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VOLUME 1

CHAPTER 5

PROCESS DESIGN BASIS

1 14-DEC-12 PDP UPDATE M. GUEYE F. BETTON F. BETTON

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.

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CONTENTS

1. GENERAL

2. FEEDSTOCK PREPARATION UNIT

3. CATALYST FEEDING

4. POLYMERISATION UNIT

5. POWDER DEGASSING AND POWDER CONVEYING

6. LIQUID RECOVERY UNIT

7. EXTRUSION FEEDING AND PELLETISATION

8. PELLET CONVEYING AND BLENDING

9. UTILITIES

10. ADDITIVE / CATALYST STORAGE BUILDING

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1. GENERAL

The information contained within this chapter details the design basis for
the polyethylene gas phase plant.

2. FEEDSTOCK PREPARATION UNIT

The ethylene and pentane systems are sized to meet Innovene-G specification. Pentane
storage is sized for 24h at maximum normal consumption. The pentane treater is sized
for 6.3 t/h feed from OSBL.

An ethylene compressor is required to maintain a minimum flow through the treater beds
to avoid exotherm.

The comonomer (Butene-1, Hexene-1 and Octene-1) system is sized to meet Innovene-
G specification. Two identical treaters are used (one in operation, one spare used during
regeneration) and are sized on the most constraining comonomer. Comonomer Buffer
Storage is sized for 20 min residence time. A comonomer recycle is provided to ensure
minimum flow through the treaters.

The Hydrogen system is sized to meet Innovene-G specification. A hydrogen

compressor is required to increase the pressure from Battery Limit. Hydrogen system is
sized for the reactor loop gas phase composition make-up flowrate.

All systems are sized for 60-110% of normal capacity, except for treaters and where
minimum flows are specifically requested by Vendor. Treaters are sized based on
normal maximum flow for catalyst quantities and design flow for hydraulics.

Adsorption time is at least 21 days on ethylene and comonomers and 30 days for
pentane and hydrogen.

Nitrogen system is sized to meet the different required Innovene-G specifications. It is

designed to ensure purification of nitrogen peak flowrates.

The Feedstock Preparation Unit and Nitrogen treaters regeneration system is sized for
one regeneration at a time.

3. CATALYST FEEDING

Ziegler (SDx or NCT) catalyst and Metallocene catalyst will be delivered by tote bin and
stored ISBL in a safe area until required (Metallocene catalyst to be stored in a storage
area maintained under 25°C). The tote bin dimensions, engineering details and supply

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will be through INEOS. Although the tote bin design is outside the scope of this PDP, the
catalyst quantity per tote bin is about 350 kg.

3 catalyst transfers (one for Ziegler SDx, one for Ziegler NCT and one for Metallocene)
but 2 injection systems (one for Metallocene and one for the two Ziegler catalysts) are
installed.

Catalyst is transferred on a batch-wise basis by gravity to the catalyst injection unit. The
frequency of transfers will depend on the catalyst productivity (grade dependant) and the
production output. The sizing of the storage capacity allows transfer of a full totebin
without interruption to the polymerisation process.

A dedicated vent collection system for streams containing catalyst powder is provided.

Ziegler catalyst is normally injected into the reactor through a single line, the additional
line is spare. Metallocene catalyst is normally injected through three lines and no
additional spare line is foreseen.

4. POLYMERISATION UNIT

The Polymerisation Unit is designed for the production of LLDPE and HDPE products
using continuous direct injection of catalyst (Ziegler SDx or Ziegler NCT or High
Performance Metallocene). The design grade mass balances are detailed in Chapter 7
of this volume. The mass balance information is typical of each grade of product only.
The polymerisation reactor operating conditions for the design grade mass balances are
detailed in Table 4.1 given at the end of this chapter.

The Main Loop Condenser 3200-E-400 is designed without any margin other than that
contained in the fouling factor. The recirculating cooling water temperature is adjusted to
compensate for the variation in 3200-E-400 heat duty by acting on fresh make-up (the
cooling water flow rate to 3200-E-400 being fixed).

Minimum PU production rate is 60% for each grade.

TEAL area is sized for 2 containers connected to process. Pumps are sized for normal
operation and purification / passivation in Ziegler operation. Volume of container for one
change-over every 14 days minimum.

Liquid additives S1 and B1 system are injected pure.

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5. POWDER DEGASSING AND POWDER CONVEYING

Degassing design operating criteria are given in Table 5.1 given at the end of
this chapter.

Envelope of conditions for safe degassing is shown in table 5.2

Recycle Gas compressor 3200-K-675 operates from 0% to 100% of the machine

capacity via variable speed motor and recycle valves, including the nitrogen case for
which lower pressure is allowed. 3200-K-675 will be a non-lubricated screw compressor.
The suction KO drum 3200-V-675 is equipped with a vane pack demister and
continuous liquid recycle.

Recycle around the Degasser 3200-V-628 by the means of 3200-DX-632 is sized for the
minimum speed of the rotary valve 3200-X-628.

Recycle around the Purge Column 3200-V-640 through 3200-X-666 is at low speed of
3200-X-666 but not less than 2,000 kg/h.

Transfer of start-up powder from 3200-V-640 to the reactor 3200-R-400 via 3200-X-666
and 3200-X-667 is maximised using 3000 Nm3/h of HP nitrogen.

Powder conveying package 3200-A-660 is sized for 105% of the production rate
(46200 kg/hr). Purge column outlet rotary valve 3200-X-640 is sized for the extruder
design rate (53000 kg/hr).

The surge capacity of 3200-V-640 is sized for 4 hours at design production rate.

The Vent Recovery Unit is sized to recover comonomer and pentane extracted from
the powder and to purify the stripping gas to the Degasser by lowering the temperature
to -35°C at Recycle Gas Compressor outlet pressure.

This temperature is achieved by means of Refrigeration on Package 3200-A-675. The

Refrigeration Package 3200-A-675 is operable with no-load.

In C8 operation only, additional degassing is carried out in the 3200-V-638 C8

Degasser.

Powder from the Degasser, 3200-V-628 is diverted to the C8 Degasser to remove

heavier hydrocarbons from the powder. A dedicated low pressure C8 VRU including a
refrigeration unit 3200-A-684 (Process conditions : 2.2 bara / -35°C) recovers the
hydrocarbons from the off gas and a centrifugal one stage compressor 3200-K-685
recycles the nitrogen-rich gas back to the bottom of the C8 Degasser.

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6. LIQUID RECOVERY UNIT

HCD storage drum 3200-V-711 is sized for plant deinventory or for 3 days storage of
normal liquid purge in Ziegler operation.

LRU distillation unit is sized for 1000 kg/h allowing treatment of full HCD storage drum
contents in about 2 days.

Residue contains up to 5% wt of TEAL. Distillate (HCC) to OSBL is free of fines and

aluminium (less than 50 ppb wt).

Clean HC drain drum 3200-V-714 and LRU residue buffer drum 3200-V-713 are sized
for 1 hour operation.

For C8 operation, LRU Recycle Fan 3200-K-711 is used to provide sparge gas to
reboiler 3200-E-711 to separate C8 / TEAL whilst maintaining low temperature in the
reboiler.

7. EXTRUSION FEEDING AND PELLETISATION

In this section, the virgin degassed powder from the Purge column 3200-V-640 goes
through a Polymer Vibrating Screen 3200-S-820 which removes oversized polymer and
then feeds the Extruder First and Second Feed 3200-M-820/821 through 3200-X-640
under flow control.

3200-X-640 and 3200-M-820/821 are designed to operate up to 120% of max production

rate.

3200-M-820/821 are designed for 10 seconds minimum residence time and are
equipped with variable speed drive to control the powder rate at extruder start-up.

Additives are fed to the Extruder First and Second Feed Screws 3200-M-820/821 by
Loss in Weight Feeders.
Individual neat additives are used. They are fed from 6 unloading stations
3200-X-835 A to F for FIBCs (also known as big bags), via additive feeders 3200-W-835
A to F designed to operate from 200 ppm dosing rate on extruder turndown (except for
antioxidants feeders, which is extruder start-up rate) up to 2500 ppm dosing on extruder
design rate depending on additives. Different types of screw internals may be used to
cover the flow range.
Each unloading station has the facility to also handle 25 kg bags.

The loading station hoppers of 3200-V-835 A to F are sized to contain at least 20

minutes of most of additives to allow change of big bag.

The virgin powder and additives are then fed directly to the extruder package
3200-A-820.

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Pellet Purge Silo 3200-V-855 (1h storage) is used at start-up and feeds directly the
Extruder Feed Hopper 3200-V-840 via rotary valve 3200-Q-855 designed to operate up
to 15% of max normal extruder rate.

The Extruder package 3200-A-840 has an overdesign capacity of 20% (53000 kg/h).

The Extruder package 3200-A-840 has a turndown capacity of 60% of design rate.

Pellets from the extruder are dried and screened to remove oversize and undersize
pellets, and pass to the Pellet Conveying Hopper 3200-V-850. The Pellet Conveying
Hopper is normally empty, but is designed with 7 minutes residence time at LAHH at
extruder design rate, with a 2 minutes residence time above LAHH at extruder design
rate, to allow an extruder stoppage.

Pellets are then transferred to the Pellet conveying and Blending Unit using a pneumatic
air conveying system 3200-A-850 designed for a pellet capacity of 56 t/h for all grades.

8. PELLET CONVEYING AND BLENDING

The pelletising line is followed by a dedicated Pellet Blending Unit with two Pellet
Blenders, 3200-M-880 A/B, with a capacity of 650 m3 each at LAHH.

Any of these silos can be used as a transition silo when necessary.

Pellets are blended continuously under weight or level control and are transferred to
OSBL via an elutriation unit using a pneumatic air conveying system 3200-A-880
(outside of PDP scope) with a 64 t/hr pellet capacity.

9. UTILITIES

9.1 VENTS & FLARE

The final sizing of all Vent and Flare Systems is the responsibility of the Engineering
Contractor.

The PDP gives a preliminary sizing based of preliminary effluent balances.

Relief Vent Drums 3200-V-150 and 3200-V-152 are cyclonic design optimised for
highest discharge flow.

Catalyst Vent Filter 3200-S-151 is designed to remove all particles larger than 0.5
microns.

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9.2 Utilities battery limits and distribution

It consists of metering and distribution of steam, steam condensate, cooling water, other
waters, instrument air and standard quality nitrogens.

9.3 Nitrogen distribution

Nitrogen is letdown to generate the various required pressure levels of nitrogen.

9.4 Primary aqueous treatment facilities

The polymer water pit 3200-T-161 recovers the polymer powder and pellets coming from
the plant. The volume is the addition of:
 Rainfall hourly intensity and a holding time of 15 minutes,
 The pellet water loop drain on extruder shutdown.
Oily water effluents and storm water effluents are sent to OSBL.

10. ADDITIVE / CATALYST STORAGE BUILDING

The additive / catalyst storage building is sized for 30 days storage for catalyst and
additives.

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TABLE 4-1 - POLYMERISATION DESIGN OPERATING CRITERIA

LL0220 LL6209 PF6130 PF8130

Production Rate (kg/hr) 44,000 44,000 44,000 40,000
Polymer composition:
- Ethylene % wt 91.87 90.0 90.3 87.69
- Butene-1 % wt 8.13 - - -
- Hexene-1 %wt - 10.0 9.7 -
- Octene-1 %wt - - - 12.31
Catalyst productivity (kgPE/gcatalyst) 16.64 9.89 5.54 5.78
Catalyst type Zg (SDX) Zg (NCT) MT MT
Reaction:
Catalyst Flow to Reactor (kg/hr) 3.7 5.4 8.8 8.0
Reactor top:
Polymerisation temperature (°C) 87 88 78 78
Operating pressure (bar a) 24.0 24.0 24.0 24.0
Fluidisation velocity (cm/s) 65 60 60 60
Fluidised bed height (m) 20 20 20 20
Gas phase composition:
Partial pressure (bar.a)
- Ethylene 10.0 10.0 15.0 15.0
- Butene-1 4.6 - - -
- Hexene-1 - 1.45 0.10 -
- Octene-1 - - - 0.03
- Hydrogen 2.7 1.4 0.08 0.08
- Pentane 2.5 0.1 2.6 2.8

Reactor Diameter = 5.1 m Working Bed Height = 20 m

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TABLE 5-1 - DEGASSING SYSTEM DESIGN OPERATING BASIS

Grade LL0220 LL6209 PF6130 PF8130

Degasser 3200-V-628

Diameter (mm) 5000

Powder height (mm) (1)

5050
NL above (upper) gas distributor

LSLL height (mm) (1)

3800
level above (upper) gas distributor

Stripping gas Trip Flow (m³/h) (4) 1550 2130 2370 2370

Stripping gas Normal Flow (m³/h) (4) 1830 2570 2830 2840

C8 Degasser 3200-V-638

Diameter (mm) 10500

Powder height (mm) (1)

7875
NL above (upper) gas distributor

LSLL height (mm) (1)

7605
level above (upper) gas distributor

Stripping gas Trip Flow (kg/h) (4) - - - 17100

Stripping gas Normal Flow (kg/h) (4) - - - 23250

Purge Column 3200-V-640

Diameter (mm) (2) 2900

Powder height (mm) (1)

6100
NL above (upper) gas distributor

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LSLL height (mm) (1)

2290
level above (upper) gas distributor

Stripping gas Trip Flow (kg/h) (4) 660 1280 1280 1280

Stripping gas Normal Flow (kg/h) (3)

780 1500 1530 1540
(4)

Notes:
(1) Level at base of powder cone.
(2) Upper degassing section.
(3) 3200-V-640 start-up flow to lower section: 772 kg/h.
(4) This flow includes degasser outlet rotary valve leakage.

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TABLE 5-2 – ENVELOPE OF CONDITIONS FOR SAFE DEGASSING

The following table displays the different deviation cases that can occur in operation and which have
been verified for degassing train design.

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Pellet
cooling
Notes Reactor Gas Production Degasser V628 V628 VRU Purge Column V640 Degasser V638 (C8) V638 VRU (C8)
water
temp.
Phase Powder Stripping Powder Stripping Powder Stripping
Temp. rate Pressure Temper. Pressure Pressure Pressure Temper. Pressure
Composition level flowrate level flowrate level flowrate
Normal All grades Normal Normal 100% Normal Normal Normal Normal Normal Normal Normal Normal 60 - - - - -
Case 1 All grades TSL Normal 100% LAL FAL Normal Normal Normal Normal Normal Normal 60 - - - - -
Case 2 All grades Normal SVP (1) 100% LAL FAL Normal Normal Normal Normal Normal Normal 60 - - - - -
Case 2bis C6 grades Normal SVP (1bis) 100% LAL FAL Normal Normal Normal Normal Normal Normal 60 - - - - -
Case 3 All grades Normal Normal 115% LAL FAL Normal Normal Normal Normal Normal Normal 60 - - - - -
Case 4 All grades Normal Normal 100% LSLL FAL Normal Normal Normal LAL Normal Normal 60 - - - - -
Case 5 All grades Normal Normal 100% LAL FSLL Normal Normal Normal Normal FAL Normal 60 - - - - -
Case 6 All grades Normal Normal 100% LAL FAL Normal TSHH (2) PSLL (3) Normal Normal Normal 60 - - - - -
Case 7 All grades Normal Normal 100% LAL FAL Normal Normal Normal LSLL Normal Normal 60 - - - - -
Case 8 All grades Normal Normal 100% LAL FAL Normal Normal Normal Normal FSLL Normal 60 - - - - -
Case 10 All grades Normal Normal 100% LAL FAL Normal Normal Normal Normal Normal Normal 90 (4) - - - - -
Case 11 All grades Normal Normal 100% Normal FAL PSH Normal Normal Normal Normal Normal 60 - - - - -
Case 12 All grades Normal Normal 100% Normal Normal Normal Normal Normal Normal FAL PSH 60 - - - - -
Case 13 All grades Normal PC5 drift (5) 100% LAL FAL Normal Normal Normal Normal Normal Normal 60 - - - - -
Case 13bis C6 grades Normal PC6 drift (5bis) 100% LAL FAL Normal Normal Normal Normal Normal Normal 60
Case 13ter C8 grades Normal PC8 drift (5ter) 100% LAL FAL Normal Normal Normal Normal Normal Normal 60 LAL FAL Normal Normal Normal
Case 14 C8 grades Normal Normal 100% LAL FAL Normal Normal Normal LAL Normal Normal 60 LSLL FAL Normal Normal Normal
Case 15 C8 grades Normal Normal 100% LAL FAL Normal Normal Normal Normal FAL Normal 60 LAL FSLL Normal Normal Normal
Case 16 C8 grades Normal Normal 100% LAL FAL Normal Normal Normal Normal Normal Normal 60 LAL FAL Normal TSHH (2) PSLL (3)
Case 17 C8 grades Normal Normal LAL FAL PSH Normal Normal

Trip cases consider the deviation of one single parameter at a time, with low stripping gas flow alarm and low level alarm on 3200-V-628, 3200-V-638 or 3200-V-640 as above.

Design of the degassing section ensures that final product hydrocarbon levels cannot lead to LEL being exceeded downstream regardless of the case considered above.

Notes:
(1) Pentane accumulation until its dew point is reached at T=Tpoly.
(1bis) Hexene accumulation until its dew point is reached at T=Tpoly.
(2) High temperature trip means stripping gas poor gas quality to V628 or V638.
(3) Low pressure trip means stripping gas poor gas quality to V628 or V638.
(4) Trip temperature to adjust typically 90°C.
(5) PC5 is increased in order to reach 50% LEL and getting the dT interlock trip on degasser.
(5bis) PHexene is increased in order to reach 50% LEL and getting the dT interlock trip on degasser.
(5ter) POctene is increased in order to reach 50% LEL and getting the dT interlock trip on degasser.

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