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    PP Process

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    TECNIMONT egy foment 4194 Ub 2.2 DETAILED PROCESS DESCRIPTION Process aspects checked and approved by technologies group of Himont thalla srt TEGNIMONT SBA -SEDE LEGALE IN MILANO = TALIA. GAPITACE SOCIALE | 7.500.000.000 iv Tecnimont Foplie 2 222.44. DETAILED PROCESS DESCRIPTION ‘The description is based on the process flow diagrams with material balance and on the P & I diagrams. Catalyst, co-catalyst and Ligui iti rage and metering The catalyst system consists of three components: - Titanium catalyst supported on HgCL2 Aluminium triethyl - Donor ¢ a silane: compound) ‘The three components are fed to the reaction separately. a. The aluminum alkyl, which is used at 100% concentration, reaches the battery Limits in cylinders 1 m3 volume about. Cylinders are unloaded by nitrogen pressure into the storage drum 06-0 111 and from it, always by nitrogen pressure, alkyl is transferred to the process metering drum 06-0 101, After filtration O6-F 101, it is fed to the reaction by means of the pumps 05-P 101 A/B which are feedback adjusted by an automatic control Loop. The drum 06-0 101 is operated at atmospheric pressure under nitrogen, blanketed through the hydraulic seal drum 06-0 103. 08-0 101 can be pressurized only for purging purposes to transfer the washing oil to exaust oil drum 06-0 702. Owing to the hazardous nature of the alkyl, the section has been provided with @ washing (with oil) and purging (with nitrogen) system in order to make the maintenance easier. The fresh oil is stored in 06-D 104 and distributed under pressure by means of the pump 05-P 102, after filtration in O6-F 102, to items (pumps, filters, instruments) that may need maintenance. The quantity of oil used for washing is shown by the volumetric flow meter 06-FQ 1103. The contaminated oil is collected into 06-0 102 and then sent to the oil treating unit. Tecnimont Faghia 8 2.2.1.3. 2.2.1.4. Donor is stored in 06-0 110 A/B and is used pure or diluted in oil, depending on the plant Load and on the desired product. The total flow to the reaction must never be Less than 0.5 L/h. Oonor is fed to the reaction through metering pumps feedback adjusted by an automatic flow control Loop. The drums 06-0 110 A/B are operated under nitrogen blanketing. age_of talyst The catalyst Ca crystalline solid having controlled par- ticle size) is dispersed in a mixture of paraffin oil and grease before being fed to the plant. The mixture con- sists of 33% paraffin grease and 67% oil in volume. It is prepared in 06-0 105 and kept at 70 °C to obtain a single Liquid phase. The oil/grease solution is transferred to 06-0 106 through the pump O5-F 105. The quantity of mixture to be transferged is pre-set by a volumetric meter. Ouring the transfer the solution is filtered in 05-F 105. The catalyst powder, stored in drums, is added ta the hot oil/grease mixture in 06-0 106. Catalyst dispersion is ensured by the ribbon agitator O5-M 105. The vessel where dispersion is carried out is provided with the vacuum pump 06-k 101 to remove any moisture present in the ail/grease mixture after transfer to 06-0 108 and any solvents traces. 06-0 108 is jacketed. Water is recirculated inside the jacket by the pump O5-P 106. The water is heated in 06-E 101 during the filling and dispersing steps and cooled with chilled water to make the mass more consistent and prevent catalyst settling. The catalyst paste is transferred to the metering syrin- ges in the reaction section by pressurizing 06-0 105 with high pressure nitragen. Catal: paste met The syringes are fitted with a piston that compresses and feeds the paste to the reaction. The movement of the piston, which determines the catalyst feeds, is controlled hydraulically by the volumetric pumps O6-P 108 AYE. Tecnimont Foglio , 4 2.2.1.5. i 2.2.1.6. Syringes switch-over is automatic, controlled by Limit switches, The syringes filling sequence is manually actuated. After filling, they are connected on, the oil side, to a hydraulic pressurizing system to prevent, (because of paste compressibility and elastic behavior of ‘the piping), stopping of the metering operation for several minutes during syringes switching, with the resulting risk of Line plugging. The pressurization system, consisting of the pumps 06-P 107 A/B, keeps the stand-by syringe at a pressure close to the working pressure so as to prevent stopping in the catalyst paste flow when the syringe is connected. An automatic device prevents connection of a non-pressurized syringe. The pumps O6-P 107 A/B and the accumulator 06-Z 105 are also used for emptying of the syringes back to 06-D 106. 59 Mntifouling additive is stored in 06-0 1712, and is fed to the 2nd loop reactor discharge through metering pumps 06-P 111 A/B, feed back adjusted by an automatic flow control loop settled by O5-FRCA 1102. The drum 06-0 112 is operated under nitrogen blanketing. The additive is used during high impact copolymer run only, in order to guarantee a better distribution of bipolymer inside homopolymer matrix and prevent from reactivity of polymer fine powder possibly coming from loop reactors. The catalyst paste flay rate is on independent variable and sets the plant load through the yield. The aluminum alkyl fed to the plant is rationed to the propilene feed to the reaction. This is done in order to keep an alkyl concentration in the reaction allowing the plant not to be affected by any minor changes in the water, oxygen or alcohol contents in the propytene feed which would cause market fluctuations in the yield and isoctaticity index. The donor is also fed in a pre-set ratio to the aluminum alkyl. These ratios are set so as to maintain the resulting aluminum/ titanium and donor/titanium ratios within the preset range under the normal operating conditions. Tecnimont Faglio N 5 In particular, the donor titanium ratio is the parameter through which the isoctaticity index is controlled within the 84/89% insoluble range. Liquid additive flow rate is slave of TEAL flow controller. ‘The feeding criterion is to start gas phase reactor with an additive/teal ratio of 0.5 by wt. The Level into gas phase reactor will be positioned in order to keep the pressure constant. The additive flow rate shall be increased unti level into reactor increases of 10% and then maintained at this value. Tecnimont fee Fagin & 2.2.2. Precontacting and prepolymerization 2.2.2.1. Precontacting_ The catalyst suspension in the oil/grease mixture, the donor and the aluminum alkyl are precontacted in 06-0 207 at about 10 “C. Here the reactive centers of the catalyst are activated for the subsequent contacts with the monomers. This operation is carried out in a smoll agitated vessel 06-0 201 (volume about 3 liters) kept at constant temperature by thermostatized water recirculation in the jacket. The feeds are sent in from top through dip tubes and the mixture is made to overflow to prevent gas pockets. The precantacting pot agitator has an outer tandem-type double mechanical seal and an inner grafoil stuffing-box seal. The space in between is kept under pressure by barrier and flushing oil. In case of the inner seal dete- rioration, the flushing oil flow is Limited to 200-300 em3/h by feeding capillary. 2222. 6 sthe propylene. ‘The catalyst mixture leaving the precontacting pot is injected into a stream af propylene cooled down to 10-20 °C in 06-E 201. The propylene flow to the injectors (vhich will determine the catalyst residence time in the prepo- lymerizer) must never be less than 2500 Kg/h to prevent plugging of the prepolymerizer feeding and discharge Lines. | 2.2.2.3. Prepolymet | ‘The reaction is conducted in a small prepoly loop reactor at the following conditions. - Temperature: 20 °C - Pressure: 34 barg (some as in the primary reactor) Residence time: about 4 minutes (set by the sum of the Propylene flows to O6-£ 201 and 06-P 200) Tecnimont Fogle §, 7 The reactor is operated completely full of Liquid (pressure well in excess of the vapor pressure of the Liquid). It has a geometric capacity of 0.46 m3. Circulation is ensured by the axial flow pump 05-P 200. The slurry velocity in the reactor is about 4 m/sec. The heat of reaction is removed by jacket cooling with chilled water. The pump 06-P 204 A/B keeps a constant flow rate in the Jacket. Thermal regulation is obtained by adjusting the water temperature with cold make-up water. The axial flow pump 06-P 200 has a double back ta back mechanical seal. Continuous propylene flushing is provided towards the reactor inside (400 kg/h) to prevent the polymer from reaching the seal surfaces. The pressure of the flushing liquid sets the barrier/lubricating oil pressure between the two mechanical seals through the pressurization piston 08-2 200. The piston is designed in order to increase the ratio oil pressure versus propylene flushing Pressure at 10%. In case of emergency (propylene shortage, failure of O5-P 200 etc.) the reactor, 06-E 201 and all the piping involved are quickly discharge to blow-down after automatic shut-off from the other plant sections. Tecnimont ee Fogln 8 2.2.3. Liquid monomer polymerization 2.2.3.1. Polymerization conditions The polymerization reaction for homopolymer or ethylenepro- pylene random copolymer production takes place in two Loop reactors in series. This arrangement, with monomer feed to both reactors, was designed to increase the mean residence time as far as possible and, at the same time, to narrow the residence time distribution. Polymerization conditions either for homopolymer or random | copolymer production are the same on bath reactors, except | the residence time which is higher in the first one. In particular: - reaction temperature 70 °C ~ pressure 33-34 barg = residence time 06-R 204 4h Cat max Load) - residence time 06-R 202 : 0.5 h (at max load) - slurry concentration 3 about 50 % wt 2.2.3.2, Prepolymer feeding Prepolymer Flows from 06-R 200 directly into 06-R 201 and is dispersed in the slurry that 1s kept circulating in the reactor. | 2.2.3.3, Propyl The propylene from the filters O6-F 201 A/B is fed to 05-R 201 under density control in the reactor. The total feed is divided into 4 streams: - Propylene fed to prepolymerization which is kept con- stant through flow rate control = Propylene flushing the prepalymerizer pump 06-P 200, kept constant through flow rate control Tecnimont apo N 2.2.9.4. 2:80:38: = Propylene flushing the pump O6-R 201 COB-P 201), kept constant through flow rate control - Propylene fed directly to 06-R 201 under total flow rate control (including the three previous flows) slave of the reactor density controller. Slurry transfer from O6-R 201 to 06-8 202_ Since O8-R 201 is operated completely full, amass flow rate equal to the sum of the inlet flows is continuousty transferred ta 06-R zOZ through the slurry transfer Line (bridge connection). In case of plugging of that Line, the slurry will be automatically transferred from 06-R 201 to 06-R 202 under pressure control, through O6-PV 2423 Located on the by-pass Line of the pump O6-P 202 (belt connection). Since the discharge in this case will be much thicker than normally, the propylene feed streams will shift towards OB-R 202. Propylene feed to 06-R 202° The propylene from the filters O6-F 201 AYE is sent to 06-R 202 under density control in the reactor. The total feed is divided into three streams: - Propylene flushing the pump of 06-R 202 (06-P 202), kept under constant flow rate contrat - Reactor pressurizing propylene, fed to 06-E 203 under pressure control = Propylene fed directly to 06-R 202 through total flow rate control (including the two previous streams), slave of the reactor density controller. Tecnimont Foglia N 10 2.2.3.6. 2.23.71 2.2.3.8. 2.2.3.8. Hydroger Hydrogen is used to control polymer intrinsic viscosity. It is injected separately into the tvo total propylene streams being fed to the loop reactors. Both hydrogen feeds are sent under flow rate control slave of a hydrogen concentration controller, taking into account even possible leakages and also the hydrogen already present in the recycled propylene. For random copolymer production, the two loop reactors are fed separately with Ethylene under flow rate control. The total amount will be set according to the desired ethylene content of the polymer as a function of the plant load. The feed will be shared between the two reactors on the basis of their productivities which can be detected fron the average temperature difference between reactor and jacket water. The split is usually 65% in 06-R 201 and 35% in 06-R 202. Slurry discharge from the re The sturry is nermaliy discharged from 06-R 202 — through 0S-LW 2213 on the line of the primary flash under Level controt on the dumper 06-0 202. In case of unavailability of 06-R 202, the level control can be switched to Hv 2505 on O6-R 201 Coperation with a single reactor). In this case the sturry will be discharge through the stand by flash Line which ends up into the primary flash through the S-way valve HV 3017. in_the rt Slurry concentration The only Limitation to the polymer concentration consists in circulating the slurry that is recycled inside the reactors by the axial pumas. The industrial experience shows that the reactors can easily be operated up to a slurry density of 560-565 Kg/m3 (corresponding to about 50% solid by weight) at the reaction temperature, Tecnimont Foglia N " 2.2.3.10 Above these concentrations pumps power absorption rises very quickly and makes their operation unstable. with the catalyst not showing any appreciable degradation (with 1.5 hours residence time) the productivity of the two reactors can be theoretically envisaged (as confirmed by the industrial experience) at 65% of the total for the first reactor and 35% of the total for the second. Obviously the polymer concentration must be kept as high as possible to abtain the maximum productivity. In order to maintain the solid concentration in the slurry, the density controllers will adjust the total propytene flow to the reactors ta the amount of polymer produced plus the liquid that is carried cut of the outlet of O6-R 20Z. The solid concentration after the discharge can be appreciably different from that in the reactor because of the polymer centrifuging effect in the elbows, It is usually higher. The total quantity of liquid fed to the reactors is actually 1.8 to 1.9 times the polymer produced (slurry concentration in the reactors -50% by weight). The same density controllers will divide the propylene stream between the two reactors according to their productivities and to the concentration of the slurry sent from 06-R 207 to O6-R 202. To prevent plugging of the slurry transfer tine from 06-R 201 and O6-R 202, the total propylene flow to O6-R 201 must not fall below 5 t/h. It follows that for plant Loads below 50% of the target capacity the reactor slurries will have to be diluted. The same operation will be necessary at low plant loads during production of — heterophasic copolymers, to allow adequately active catalyst to reach the gas phase reactor. 05-0 202 (Dumper) and 06-€ 203_ ‘The combination of an expansion drum, 06-0 202, and an evaporator, 06-E 203, is exploited to keep the reactors always full and prevent at the same time any pressure fluctuations in case of unbalance between inlets and outlets or quick temperature variations in the reactors. A pressure of 4 bar above the monomer vapor pressure at the reaction temperature Will be maintained in the expansion drum, by means of the vaporizer O6-E 203. Tecnimont Foglia 13 The vhole system, which is filled with demineralized water, is protected against corrasion by nitrogen blanketing of the expansion drum, by accurate pH control and passivation additives make-up, added via 06-Z 203. Ouring plant start-up the reactors jacket water is drawn, to the operating conditions by means of two steam heated exchangers 05-£ 204 and 06-E 205. 2.2.3.93. Stand by connections _ Each top reactor elbow is provided with a valve (operated from the Control Room) for gas venting during reactor fil- ling. The valves can be used, in case of unavailability of both primary and stand-by flash Lines, to dispose of the entire discharge flow from 06-R 202 to blow-down. Each bottom elbow is provide with a discharge valve, operated from Control Room, to drain reactors to the degassing section through the flash (ines. 2.2.3.14. Emergency devices In case of emergency on any of the reactors Chuge propylene leakage, failure of the slurry circulation pump etc.) the reactor involved can be automatically shut off and isolated fron the rest of the plant. Three actians can be performed to protect each reactor: - Emergency killing: whenever it is necessary to stop the reaction quickly, @ mixture of nitrogen and carbon monoxide can be injected into the lower part of each reactors leg. The operation is controlled fron the contrat room. - Polymer discharge from the bottom: in case of failure of the slurry circulation pump and ineffective killing, the settled solid phase can be discharge to the H.P. blow-down vessel 05-0 601 where the reaction stops because of the low temperature. This operation can be performed by the operator through board H5 or autonati- cally through PS installed on Lower reactors bends. - Rs ultimate solution, the reactors are protected by | + safety valves on the upper elbows connected to the high pressure blow-down. Tecnimont Fogo N 4 2.2.4, 2.2.4.1. Since a large quantity of Liquid monomers is discharged by Loop reactors together with polymer, this must be re- covered. The first operation consists of a complete evaporation of the Liquid and it is performed in a pipe at high velocity. The required heat is supplied through a steam-heated jacket. AR cascade control sets the steam pressure to the jacket through 2 temperature controller on the vapors Coming out the top of the degassing stage. This solution provides the possibility of adjusting the flash evaporating Capacity to the plant Load, keeping the wall temperatures as low as possible. Two flash Lines are provided: a primary flash for normal operation and a secondary for plant emptying and emergencies caused by abnarmal running of the sections downstream the reaction. The stand-by flash is aligned tot he primary flash through HV 3017 during normal operation. In case of upsets in the flash drum (O6-CY 301) the reactor discharge can be aligned to the secondary flash (HV 2512) that can be aligned to the blow-doun (HV 3017) to dispose of all the reactor discharge flow during downtime. After Leaving the flash piping, the solids are separated from the gas in 06-CY 301. The flash drum activator O6-M 301 on the gas outlet from 06-0 301 prevents any substantial solid entrainment in the gas stream. The polymer collected from the bottom of the flash Separator is discharge under level control to the recycle gas filter 06-F 301. Temperature and flow rate of gas leaving 06-CY 301 are controlled. Temperature controller acts on the pressure of the steam in the flash piping jacket while the flow rate controller acts on the flushing propytene inlet valve at the beginning of the flash pipe to keep a minimum speed to convey the solid regardless of reactor slurry discharge. The gas Leaving 05-0 301 is directly sent to the scrubbing tover 05-C 301. Fogle 2.2.5, 2.2.5.1. Low pressure di re rine 92: The polymer and monomer stream coming from the flash drum Q6-CY 301 (homopolymer or random copolymer run) or from the gas phase reactor (heterophasic copolymer run) are fed to the low pressure degasser 05-F 301 together with 06-C 307 bottom drain and the gas stream recycled from polymer steaming section. A 50/50 Irganox oil mixture is injected to stabilize the polymer along this connecting Line. 06-F 301 is a bag type filter. The filter bags are automatically cleaned by counterwashing with propylene gas from the top of propylene scrubbing tower after adequate pressure re- duct ion. A Liquid separator (blow back gas drum), prevents Liquid propylene from reaching the filter bags. The polymer collected at the bottom of the filter is continuously discharged to the steaming section under Level control. The filtered gas is sent to washing and compression. A guard filter (O6-F 302) prevents any Large amounts of powder fron reaching the compressor in case of rupture of the bags of the primary filter, Safety Devices = incase of failure of the recycle gas compressor (06-PA 3078), @ spare compressor 06-PA 3018 is provided. During this switch-over the whole gas flow leaving the filter can be sent, under pressure contral, to the flare systen. - should the flow rate to the filter exceed the compressor intake or the flare discharge capacity (only as result of matfunctioning of 06-PA 301 A/B or O6-CY 301 or 06-R 401 valves), a high pressure shutdavn system cuts off any discharge to the filter. - incase of upsets in 05-F 301 due to bottom discharge difficulties or bags damages the polymer feed can be routed through HV 3126 to the blow-dovn to allow a nor- mat plant shutdown. When the emergency ceases HV 9126 is aligned to 06-F 301 again. Tecnimont Fogiwn 16 - in order to avoid water return to the filter from the downstream steamer, the 05-F 301 pressure must always be higher than that of the steamer 06-0 S01. A O6-F 901 - | 06-0 501 differential pressure gauge cuts off the discharge from the filter whenever the pressure difference drops to zero or is inverted. - a low temperature shutdown on the filter bottom pre- vents any Liquid propylene (exceptionally present in the filter? from flowing to the steamer. = a minimum Level shutdown an the filter bottom prevents Discharge of huge quantities of propylene gas to steamer. = the filter is protected against overpressure by a sa~ fety valve connected to the flare header. 2.2.5.2. Recycle and Compression gas_washing column (06-C 302 -"05-E 304 - 05-0 304 - 06-PA 307 A/E) | Gas leaving the filter 06-F 301 is washed with oit and Atmer 163 (ratio 2:1 volume) in the column O6-C 302 in order to remove any powder entrainment and reduce the aluminum alkyl content of the recycled gas. The mixture, which is kept circulating in 06-C 302 by the pumps 06-P 304 A/B gets richer and richer in aluminum alkyl and must be replaced at regular intervals. ‘Tecnimont FopieN 17 The gas Leaving 06-C 302 is cooted down to 40-So*C in 06-E 304. Any entrained Liquid is removed in 06-0 304. The gear pump 06-P 303 is used to transfer to O6-C 302 the Liquid collected in 06-0 30¢ and in the O6-PR 301 A/B suction snubber as well as to fill the system with fresh oil. Tt is also used for all compressor washing and purging operations. The gas leaving 06-0 304 is compressed by 06-PA 301 ANB to 20 barg and sent to O6-C 301 during Homapolymer or Random Copolymer run, or to O6-C 402 during Heterophasic Copolymer run. Compressor suction pressure is controlled by recycling some of the gas from delivery to suction upstream of O5-E 304). The suction capacity of 05-PA 307 A/B is roughly adjusted to the gas load from 06-F 307 by step-by-step partializat ion. safety Devices ALL the equipment between 06-F 301 and O6-PA 301 A/B are protected against overpressure by the filter safety valve. In case of external fire the equipment pressure is released | to the flare. Tecnimont Fogo 1% 2.2.6. 22.645 2.2.6.2. ne scrubbing and plant fee: Scrubbing (06-C 301) and condensing (06-E 301)_ In order to remove any entrained powder and Teat, the gas stream fron 05-CY 301 top is fed ta the propylene scrubber 06-C 304, together with compressed gas from 06-PA 301 A/B (homopolymer or random) or ethylene stripper bottom stream (high impact). A continuaus drain of S00 kg/h from the scrubber botton to the Low pressure degasser O5-F 301 prevents solid buildup inside the column. Washing propylene is fed to the column top under Level control on the bottom. In order to maintain a constant reflux of about S000 kg/h, independent from the plant load, a battom reboiled 06-€ 303 15 provided. ALL the gas leaving 06-C 301 top is condensed in 06-E 301. A pressure controller adjusts the flooding of the condenser 06-E 301. A purge gas stream under automatic flaw rate control is routed to off gas header from 06-£ 301 to keep the desired propane content in reactors feed. Pumps 06-P 302 A/@ ensure reflux to the column and conveyance of the condensed pro- pylene + propane to the reactor feed tank. ve. The recycle propylene condensed in 06-E 301 is sent to the feed tank 06-0 302. Fresh propylene is fed in under Level control on this tank. The recycle (60% wt propylene) and the fresh feed are combined and fed to reactors through high head pumps 05-P 301 A/B. In order to keep pressure in propylene header ta reaction as stable as possible, the pumps are operated at constant capacity through flow rate control and recycling to 06-0 302. For the same reason the feed tank inside pressure is kept constant by evaporating part of the Liquid make up in 05-E 302, therefore raising also the NPSH available on pumps 06- P 307A/B. The cooler 06-£ 30S on pumps recycle avoids heating while plant not running. Tecnimont 2.2.76 2.2.7.4. Gas phase copolymerization Heterophasic high-impact copolymers are obtained by adding a gummy phase, consisting of ethylene-propylene bipolymer, to the homopolymer matrix coming from bulk polymerization in Loop reactors. Reactor 06-R 401 Polymerization of high impact copolymer is carried out in the vertical cylindrical reactor 06-R 401. The polymer forms a bed fluidized by means of reacting monomer gases recycled to reactor bottom by the centri- fugal compressor Ob-k 401 and blown at high velocity under the polymer bed by a specially designed grid. Polymer particles mechanical action that impinge on the wall and a continuous purge of gas to the cyclone 06-CY 401, connected on its bottom to the bag filter 06-F 301, ensure adequate cleaning and avoid any powder build-up. The clean top stream from 06-CY 401 is recycled to the cen- trifugal compressor suction. The gas surface velocity must not be Less then 0.7 m/s in order to achieve @ good fluidization regime. Operating conditions of copalymerization reactor are the fotlowing: Pressure: 14 bar.g Temperature: 60°C Mean residence time: 0.5 h Cat max Gapacity) Average solid bed density: 350 kg/m R slow scraper, 06-M 401, prevents polymer accumulation on the reactor walls. The homopolymer is fed from O6-CY 30% to the top of reactor while the copolymer is discharged under Level control fron the bottom to the low pressure degasser through a not fluidized discharge "pocket" also stirred by 06-M 407. Tecnimont Fag N e272. 2.2:7.95 2.2.7.4. 222768. Cooling systen The heat produced during the reaction is removed in a vertical heat-exchanger: 06-E 401. Cooling is provided by circulating demineralized water Coming from 06-E 202 under temperature control. ‘Compe The Fluidization stream is recirculated by means of the centrifugal compressor 05-K 401. Gas flow rate is recorded and can be varied over a certain range by acting on the guide vanes on compressor suction fron the controt room. In any case the superficial fluidization velocity must not be Less than 0.7 m/s. This condition ensures the compressor always working outside surge Limit. Reactor pressure control is essential to this purpose. eal During high-impact copolymer runs, gas from 06-PA 301 is pre-cooled in 06-E 403 and fed to the stripper O5-C 402. The gas vapors, rich in ethylene and hydrogen, are re- cycled to gas phase reactor; the bottom stream, con- sisting of propylene and propane, is fed to 06-C 301 with gas coming from 06-CY 301. The top column temperature is adjusted to keep the operating pressure of O6-R 401 at the required Level acting on the amount of propane recycled to O6-R 401. Eventual light inerts can be vented from the column top under flow rate control. ethyl Ethylene is fed to 06-R 401 under flow rate control, set on the basis of the homopolymer flow rate from loop reactors and of desired ethylene content in the final product, through the OCS system. Tecnimont Foglia 21 2.2.7.6. 2.27.7. 2.2.7.8. Propylene feed_ Propylene is supplied as Liquid from B.L. to 06-k 407 deli- very under flow rate control, which must be set by the gaschromatographic analyzer of reactor gas mixture, since no easily assessed propylene quantities enter 06-R 407 together with homopolymer from 05-CY 301. In this way the ethylene/propylene ratio in 06-R 401 (that determines the composition of the copolymer produced) is fixed. Hydrogen _feed_ Hydrogen is fed to 06-R 401 under flow rate contral, set by the gas composition gaschromatographic controller, because of undetected quantities eventually fed to the gas phase together with the homopalymer from 06-CY 301 andor vented from the top of 06-C 402 to keep the Light inerts content (ethane, nitrogen, methane, etc.? Low. Hydrogen content of the monomer mixture determines dipo- lymer intrinsic viscosity. Pressure control in 06-R 407 The pressure in 05-R 401 must be kept close to the opera~ ting levels (14 barg) far the following reasons: - ensure a working point (flow rate head) for 06-K 401 sufficient to keep the polymer bed thoroughly fluidized. For this reason the pressure must never fall below 3 barg. - ensure sufficient gas circulation to keep a low dT between reactor gas inlet and outlet. = ensure an adequate heat transfer coefficient in 06-f 401 - maintain a sufficient monomer concentration (molefm) to guarantee the required production. ‘The pressure will be kept at the desired level (in the production of polymers having different bonded ethylene contents or at different Loads? by adjusting the solid level into reactor, according to the required dipolymer production (so as to keep the lowest possible level in the reactor and will be influenced through the inert content in ‘the reactor (mainly propane). Tecnimont on mc Fagin 22 The propane amount is adjusted by acting on 06-C 402 top temperature and on gas flow fate from 06-CY 401 to 06-F 301, up to complete capacity of the recycle compressor 05-PR 301 A/B. 2.2.7.8. Emerg Since the system does not have a large monomer hold-up, the operating risks are not high. However a severe upset can result from electric power black-out or failure, for any reason, of the Fluidization gas compressor. In both cases, the reactor will be automatically shut off and quickly depressurized ta flare to prevent polymer sticking in the reactor. If necessary, CO (diluted with nitrogen) can be injected into the system to stop the reaction quickly. Tecnimonr othe N 23 2.2.6, 2.2.8.1. 2.2.8.2. Steaming and recovery of monomers dissolved in the polimer Steamer 06-0 501. From the Low pressure degasser 06-F 307 the polymer, which still contains 1% wt of dissolved monomers (mostly propy- lene + propane), plus %7- 1.53 vt of gas Tlowing across fitter discharge valve, is fed by gravity to a removed bed steam treatment. Geactivation of the catalyst residues and stripping of the Uissolved hydrocarbons are obtained in this unit. The item is a vertical cylindrical vessel with a slow agitator that guarantees a polymer plug flow through the vessel. The steam distributer consists of a sieve plate. Polymer is discharged by gravity under level controt. The outgoing gases flow through a cyclone (OE-CY 501 steamer cyctone? for removai of the entrained polymer fines. In order to avoid vater condensation anc hence corrosion, the unit is completely jacketed with steam. ca The steam from the steamer 06-0 01 is sent ta the steamer serubber 06-C S01 end condensed in 05 E SD1. Funps 06-P 501 Ale Keep the water circulation in the scrubber. R plate in- side the column collect the water condensed from 06-2 501 and sends it to 3 decanter (06-0 S03). The Lighter organics Coil or oligomers) overflows anc are discharged in a drum while water is recycled to the top of the column. The condensate and any polymer traces are discharged from 06-C 501 bottom under Level control. The overhead gas

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