MANUFACTURING OF LINEAR LOW DENSITY POLYETHYLENE (LLDPE)

MANUFACTURING OF LINEAR LOW DENSITY POLYETHYLENE (LLDPE)

Linear low-density polyethylene (LLDPE) is a substantially linear polyethylene, with significant numbers of short branches, commonly made by copolymerization of ethylene with longer-chain olefins. Linear low-density polyethylene differs structurally from conventional low-density polyethylene because of the absence of long chain branching. The linearity of LLDPE results from the different manufacturing processes of LLDPE and LDPE. LLDPE is produced at lower temperatures and pressures by copolymerization of ethylene and such higher alpha olefins as butene, hexene, or octene. The copolymerization process produces an LLDPE polymer that has a narrower molecular weight distribution than conventional LDPE and in combination with the linear structure, significantly different rheological properties.

Process block diagram

STRIPPING & BLENDING BAGGING FINISHED PRODUCT

EXTRUSION & PELLETIZATION ADDITIVES POLYMER SEPERATION MONOMER SOLVENT OFF GASES & GREASE TO VAPOURIZER

ALUMINA SPENT ALUMINA

SOLUTION ADSORBER

CATALYST PREPERATION ETHYLENE

POLYMERIZATION

SOLVENT RECOVERY

SOLVENT MAKEUP SOLVENT MONOMER PURIFICATION

Sections in LLDPE UNIT

Synthesis Section Distillation Section Extrusion, Stripping and Blending Section

Synthesis Section
The process solvent, cyclohexane ,and the comonomer, either butene-1 or octene-1 are recycled from the recovery area, combined and passed through a purifier to remove trace impurities. Fresh ethylene is dissolved in this stream and the combined mixture is pumped under moderate pressure into the reaction area, where the solution is tempered as required. The reaction area consists of three reactors: a pipe reactor, a stirred autoclave and a trimmer reactor. By varying the flow through these reactors (series and/or partial parallel), the catalyst and hydrogen injection points and the process temperatures, the various resin properties can be produced. The catalyst causes the ethylene and comonomer to polymerize exothermically which raises the solution temperature. The stream leaving the reaction area contains polyethylene dissolved in cyclohexane together with unreacted ethylene and butene (or octene). Deactivators are added to stop the reaction where necessary and prepare catalyst residues for adsorption. The Solution Preheaters increase the solution temperature further to promote efficient catalyst removal in the Solution Adsorbers and provide the necessary energy for subsequent solvent separation. The adsorption process produces some comonomer isomerization plus other impurities. The catalyst-free solution is then dropped in pressure through staged Separators causing solvent and unreacted ethylene and comonomer to flash off for recovery, leaving molten polymer containing a residual amount of cyclohexane. The butene-1 make-up is provided at battery limits as a pure butene-1 stream.

Distillation Section
The cyclohexane, ethylene and butene (or octene ) plus a number of inerts and impurities are separated in the recovery area, mainly by distillation. The major streams leaving the recovery area are: Recycle cyclohexane Unreacted ethylene Recycle comonomer, butene-1 or octene-1 Butene-2 (both isomerized butene-1 and that present in the ethylene feed) is pumped to outside battery limits for recycle to the refinery. Isomerized octene-1, i.e. octene-2, is used as fuel. Low molecular weight polyethylene (RB) which is used as a boiler fuel in the higher temperature Vaporizer. Other impurities that are purged to waste or flare.

Extrusion, Stripping and Blending Section

The polymer, containing residual cyclohexane, is extruded and melt cut into pellets. Additives may be injected in liquid form either into the Intermediate Pressure Separator outlet stream or into the Extruder barrel. Solid additives or recycle polymer can be added to the Main Extruder through a Satellite Extruder. The residual cyclohexane in the pellets is removed from the polymer in the Resin Stripper, by counter current flow of steam. The cyclohexane is recovered and returned to the process. The polymer is sent to the Blenders for blending to eliminate small property variations which occur during production. Once blended, the polymer is ready for packaging.

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