POLYETHYLENE PLANT :

ABSTRACT :Over 80 million tonnes of polyethylene is manufactured each year making it th

low density ( LLDPE) (ca 0.915-0.940 g cm )-3and high density (HDPE) (ca 0.940-0.965 g cm ).P -3
of ethane and propane, naphtha and gas oil. The LDPE polymerisation process is operated under

The Reactions are as follows :

1] INITIATION : RH + O 2 —› ROOH
ROOH —› RO • + HO •
R • + CH 2 =CH 2 —› R—CH 2 —CH

2]CHAIN PROPAGATION : ᵙᵙᵙᵙᵙᵙCH 2 —CH 2 • + CH 2 =CH 2 —› ᵙᵙᵙᵙᵙᵙCH 2 —CH 2 —CH 2 —CH

Then Chain Branching and Chain Transfer takes place. The final step is termination.

3]CHAIN TERMINATION : ᵙᵙᵙᵙᵙᵙCH 2 —CH 2 • + CH 2 =CH 2 • —› ᵙᵙᵙᵙᵙᵙᵙCH 2 —CH 2 —CH 2 =CH 2

b
7

d
a 1 2 e

c
8
MATERIAL BALANCE :
polyethylenef FEED:

REACTOR : 3
e h

ethylene g

Now product stream h = polyethylene (P

h= 94 kg/hr approx.

In high pressure extru

EXTRUDER : 15% of excess ethylen

4
h i= PE+ 10% of
j= W+E
E - EREMOVED =
i

Now the almost pure e

LOW PRESSURE i

EXTRUDER : n=
m=
-23.375
275
n 5
 m

COOLER : Here the stream from low pressure extru

c n
8

LOW PRESSURE EXTRUDER :

l
6
j

COOLER :
b l

EXTRUDER : m
o
9
ENERGY BALANCE OF POLYETH

REACTOR :
ENTHALPY CHANGES TEMP(K) T2-T1

For Ethylene

First stage Outlet Temp 393.15 40

Second stage outlet Temp 433.15

Constants Specific Enthalpy (KJ/mol)

a 3.798 2217.56
bx 10-3 156.5
c x 10-6 -83.467
dx10-9 17.562

HIGH PRESSURE EXTRUDER :

ENTHALPY CHANGES TEMP(K) T2-T1

For Polyethylene

First stage Outlet Temp 383.15 50

Second stage outlet Temp 433.15

Constants Specific Enthalpy (KJ/mol)

a -39.959
bx 10-3 730.3548
c x 10-6 -5887 -427431
dx10-9 14834.97

ENTHALPY CHANGES TEMP(K) T2-T1

For Ethylene

First stage Outlet Temp 443.15 30

Second stage outlet Temp 473.15

Constants Specific Enthalpy (KJ/mol)

a 3.798 1789.89
bx 10-3 156.5
c x 10-6 -83.467
dx10-9 17.562

ENTHALPY CHANGES TEMP(K) T2-T1

For Waxes

First stage Outlet Temp 413.15 60

Second stage outlet Temp 473.15

Constants Specific Enthalpy (KJ/mol)

a 100.92 8964.752
bx 10-3 -111.839
c x 10-6 498.54

LOW PRESSURE EXTRUDER :

ENTHALPY CHANGES TEMP(K) T2-T1
For Polyethylene

First stage Outlet Temp 418.15 -35

Second stage outlet Temp 383.15

Constants Specific Enthalpy (KJ/mol)

a -39.959 -9203.83
bx 10-3 730.3548
c x 10-6 -5887
dx10-9 14834.97

ENTHALPY CHANGES TEMP(K) T2-T1

For ethylene

First stage Outlet Temp 393.15 -20

Second stage outlet Temp 373.15

Constants Specific Enthalpy (KJ/mol)

a 3.798 -1049.87
bx 10-3 156.5
c x 10-6 -83.467
dx10-9 17.562

COOLER :
ENTHALPY CHANGES TEMP(K) T2-T1
For ethylene

First stage Outlet Temp 383.15 -15

Second stage outlet Temp 368.15

Constants Specific Enthalpy (KJ/mol)

a 3.798 -776.081
bx 10-3 156.5
c x 10-6 -83.467
dx10-9 17.562

LOW PRESSURE EXTRUDER :

ENTHALPY CHANGES TEMP(K) T2-T1
For ethylene

First stage Outlet Temp 453.15 -20

Second stage outlet Temp 433.15

Constants Specific Enthalpy (KJ/mol)

a 3.798 -1165.72
bx 10-3 156.5
c x 10-6 -83.467
dx10-9 17.562

ENTHALPY CHANGES TEMP(K) T2-T1

For Waxes

First stage Outlet Temp 473.15 -20

Second stage outlet Temp 453.15

Constants Specific Enthalpy (KJ/mol)

a 100.92 -3121.59
bx 10-3 -111.839
c x 10-6 498.54

PRIMARY COMPRESSOR :
ENTHALPY CHANGES TEMP(K) T2-T1
For Ethylene

First stage Outlet Temp 368.15 -10

Second stage outlet Temp 358.15

Constants Specific Enthalpy (KJ/mol)

a -39.959 -1594.58
bx 10-3 730.3548
c x 10-6 -5887
dx10-9 14834.97

SECONDARY COMPRESSOR :
ENTHALPY CHANGES TEMP(K) T2-T1
For Ethylene

First stage Outlet Temp 358.15 35

Second stage outlet Temp 393.15

Constants Specific Enthalpy (KJ/mol)

a -39.959 6690.601
bx 10-3 730.3548
c x 10-6 -5887
dx10-9 14834.97
the world's most important plastic.Polyethylene is produced in three main forms: low density (LDPE) (< 0
Polyethylene is made by several methods by addition polymerisation of ethene, which is principally prod
er very high pressure (1000-3000 atm) at moderate temperatures (420-570 K).Structure of Polyethylene

H2

l
6

4
3 h

n 5
 m
o
9

: 1000 kg/hr

COMPONENTS qty Units

polyethylene (f) 0.5 kg/ton ETHYLENE CONSUMED: 275 kg/hr
ethylene(g) 0 kg/hr EXCESS ETHYLENE: -275 kg/hr
e 1000 kg/hr

PE) + excess ethylene (E) + chain transfer agent(g)

<neglecting catalyst stream as it is negligible>

uder (4) ,the product stream h enters at the same pressure condition.
ne is converted into waxes W and 90% of excess ethylene E remaining is removed

fE components QTY Units

waxes -41.25 kg/hr
-23.375 E Ethylene -233.75 kg/hr
E removed -210.375 kg/hr
j -251.625 kg/hr
i 251.625 kg/hr
E - EREMOVED = -23.375 kg/hr

ethylene stream enters low pressure extruder and here ethlyene is completely removed

kg/hr
kg/hr
uder n goes to cooler

c=n= -23.375 kg/hr

The impure stream j from high pressure extruder (4) enters low pressure extruder (6) via stream j.
Here waxes are completly removed and sent to stream k

component qty units

j -251.625 kg/hr
k -41.25 kg/hr
l -210.375 kg/hr

Now recycled ethylene stream l is entering cooler (7) to remove traces of any waxy contents left and
is then sent to primary compressor through (b)

b=l= -210.375 kg/hr

(neglecting traces of waxy content removed)

The pure polyethylene stream in (m) enters the extruder (9) where some stablising agent are added
and finally polyethelyene leaves as (o)

o= 275 kg/hr

Also pure ethylene stream is calculated as follows :

 a= e-b-c
a= 1233.75 kg/hr

HYLENE PLANT :

T22-T12/2 T23-T13/3 T24-T14/4

16526 6833050.23 2827481637

Pressure (KPa)

151987.5

T22-T12/2 T23-T13/3 T24-T14/4

20407.5 8339737.79 3412367105

Pressure (KPa)
T22-T12/2 T23-T13/3 T24-T14/4

13744.5 6299292.67 2888082614

Pressure (KPa)

T22-T12/2 T23-T13/3

26589 11800915.4

Pressure (KPa)

T22-T12/2 T23-T13/3 T24-T14/4

-14022.75 -5621787.7 -2.255E+09

Pressure (KPa)

T22-T12/2 T23-T13/3 T24-T14/4

 -7663 -2936745.1 -1.126E+09

Pressure (KPa)

T22-T12/2 T23-T13/3 T24-T14/4

-5634.75 -2116975.1 -795452995

Pressure (KPa)

T22-T12/2 T23-T13/3 T24-T14/4

-8863 -3928305.1 -1.741E+09

Pressure (KPa)

T22-T12/2 T23-T13/3
 -9263 -4290825.1

Pressure (KPa)

T22-T12/2 T23-T13/3 T24-T14/4

-3631.5 -1318862.6 -479005463

Pressure (KPa)

T22-T12/2 T23-T13/3 T24-T14/4

13147.75 4942525.2 1859343925

Pressure (KPa)
 -3
0.930 g cm ) and linear
duced by the cracking
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d