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LOOP REACTOR
General Equation:
nC2H4
(CH2-CH2) n
where n: 2
2C2H4
(CH2-CH2) n
C4H4
C2H4 C2H4
C2H4 C2H4
C4H4 + 2H2
C2H4 C2H4
Stream 3
Stream 7
A = F
B= 27581.59 kg/hr
Loop Reactor
0 kg/hr Ethylene
0 kg/hr Hydrogen
For the comonomer and diluent chemical which are 1-hexene and isobutene have equal
mass flowrate of inlet and outlet. This is due to the equation involved in the loop reactor are only
ethylene and hydrogen. The rest were comonomer and diluents chemical are used just to enhance
the process of polymerization.
i= o +
Ethylene
27029.96
-1
827.447= o-
Hydrogen
52542.93
-2
-2
137.908= o- 2
1-hexene
137.908
137.908
Isobutene
275.816
275.816
Polyethylene
+1
26202.51=
= 26202.51
Ethylene:
i= o +
827.447 = o +
827.447 = o + 26202.51
o = 27029.96 kg/hr
Hydrogen:
i= o +
137.908 = o - 2
137.908 = o 2(26202.51)
137.908 = o 52405.02
o = 52542.93 kg/hr
TOTAL (Inlet), A = 01 + 02 + 03 + 04
= 27029.96 + 52542.93 + 137.908 + 275.816
A = 79 986.61 kg/hr
FLASH CHAMBER
The unreacted diluent (Isobutane), any monomer vapors (ethylene) and all co-monomer
(1-hexene) recovered in flash vessel typically condensed and reused in polymerization process.
Meanwhile hydrogen was completely used in this flash chamber. The product leave the flash
chamber was polyethylene contain 98% purity and small excess ethylene.
Composition (weight/weight)
Inlet Stream (No. 7)
Ethylene
0.03
0.68
0.02
Isobutane
0.01
0.22
1-Hexene
0.005
0.10
Hydrogen
0.005
Polyethylene
0.95
0.98
Flash Chamber
Stream 9
B = 27163.69 kg/hr
i) Polyethylene:
= 0.95 x 27581.59 kg/hr
= 26202.51 kg/hr
ii) Ethylene:
= 0.03 x 27581.59 kg/hr
= 827.45 kg/hr
iii) Isobutane:
= 0.01 x 27581.59 kg/hr
= 275.82 kg/hr
iv) 1-Hexene:
= 0.005 x 27581.59 kg/hr
= 137.91 kg/hr
v) Hydrogen:
= 0.005 x 27581.59 kg/hr
= 137.91 kg/hr
i) Ethylene:
= 0.68 x 417.90 kg/hr
= 284.17 kg/hr
ii) Isobutane:
= 0.22 x 417.90 kg/hr
= 91.94 kg/hr
iii) 1-Hexene:
= 0.10 x 417.90 kg/hr
= 41.79 kg/hr
i) Polyethylene:
= 0.98 x 27163.69 kg/hr
= 26620.42 kg/hr
ii) Ethylene:
= 0.02 x 27163.69 kg/hr
= 543.27 kg/hr
DRYER
The inlet components enter the dryer were polyethylene and excess ethylene. The
removal of moisture content for the product occurred here which it generally will remove about
0.2% to 0.5% moisture content by weight.
Composition (weight/weight)
Inlet Stream (No.9)
Ethylene
0.02
0.02
Polyethylene
0.98
0.98
Stream 9
Stream 17
in = 27183.69 kg/hr
Stream 9 = Stream 17
in = out
ii) Ethylene:
= 0.02 27163.69
= 543.27 kg/hr
COMPRESSOR
Component
Composition (weight/weight)
Inlet Stream (No.8)
Ethylene
0.67
0.65
Isobutane
0.22
0.95
1-Hexene
0.1
0.35
0.05
Stream 8,
F = 417.90 kg/hr
COMPRESSOR
To find T
T = 417.90 19.28
T = 398.62 kg/hr
HEAT EXCHANGER
Component
Composition (weight/weight)
Inlet Stream (No.12)
Ethylene
0.65
0.99
1-Hexene
0.35
0.01
Stream 13
A = 398.62 kg/hr
B = 398.62 kg/hr
Heat Exchanger
Stream 13
VENT SCRUBBER
Component
Composition (weight/weight)
Inlet Stream
(No.13)
Ethylene
0.99
1.00
1-Hexene
0.01
1.00
Top Stream
T = kg/hr
139.29 kg/hr ethylene
Stream 13
A = 398.62 kg/hr
Vent Scrubber
394.63 kg/hr ethylene
3.986 kg/hr 1-hexene
Bottom Stream
B = kg/hr
Kg/hr 1-hexene
DISTILLATION COLUMN
Component
Composition (weight/weight)
Inlet Stream (No.12)
Isobutane
0.95
0.05
1.00
1-Hexene
0.05
0.95
Top Product
T = 1.02 kg/hr
0.969 kg/hr 1-Hexene
0.051 kg/hr Isobutane
Stream 12, Bottom
Distillation column
F = 19.28 kg/hr
18.316 kg/hr Isobutane
0.964 kg/hr 1-Hexene
Bottom Product
B = 18.26 kg/hr
18.26 kg/hr Isobutane
To find T:
T = 19.28 B
T = 19.28 18.26
T = 1.02 kg/hr
PURGE COLUMN
The product and excess ethylene leave the dryer enter the purge column for removing
residual liquid from the polymer solids. The purge means is typically a nitrogen purge column
through which nitrogen gas is fed to remove accumulated liquid from polymer slurry. The excess
amount of ethylene as well as nitrogen will be recycled to purification column for further usage
in polymerization process.
Composition (weight/weight)
Inlet Stream (No. Inlet Stream (No.
17)
10)
Outlet Stream
(No. 18)
Outlet Stream
(No. 11)
Ethylene
0.02
0.05
Polyethylene
0.98
1.00
1.00
0.95
Nitrogen
Stream 18, T
10322.21 kg/hr Nitrogen
453.27 kg/hr Ethylene
Stream 17, F1
26620.42 kg/hr Polyethylene
543.27 kg/hr Ethylene
Purge Column
Stream 10, F2
Stream 11
10322.21 kg/hr Nitrogen
B= 26620.42 kg/hr
26620.42 kg/hr Polyethylene
i) Polyethylene:
= 0.98 27163.69
= 26620.42 kg/hr
ii) Ethylene:
= 0.02 27163.69
= 543.27 kg/hr
i) Nitrogen:
= 0.95 10856.48
= 10322.21kg/hr
ii) Ethylene:
= 0.05 10856.48
= 543.27 kg/hr
EXTRUDER
The final product which is polyethylene goes to the last equipment for pelletizing.
Extrusion process takes place where is a process used to create objects of a fixed cross-sectional
profile. A material is pushed or drawn through a die of the desired cross-section.
Composition (weight/weight)
Inlet Stream (No. 11)
Finishing Stream
1.00
1.00
Polyethylene
Stream 11
Finishing Stream
in = 26620.42 kg/hr