2.°C / W
CW CHARACTERISTICS UNITS VALUE
Total Hardness (TA) as CaCO3 mg eq/l TBD
Total Alkalinity mg/l TBD
Calcium Hardness mg/l TBD
Conductivity μS/cm TBD
Chlorides (as Cl) Ppm wt 250 (as preliminary

figure)
Sulphates mg/l TBD
Dissolved Solids mg/l TBD
pH - TBD
Total Fe mg/l TBD
Total Al mg/l TBD

Cooling water treatment will include anti-corrosion agent, scale inhibition and biocide as
appropriate. It will be suitable to be used for CS or SS heat exchangers.
OWNER REFERENCE

BASIS OF DESIGN
FUEL GAS: from OSBL
Fuel Gas is only used for flare purging.
Molecular weight from 16 to 58 kg/kmol.
OWNER REFERENCE

BASIS OF DESIGN
ATTACHMENT E
PLOT LAYOUT SPACING OF EQUIPMENT RP44-7

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Project Package Originator Discipline Doc. Type Unit n° Serial n°

Technologies RAPID L20 INE PRO DES 3200 0001

0 05-NOV-12 ISSUE FOR PDP M. GUEYE F. BETTON F. BETTON

Technologies RAPID L20 INE PRO DES 3200 0001

Technologies RAPID L20 INE PRO DES 3200 0001

ATTACHMENT A RAW MATERIAL CONDITIONS AT LLPDE BATTERY LIMIT

ATTACHMENT B RAW MATERIAL COMPOSITIONS AT LLPDE BATTERY LIMIT AND

ATTACHMENT C UTILITY CONDITIONS AT LLPDE BATTERY LIMIT & AT USERS

ATTACHMENT D UTILITY COMPOSITIONS AT LLPDE LIMIT

ATTACHMENT E PLOT LAYOUT SPACING OF EQUIPMENT RP44-7

Technologies RAPID L20 INE PRO DES 3200 0001

1.1 FUNCTIONS OF UNITS

Feedstock Preparation Unit

Ethylene, comonomer (butene-1, hexene-1, octene-1), hydrogen, pentane, TEAl, liquid

Powder degassing and Powder conveying

Polymer product (powder) is removed by lateral withdrawal systems. Residual

Technologies RAPID L20 INE PRO DES 3200 0001

Extrusion feeding and Pelletisation

Pellet conveying and Blending

Liquid recovery Unit

Vents & Flare

Utilities battery limits

Primary aqueous treatment facilities

Technologies RAPID L20 INE PRO DES 3200 0001

1.2 SCOPE OF THE PROCESS DESIGN PACKAGE

The Units for the Plant are:

Feedstock Preparation Unit (200)

Catalyst Injection Unit (300)

Polymerisation Unit (400)

Degassing and recycle Unit (600)

Vent Recovery Unit (600)

Liquid Recovery Unit (700)

Additive and Pelletising Unit (800)

Pellet Blending Unit (800)

Reagents and Utilities Unit, including:

Technologies RAPID L20 INE PRO DES 3200 0001

2. PLANT CAPACITY, OPERATING FACTOR AND PRODUCT MIX

2.1 PLANT CAPACITY AND OPERATING FACTOR

Technologies RAPID L20 INE PRO DES 3200 0001

2.2 DESIGN GRADE SLATE

The design grades for the Polymerisation loop are:

Innovene PEG Rate kT/a

LL6409AA Film LL C6 Hexene-1 Ziegler 44 26

LL6608AA Film LL C6 Hexene-1 Ziegler 44 26

LL6130AA Film LL C6 Hexene-1 Ziegler 44 35

PF6212AA Film mLL C6 Hexene-1 Metallocene 44 70

PF6612AA Film mLL C6 Hexene-1 Metallocene 44 35

PF6130AA Film mLL C6 Hexene-1 Metallocene 44 53

HD3850UA Rotomolding Hexene-1 Ziegler 44 17

LL8409AA Film LL C8 Octene-1 Ziegler 44 -

LL8608AA Film LL C8 Octene-1 Ziegler 44 -

LL8130AA Film LL C8 Octene-1 Ziegler 38 -

PF8212AA Film mLL C8 Octene-1 Metallocene 40 -

PF8612AA Film mLL C8 Octene-1 Metallocene 44 -

PF8130AA Film mLL C8 Octene-1 Metallocene 40 -

HD8850UA Rotomolding Octene-1 Ziegler 44 -

Note 1: Used for additive storage sizing only.

Technologies RAPID L20 INE PRO DES 3200 0001

Innovene PEG Rate

LL0220AA Film LL C4 Butene-1 Ziegler 44

LL0230AA Film LL C4 Butene-1 Ziegler 44

LL0410AA Film LL C4 Butene-1 Ziegler 44

LL0640AA Film LL C4 Butene-1 Ziegler 44

HD3840UA Rotomolding Butene-1 Ziegler 44

Technologies RAPID L20 INE PRO DES 3200 0001