SC2 cracking furnace

These chemical converter units are the Pyrolysis Furnaces

Long carbon chain molecules cracking to smaller parts in the special alloy tubes in the radiation zone (800 – 850 °C)

SC-1 block diagram

Information about polymer units of TVK

„…locally large, but globally small, …how can we do anymore? „

Basic behavior of polyolefin units

Sales&M

arketing

Low MI

High MI

HO

MO CO

PO

PolymerUnits

Production

Cyclical industry with frequent transitions on a dynamic market

TVK’s PP in 2012 PP-3 PP-4

Average cycle lenght ~33 days ~31 days

Reactor grades 10~11 17~18

Final product 24 29

Nr. of transitions/cycle 9~10 16~17

Off-spec. ratio 1,1% 0,1%

Transition grade ratio 2,3% 1,7%

TVK’s PE in 2012

PE-1/LD2 PE-1/HD1 PE-2

Average cycle lenght

~24 days ~28 days ~30 days

Reactor grades 7 9 7

Final product 11 10~11 10

Nr. of transitions/cycle

6 4/line 6

Off-spec. ratio 5,1% 1,8% 1,07%

Transition grade ratio

0,8% 0,2%* 0,3%** Transition grades were created in Q4, 2012

PP4PP3

TVK’s polymer technology review

The „troops” that we have

PolyPropylenePP: linear polymer built from propylene and in some cases contains also ethylene

Tradename: Tipplen (TVK)

Three main types: homo PP, random copolymer PP (C2: (C2: 00..5-5-6.56.5%%)) and block copolymer PP (C2:(C2: 5-2 5-255%%))

Properties:

Melt index: 0.2 - 80g/10 min (230oC/2,16 kg)

C2 content: 0.5 – 20wt%

Melting range: 140 – 165oC

Licensors:

PP3; PP4: LyondellBasell / Spheripol (loop Rx with monomer as diluent)

PP-3 Unit – 100 KTA (1989) PP-4 Unit – 180KTA (1999)

Spheripol PP advantage-disadvantage

Bulk Loop vs. Gas phase reactor technology

Higher CAPEX

Easy Temperature Control at Reactors

Shorter Grade Transition Time

Narrower Product Portfolio (It means lower C2 content random

PP, TPO grades)

Lower Volatile Content in PP (Just at CR grades)

Better Catalyst Activity

Low Density Polyethylene

LDPE technologies: autoclave/tubular reactorLDPE-2 Plant started in 1991.Annual capacity: 65 ktProduct

Tradename: TipolenDensity: 0.919 – 0.925 g/cm3

Melt index: 0.2 – 4.6 g/10 min (190oC/2.16 kg)Main application: film blowing

Licensor: LyondellBasell

LDPE technologies: autoclave/tubular reactorLDPE-2 Plant started in 1991.Annual capacity: 65 ktProduct

Tradename: TipolenDensity: 0.919 – 0.925 g/cm3

Melt index: 0.2 – 4.6 g/10 min (190oC/2.16 kg)Main application: film blowing

Licensor: LyondellBasell

tubular

autoclave

LDPE tubular vs. autoclave

Shematic process of LDPE-2 Plant

High/Medium Density Polyethylene

HDPE/MDPE: Polyethylene having only short chain branches on the linear main chain

Tradename: Tipelin (TVK)

Properties:

Density: 0.935 – 0.965 g/cm3

Melt index: 0.1 - 50 g/10 min (190 oC/2,16 kg)

Melting range: 125 – 135oC

Licensor:

PE1/ HDPE-1: Chevron Phillips (loop Rx with light diluent)

PE2 / HDPE-2: Mitsui Chemicals Inc. (stirred tank Rx with heavy diluent)

0,915 0,926 0,940 0,970

No of SCB

HDPEMDPE

LLDPE

PE-1/HDPE-1 Unit – 200KTA (1986)

Treaters

ethylene

isobutane

hexene-1

hydrogen

Loop Reactor(90 – 106°C; 42barg)

Flash Tank (60°C; 0,3barg)

Cyclone

Bag Filter

Dryer (70°C)

Purge Column (75°C)

HDPE fluff to powder silos

Flash Gas to recycling system

PowderSilos

(8pcs)Homogenizer

Additives

• Silo farm (28 silos)• Bagging machines (2 lines)• Truck loading facility

Continuous Intensive Mixer (CIM)

Repellet

Extruder (210°C)

DryerClassifierScales

HDPE pellets

PE-2 / HDPE-2 Unit – 220KTA 2004

Termék

H2

Comonomer

Centrifuge

Dryer / 105°C

Powder Silo

Pellet Silo

TEAL

Solvent tank

Homogenizer

Daily tank

Mixing

silo

Low Polymer (LP)

VOC: ~33 -> 0,1wt%

2/3

1/3

Fresh solvent

Packa-ging

Packa-ging

R1: 85°C/7barg R2: 75°C/2.5barg220°C

Advantages, disadvantages in the HDPE units

PE-1/HDPE1 vs. PE-2/HDPE-2

Less rotation maschine - Higher reliability Excellent diluent recovery Broad density range (0,962-0,935) Lower catalyst costs Less steam consumption Lower volatile content (instead of MDPE) MI correction in the extrusion section

Higher electricity consumption Just monomodal products Longer transitions Lower flexibility

Wider product range (mono and bimodal) Shorter grade transition time High flexibility Lower pressure in the reactor part Start and stop without flaring Lower ESP in the extrusion section Possibility to use C3- instead of purchased

co-monomer

Higher steam consumption in the diluent recovery section

Higher specific diluent consumption Higher volatile content Higher maintenance costs

Process Control - Optimization

Try to find….…keep it…

…automate it.

General process control scheme

Optimization

3 basic rules:1 – Safety2 – Quality3 – Economic goals

The economical situation forces the polymer producers to find „new operating region”, and they would be able to adopt new technics to remained there in every different workpoints.

Weak demand

APC the most common tool for optimization The APC is not a „magic weapon”. This is that tool wich can help us to keep the plant

near to the optimum continuously if the operators are familiare with that. The two most critical behaviors of a polymer plant: Non-linearity, multivariable

Thank you for your kind attention!