Classification: Internal Use

SAN Parking Guidelines:

By Jeff Simons

SAN lines are normally parked for maintenance due to a mechanical failure. The failures may occur
suddenly without warning or may have warning signs that allow for a more proactive park.

The goal in either case is to cool and thin the reactor contents so the exothermic reaction can be
controlled and the reactor does not set up. Additional NOM, EB and recycle from the decanter are
often used to cool and thin the reactor.

For a planned park, the idea is to reduce the inventory in the system prior to stopping and letting
the inventory slowly build up in the reactor during the park. This helps to keep things thin and
cool and makes restart simpler with less off grade.

For an emergency failure, the system inventories normally go up as rates are reduced. As soon as
you recognize that the line will be in emergency park mode, turn off the peroxide flow to the
reactor. These failures often require an increased rate of NOM as feeds are cut (5 to 10 kg
minimum of additional NOM) as well as feeds or recycle to cool and thin the reactor. If the level
gets too high and more cooling or thinning is required then EB is required.

For a planned park the normal method is:

1. Estimate the amount of time that maintenance requests. Multiply that time by 2 to
estimate the total amount of time required.
2. If the total repair time is < 4 hours:
a. Prior to the park, reduce production rates but maintain the prepoly pumps and
downstream equipment at a higher rate, just like a shutdown. This will start to
reduce the level in the reactor. Reduce the level in the reactor so that you can
maintain feeds into the reactor at 700 kg/hr of rates and after the park is over have
a normal level in the reactor. So, if you are going to be down for four hours you
need to remove at least: 4 hrs * 1100 kg/hr of feed into the reactor = 4400 kg. So
lower the level by at least 4400 kg. However, it is always a good practice to be
conservative, so we would typically reduce the level by 25% more if possible.
b. As you are reducing level in the reactor, add 50% more NOM than the condition
card calls for. This will thin the contents and help on restart.
c. When the reactor is at the desired level, empty out the flash chambers. At this
point you can stop all 3 polymer pumps.
d. Maintain normal temperatures (per the condition cards) on flash chamber heaters
and flash chambers. Maintain normal vacuum.
Classification: Internal Use

e. Every hour during the park (if possible depending on where the maint failure is)
move ~ 500 kg of material from the reactor to the FC 1 to FC 2 to the floor. This is
especially important for the prepoly line as the contents of that pipe will go to 100%
conversion and be very difficult to pump on restart if you don’t periodically replace
the material in that pipe.
f. Remember – even with a screen changer, pelletizer or diverter valve failure, the PSE
on the outlet of the FC 2 melt pump can be removed and material can be purged
to the floor at that location. Moving material significantly eases the restart.
g. Once maintenance is complete, restart the line. Do an adequate purge on the die
plate. Segregate the off grade material and increase QC testing to hourly to
determine the quality status of material.

For an emergency park (more like a crash), the goal is to cool and thin the reactor contents.

1. Cut rates immediately to 700 or 1500 kg/hr. Reduce reactor pressure in steps to keep from
overwhelming the vent scrubber and to insure the vapor in the reactor is allowed to cool in
the condenser so the cool/refluxed/condensed monomer rains back into the reactor
providing cooling and thinning. Never vent through the other vent paths unless it is a true
emergency.
2. Add additional NOM, typically 5 to 10 kg.
3. The reactor level will rise and torque will increase. Use reactor feeds to cool the reactor as
rates are cut, with the goal of having the melt temperature at 105 more or less before the
feeds are turned off.
4. Manage inventories in the flash chambers. Generally, less material in the flash chambers is
better from a quality standpoint on restart. So, if you can hold up material in the reactor
do so.
5. Periodically, just like above, move material from the reactor through the system to the
floor. Material removed from the system allows you to add more feeds to further cool and
thin. Do not be afraid to purge tons of material if required.