INPLANT TRAINING

ON
IN

From:-02/01/2014 to 31/01/2014

Submitted by:Prithwish Kumar Saha.

(3rd year Chemical Engg.)
Haldia Institute of Technology

&

Parikshit Roy.

(3rd year Chemical Engg.)

Calcutta Institute of Technology

ACKNOWLEDGEMENT
Riding the wings of change is a technical skill that professionals in industries
have to learn and perfect. To ensure progress for industries in todays cut throat
industrial arena, engineers need to constantly update themselves from an industrial
perspective. To learn from this approach we the students have to avail of the
industrial training that is included in our curriculum.
It will be a wonderful opportunity to express our gratitude to Mr. Subhadip
Chattaraj(HR Depertment), Sukheshwar Mondal(Senior GM of Polymer),Mr.
Amaresh Sinha(Team Leader of HDPE),Mr. Prosenjit Ghosh(assistant Team Leader
of HDPE), Mr. Sarit Dey (Faculty of HDPE and head of training Department),Mr.
Ajoy Kumar Dey (Employee of HDPE) and withheld all the team (field member and
control room employees)member of HDPE department who gave us wonderful
support and co-operation in each and every field and help us to gain overall
knowledge so that we can complete our training successfully.
We were fortunate enough to pursue training in one of the most sophisticated and
modern plant, Haldia Petrochemicals Limited. The experience gained during this
period gave us an insight as to how the processes actually occur in practice.
During this short stay, we were able to decipher a detailed overview of the entire
process, thanks to all the operators, field engineers, present in the site. Last but not
the least; we are highly grateful to our colleges for providing us this precious
opportunity.

CONTENTS

Serial
No.

01
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.

Topic

About HPL
HDPE Overview
Raw Material
Process Description
Sections of HDPE
Reactor Heat Removal
Separation and Drying section
Storage and Packing
Hexane Recovery
Refrigeration system
Instruments used in HDPE
Conclusion

Page No.

04-13
14-15
16
17-23
24-26
27-29
31-33
34
35-37
41-42
44-57
58

PREFACE
In plant training is a vital part in the progress of fledgling engineers. For us this is
the first rendezvous of practical knowledge with the theoretical concepts acquired
during the years in college.
We are very fortunate that we got the opportunity of under going training in one of
the most sophisticated modernized and fully automated petrochemical plant, HPL.
The experience gained during this short stay here was fascinating to say the list. It
was a tremendous feeling to see the practical operation of different equipments
and processes, which are beyond the scope of any books .We are deputed in
H.D.P.E. plant for our training.
Each one of us was overwhelmed by the sheer size and complexity of the plant.
What still fascinates us is how such a big unit is being monitored and operated with
the desired results.
In this short stay it was not possible for us to wholly decipher the detailed
functioning of the plants; but still we are fortunate enough to get a sound overview
of the unit and to be familiar with different types of instruments and equipments,
Thanks to the guidance extended by the people of HDPE Department.

ABOUT HPL

Haldia Petrochemicals Limited is naphtha based integrated Petrochemical

Complex, located 125km from Kolkata, at West Bengal, India.

It is an Rs.6000 crore Naphtha based project which has been set up for the first
time in the eastern region at Haldia, a port town south of Calcutta. The plant
manufactures a wide range of Polyolefin and associated liquid co-products. The
naphtha cracker capacity for the first phase is 520 KTPA ethylene, with
technology from ABB Lummus, USA.
The West Bengal Government, The Chatterjee Group (TCG) and the TATA
Group jointly promote the HPL. The company is jointly promoted by WBIDC,
Chatterjee Petrochem (Mauritius) Co. Ltd. and the TATA group.

Bechtel, USA had been retained as project management contractor for the
company during the project implementation stage along with EIL providing
project services.
HPL manufactures over 1 million tons of world class polymers-Linear Low
Density Polyethylene(LLDPE), High Density Polyethylene(HDPE),
Polypropylene(PP) and chemicals such as Benzene, Butadiene, C4 Reffinate,
Liquefied Petroleum Gas(LPG), Euro-IV complaint Motor Spirit and
Cyclopentane.

HPLS VISION
To be a dynamic, strong and flourishing organization recognized as a leading provider of
customer focused, innovative products and services.
An admired company acknowledged as being superior (and exceptional) by all.

An acknowledged leader. The preferred partner

HPLS MISSION
To achieve sustainable and profitable growth through delivery of innovative, world class
products and services of exceptional value to our customers.
We are a company of outstanding people who care for customers, care for each other and
care for the community and environment. We take pride in the quality of our products and
services, our business ethic, and are passionate about winning.
We will achieve this through superior knowledge and our total commitment to create
outstanding value for our shareholders and customers.

HSE VISION (HEALTH, SAFETY & ENVIRONMENT POLICY)

"Be a global leader in industry in demonstrably implementing
Health, safety & Environment
Improving practices."

PLANT AT A GLANCE
The following plants are there in the complex:

Naphtha Cracker Unit (NCU)

Butadiene Extraction Unit (BDEU)
Pyrolysis Gasoline Hydrogenation Unit (PGHU)
Benzene Extraction Unit (BEU)
C4 Hydrogenation Unit (CHU)
High Density Polyethylene (HDPE) Plant
Linear Low Density / High Density Polyethylene (LLDPE/HDPE) Plant
Polypropylene (PP) Plant
Integrated Offsite Plant (IOP)
Nitrogen Plant
Captive Power Plant (CPP)

BASIC OVERVIEW OF HPL

Naphtha Cracker Unit (NCU)

Butadiene Extraction Unit (BDEU)

C-4 Hydrogenation Unit (CHU)

High Density Poly-Ethylene (HDPE)

Linear Low Density Poly-Ethylene Plant (LLDPE)

Poly-Propylene Plant (PP)

Captive Power Plant (CPP)

Combined cycle cogeneration power plant (Capacity 116 MW) meets the power
and steam requirement of the plant during continuous run, start up at emergency
situations. The steam generated is supplied to the various units at four different
pressure levels as given in the table below:
Pressure Type

Pressure (kg/cm2)

Temperature (C)

Super High Pressure (SHP)

129

540

High Pressure (HP)

43

415

18.5

321

245

Medium Pressure (MP)

Low Pressure (LP)

COMPLETE DETAILS OF THE PLANT UNITS

Plant units

Capacity

Revamped Capacity

Technology/Licensor

Naphtha Cracking Unit

(NCU)

520 KTPA

670 KTPA

ABB LUMMUS, USA

Butadiene Extraction
Unit (BDEU)

90 KTPA

120 KTPA

BASF, GERMANY/ ABB LUMMUS,

USA

Pyrolysis Gasoline
Hydrogenation Unit
(PGHU)

330 KTPA

420 KTPA

IFP, FRANCE

Benzene Extraction
Unit (BEU)

95 KTPA

125 KTPA

LURGI, GERMANY

C-4 Hydrogenation
Unit
(CHU)

130 KTPA

170 KTPA

IFP, FRANCE

Polypropylene Plant
(PP)

255 KTPA

320 KTPA

MONTELL, HOLLAND

Linear Low Density

Polyethylene (LLDPE)

260 KTPA

320 KTPA

MONTELL, HOLLAND

High Density
Polyethylene (HDPE)

240 KTPA

320 KTPA

MITSUI, JAPAN

Captive Power Plant

(CPP)

116 MW

150 KTPA

LARSEN & TOUBRO, INDIA

Nitrogen Plant (BOO)

9000Nm3/hr.

11800 Nm3/hr.

PRAXAIR, USA

Diagrammatic View of overall Process in HPL

HIGH DENSITY POLY-ETHYLENE PLANT (HDPE)

Name of the technology: Slurry Clean and Excellent (HPCX) Process

Supplier of the technology: Mitsui (Japan).
LICENSER: TECHNIMONT
DETAILED ENGG: DAELIM ENGG, Korea
PROCESS: HPCX
Catalyst: Zeigler-Natta catalyst (Ti based,MgCl2 supported heterogeneous catalyst)
Co catalyst: AluminiumTriethyl (Organometallic type)
Solvent: Hexane
Feed: Ethylene
Chain Terminator: Hydrogen
Co monomer: Propylene, 1-Butene
Design Capacity: 240 KTPA for two trains, 120 KTPA each for 8000 hrs. operating
hours. After expansion its capacity will be 320 KTPA.
This process is called CX or Clean and Excellent process because of
super high active catalyst (99.9%)
o
o
o
o
o

Less waste generation

Better solvent recovery
High product quality
High productivity
Less pressure and temperature which reduces the equipment cost

HDPE PLANT OVERVIEW

Raw materials required

MONOMER
1. Ethylene:
Ethylene gas is controlled at 12kg/cm2 by PIC and is fed into the recycle gas line to the
polymerizes under FRC control.

CHAIN TERMINATING AGENT

2. Hydrogen
Hydrogen gas is controlled at 12kg/cm2 by PIC and is fed into the ethylene gas line to the
polymerizes under AC/FC control to be premixed with ethylene.

CO-MONOMER
a) Propylene:
High purity and liquefied propylene is fed to propylene vaporizer 7V-232 under LC control. The
propylene so fed is heated by LP steam in 7V-232to become propylene gas having a pressure of
14 kg/cm2. Such gas is premixed with ethylene gas at a given rate under FC.

b) Butene-1:
High purity and liquefied butene-1 is fed to butene-1vaporizer 7V-233 from butene-1 holder 7V234,in which it is heated by LP steam in 7V-232to become butene-1 gas having a pressure of 12
kg/cm2.Such gas is premixed with ethylene gas at a given rate under FC.

SOLVENT
Hexane:
Hexane pressurized up to 12 kg/cm2 by H.P Hexane pump 7P-708A/B is dehydrated in
hexane dryer 7V-703A/B to become dehydrated H.P Hexane having a5ppm or less water
content, then fed to each polymerize under FC control with the purpose of controlling
the slurry concentration in it. In the meantime, each catalyst feed line to polymerize is
connected to the hexane inlet nozzle so that the feed catalyst is washed with hexane
stream all the time; in this way, it prevents clogging due to the partial polymerization.
Part of mother liquor from the centrifuge is recycled back to polymerize.

PROCESS DESCRIPTION:
Basic properties of HDPE that should be checked and maintained during the process are:

MFI: Melt Flow Index (gm/10mint.)

MFI is the quality control test that measures how easily the polymer resin flows. It is the
amount of polymer, in grams, that is forced out of a capillary die of specified inner diameter
and length (2.o9 mm x 8.0 mm), in 10 minutes at a certain temperature of 190 0c and
certain specified weight of 2.16 kg.
MFI is controlled by H2/C2 Molar Ratio and catalyst concentration in reactors

Density
-

Density is control by Co-monomer(propylene or 1-butene) feed rate

- LC ( Yellowness Index)
-

Degradation of Polymers due Temperature & Oxidation.

LC is controlled by Solid, Liquid & Water stabilizer.

I. CATALYST SECTION (100)

CO-CATALYST PREPARATION:
There is Tri-ethyl aluminum (TEAL-imported from japan) tankers in which the co-catalyst is
stored. By nitrogen purging in one side of the tank, the TEAL is supplied to the cocatalyst
preparation tank (V1111). Solvent (1st addition) is added from the hexane chamber and no
stirrer is there in the tank. The mixing is done by bubbling N2 through the mixture. The flow
of nitrogen can be controlled by rotameter. No chilling is required in this tank. The
concentration of the TEAL in the solution is 200 g/lt. Due to gravitational force, the cocatalyst is stored in another tank V-1112. The co-catalyst is sent to the reactors.

CATALYST PREPARATION:
USED: Zeigler Natta catalyst. Pure PZ (Ti conc. 3.7 milimole/gm) or
mixture of PZ & RZ (Ti conc. 6.5milimole/gm(more active))
2
b) OPERATING PRESSURE OF N2: 0.1-0.3 kg/cm G
0
c) OPERATING TEMPEARURE: 0-20 C
a) CATALYST

d) Zeigler-Natta catalyst: TiCl4 (yellow, it easily gets oxidized in presence of O2) in a

very small amount is impregnated in MgCl2 (base) & small amount of Ti dust.

The catalyst is charged into a feed drum 7V-1110A/B by nitrogen purging into from the bottom of the
catalyst drum. It is done because the catalyst easily catches fire when it comes in contact with the
atmosphere. The catalyst feed drum is already filled with hexane. The catalyst is mixed with hexane
by means of a feed drum agitator. Entrainment of the hexane with the vent gas goes through vent gas
condenser 7E-1104. The condensate is collected in drain pots 7V1127. The catalyst prepared is
transferred to the two polymerize according to the series or parallel connection.

II. POLYMERIZATION SECTION:

For the poly reactor a low pressure (below 10kg/cm2) hexane slurry process is employed,
using polymerisers7R-1201 AND 7R-1221Lined up in parallel or series.
Ethylene monomer which is the main raw material, dehydrated hexane for adjusting the
slurry concentration, and catalyst are continuously fed at specified rates to polymerize.
Hydrogen as molecular weight controller and either propylene or butane-1 for adjusting the
density is continuously premixed with ethylene gas, such mixture is fed into the recycle gas
line leading to polymerize. Its heat of reaction is removed by the latent heat of hexane.Slurry
cooling system and by polymerize jacket cooling. Control of polymer properties,MFR,
density and NNI of polymer in polymerisers.is carried out by adjusting polymerization
conditions.

MODE OF REACTION (POLYMERIZATION):

For series:
The material of flash drum 1 (7V-1203) is transferred to the reactor 2 (7V-1221) for
further conversion. No solvent or co-monomer is supplied there. Then the product
through dilution drum 2 (7V-1222) and flash drum 2 (7V-1223) goes to the
centrifuge.

Reactor 1

Reactor 2

1st flash drum

(High MFI)

(Low MFI)
Centrifuge

2nd flash drum

For
Drying/Extrusion

a) For parallel B:
The reaction conditions in the two reactors are completely different. The catalyst,
monomer, H2 ratios are completely different. The products from the two flash drums
are mixed with a certain ratio to give a certain mixed grade of polymer.

Reactor 1
(High MFI)
2nd flash
drum

Centrifuge

Reactor 2
(Low MFI)

For
Drying/Extrusion

b) For parallel A:
The reaction conditions are same in the two reactors. The vapours coming from the
flash drum 2 (7V-1223) and flash drum 1 (1203) sent for cooling.

Reactor 1
2nd flash
drum

Centrifuge

Reactor 2
For
Drying/Extrusion

Ethylene is a rather stable molecule that polymerizes only upon contact with catalysts. The
conversion is highly exothermic, that is the process releases a lot of heat. Coordination
polymerization is the most pervasive technology, which means that metal chlorides or metal
oxides are used. The most common catalysts consist of titanium (III) chloride, the so-called
Ziegler-Natta catalysts.
The MFI or the melt flow index indicates the polymer characteristics which is described by
mitsui chemicals,Japan and in relation with density as follows:-

The process of mitsui chemicals (Japan) is divided into some best

process here are those

Equistar Slurry

Hostalen Process

Equistar Maruzen

Process Flow Diagram of HDPE

Different sections of HDPE plant:

HDPE plant consists of the following sections and system:
1. Section 100 catalyst feeding
2. Section 200 polymerization section
3. Section 300 separation and drying
4. Section 400 Pelletizing section
5. Section 700 solvent recovery section

1. CATALYST FEEDING SECTION

PZ/RZ CATALYST is charged into PZ feed drum 7V-1110A/B which has been filled with
specific quantity of hexane. PZ/RZ catalyst is dissolved in hexane by means of feed drum agitator.
Preparation of PZ catalyst is carried out every three days. The frequency depends on the actual
rate of catalyst consumption. The entire parts of PZ catalyst preparation system is operated under
nitrogen pressure between 0.1&0.3 kg/cm2 g.Vent gas at the time of pressurizing or
depressurizing is passed through vent gas condenser 7E-1104 &discharged into the flare.

Catalyst preparation:
PZ/RZ catalyst is charged into PZ feed drum system.
Entrainment of hexane with the vent gas is condensed as it goes through 7E-1104 and is
collected in drain pots 7V-1127.

Catalyst feed:
PZ catalyst which has been diluted to a specified concentration in 7V-1110A/B is fed to each
polymerizer by PZ feed pump 7P-1105A/B and/or C. units served by this pumps are as follows
7P-1105A/B

7R-1201

7P-1105B/C

7R-1221

2. POLYMERISATION SECTION
For the poly reactor a low pressure (below 10kg/cm2) hexane slurry process is employed, using
polymerisers7R-1201 AND 7R-1221Lined up in parallel or series.

Ethylene monomer which is the main raw material, dehydrated hexane for adjusting the slurry
concentration, and catalyst are continuously fed at specified rates to polymerizers. Hydrogen as
molecular weight controller and either propylene or butane-1 for adjusting the density is
continuously premixed with ethylene gas, such mixture is fed into the recycle gas line leading to
the polymerizers. The heat of reaction is removed by the latent heat of hexane. Slurry cooling
system and by the polymerizers jacket cooling. Control of polymer properties, MFR, density and
NNI of polymer in polimerisers.is carried out by adjusting polymerization conditions.

Raw materials &solvent fed to polymerizers.

1. Ethylene
Ethylene gas is controlled at 12kg/cm2 by PIC and is fed into the recycle gas line to the
polymerizers under FRC control.

2. Hydrogen
Hydrogen gas is controlled at 12kg/cm2 by PIC and is fed into the ethylene gas line to the
polymerizers under AC/FC control to be premixed with ethylene.

3. a. Propylene
High purity and liquefied propylene is fed to propylene vaporizer 7V-232 under LC control .the
propylene so fed is heated by LP steam in 7V-232to become propylene gas having a pressure of
14 kg/cm2. Such gas is premixed with ethylene gas at a given rate under FC

3. b. Butene-1
High purity and liquefied butene-1 is fed to butene-1vaporizer 7V-233 from butene-1 holder 7V234,in which it is heated by LP steam in 7V-232to become butene-1 gas having a pressure of 12
kg/cm2.Such gas is premixed with ethylene gas at a given rate under FC

4. Hexane
Hexane pressurized up to 12 kg/cm2 by HP. Hexane pump 7P-708A/B is dehydrated in hexane
dryer 7V-703a/b to become dehydrated HP hexane having a5ppm or less water content, then fed
to each polymerizers under FC control with the purpose of controlling the slurry concentration in
it. In the meantime, each catalyst line the polymerizers connected to the hexane inlet nozzle so
that the feed catalyst is washed with hexane stream all the time; in this way, it prevents clogging
due to the partial polymerization. Part of mother liquor from the centrifuge is recycled back to
the polymerizer.
CONTROLLING PARAMETERS IN A POLYMERIZER

Reactor Temperature
Reactor Pressure
Slurry Concentration
Ti. Concentration in Reactor
AL/Ti ratio in Reactor
H2/C2 Molar Ratio

Reactor Heat removal

Polymerization is exothermic reaction. Generated heat removed from reactors by
three means :
1. By Re-cycle gas flow(50% of total heat generation)
2. By reactor jacket temp control (10% of total heat generation)
3. By Slurry-Cooler (40% of total heat generation)

REACTOR TEMPERATURE CONTROL

OVERHEAD CONDENSER

TIC

RECYCLE GAS BLOWER

REACTOR

ACCUMULATOR

FLASH DRUM:
From the reactor, the effluent overflows to a flash drum through a dilution drum For two-stage
polymerization, both flash drum and dilution drum are two in number each operating after the each
reactors. The basic purpose for the use of flash drum is to separate the unreacted monomers, gaseous
hydrocarbons, and hexane from the polymer slurry. The temperature of the flash drum is maintained at
65C and the pressure is very low which facilates the gases and vapors to separate by flashing.

CALCULATION OF HEAT REMOVAL (1st reactor):

Name of the system

Inlet temperature(0c)

Outlet temperature(0c)

Cooling water Mass flow

rate (tons/hr.)

Overhead condenser

34.5

38.5

1030

Slurry cooler

40

49.0

320

Jacket cooler

33.9

39.67

125

CALCULATION:
Heat remove by jacket = m.Cp.T=125.103.1.(39.67-33.9)=721250 Kcal/Hr.
Heat remove by slurry cooler =m.Cp.T= 320.103.1.(49-40)= 2880000 Kcal/Hr.
Heat remove by overhead condenser =1030.103.1.(38.2-34.5)=3811000 Kcal/Hr.
We know that Cp of water = 4.2 kj/kg k.=1Kcal/gm.K
So heat generation is calculated by using the following eqn:

H = m.Cp. T

Calculated heat load

Name of the system

Kcal/hr.

Design heat load

Kcal/hr.

3811000

OVER HEAD CONDENSER

4071917

2880000

SLURRY COOLER

3000000

721250

JACKET COOLER

747000

7412250

TOTAL HEAT REMOVED

7818917

% of Heat Removal:
Name of the system

Train-1(Reactor-1)

OVER HEAD CONDENSER

51.41%

SLURRY COOLER

38.85%

JACKET COOLER

9.74%

OVERFLOW SLURRY HANDLING:

Since the over flow slurry contains bubbles of mixed gas in the polymerize the slurry is
separated in the first dilution slurry drum 7V-1202 and second dilution slurry drum 7V-1222into
liquid and gas phases, and the separated gas is sent back to the polymerize through the gas balance
lines between 7R-1201 and7V-1202 and between 7R-1221 and 7V-1222. The polymer slurry is
flashed into the first flash drum 7V-1203 and second flash drum 7V-1223 and the temperature
becomes about 65 degree C . The flashed gas from the flash drum is cooled to 0 degree C by the
first flash gas condenser 7E-1202 and flash gas condenser 7E-1222 and the flash gas cooler 7E1223.The gas is not condensate through the mentioned cooling step is passed through the
compressor section drum 7V-226 and pressurized to 4.5kg/cm2G by the flash gas compressor 7K222 and sent to the naphtha cracker. The polymer slurry in 7v-1223 is transferred to the centrifuge
7SE-1301 through the slurry transfer pump 7P-1221A/B.

Polymerizer recycle gas

Ethylene, hydrogen& either propylene or butene-1 are mixed with polymerizers recycle gas, and
fed to 7R-1201 and 7R-1221 through the gas injection pipes. The feed raw material gases are
thoroughly dispersed by the three stage turbine agitator to be dissolved in hexane and the
ethylene gas polymerized in presence of catalyst and forms polymer slurry having a specified
concentration at this time, the pressure is maintained by hydrogen partial pressure.
Recycle gas comprising of ethylene & hydrogen is blown into the top of the polymerizer &
ethylene is polymerized during its passage through the adequately agitated hexane phase. More
than half of the heat generated by polymerization is removed by latent heat of hexane.

The recycle gas containing plenty of hexane vapor is transferred to first overhead condenser 7E1221 where it is condensed and cooled, and further transferred to the first hexane accumulator,
7V-1205 and second hexane accumulator 7V-1225 to be separated in to condensate hexane and
recycle gas. The recycle gas so separated is pressurized in the first recycle gas blower 7B-1201
and second recycle gas blower 7B-1221 and blown in to the top of the polymerizer while its flow
rate is controlled under TC in order to maintain the polymerization temperature at a specified value.
Condensate hexane separated in 7V-1205 and 7V-1225 is recycled to the polymerizer through the
first condensate recycle pump 7P-1202 A/B and the second condensate recycle pump 7P-1222
A/B. part of the condensate hexane is used for flashing at a specified rate under FC in the gas
outlet piping for 7R-1201 and 7R-1221.

Slurry cooler:
Polyethylene slurry in 7R-1201 and 7R 1221 is circulated through the first slurry cooler 7E-1204
and second slurry cooler 7E-1224 by the first slurry cooler pump 7P-1203 and second slurry cooler
pump 7P-1223 to remove polymerization heat together with recycle gas system and reactor jacket
cooling system.

Overflow slurry handling:

Since the over flow slurry contains bubbles of mixed gas in the polymerizer the slurry is separated
in the first dilution slurry drum 7V-1202 and second dilution slurry drum 7V-1222into liquid and
gas phases, and the separated gas is sent back to the polymerizer through the gas balance lines
between 7R-1201 and7V-1202 and between 7R-1221 and 7V-1222. The polymer slurry is flashed
into the first flash drum 7V-1203 and second flash drum 7V-1223 and the temperature becomes
about 65 degree C. The flashed gas from the flash drum is cooled to 0 degree C by the first flash
gas condenser 7E-1202 and flash gas condenser 7E-1222 and the flash gas cooler 7E-1223.The
gas is not condensate through the mentioned cooling step is passed through the compressor section
drum 7V-226 and pressurized to 4.5kg/cm2G by the flash gas compressor 7K-222 and sent to the
naphtha cracker. The polymer slurry in 7v-1223 is transferred to the centrifuge 7SE-1301 through
the slurry transfer pump 7P-1221A/B.

3. SEPARATION AND DRYING SECTION

Separation:
The product slurry is fed through the second slurry transfer pump 7P-1221A/B to the horizontal
type centrifuge 7SE-1301 rotating at a high speed ,in which polymer is separated by centrifugal
force .
The polymer is discharge from the centrifuge by the screw conveyor provided in the bowl in the
form of wet cake containing hexane by approximately 30% weight and fed to dryer 7SE-1302
via the wet cake screw feeder 7ME-1301.
Meanwhile hexane overfl0ows the weir provided in the bowl and flows into the mother liquor
drum 7V-1301 and then pressurized by the mother liquor transfer pump 7P-1301A/B so that part
of it will be sent back to the polymerization section and the remainder will be fed to the hexane
recovery section.

Drying in following sections

1) CENTRIFUGE
Used to separate hexane from powder. It comprises with a bowl, a screw & planetary gear. Bowl
is rotated by a motor & it rotates the planetary gear. Screw is attached with the planetary gear.
Due to the differential speed between the screw & the bowl powder gets separated from hexane.
2) STEAM TUBE ROTARY DRYER:
Mixed gas consisting of nitrogen and hexane vapor flows through the Dryer 7SE-1302 (7SE-2302)
counter currently with the product. When the product powder leaves 7SE-1301 (7SE-2302) after
about 30 minutes holding time, it contains less that 0.2% volatile matter (as hexane) and its
temperature is approximately 1000c. Low pressure steam is supplied to the steam tube in 7SE-1302
(7SE-2303) as the heat source after its pressure and temperature have been reduced to0.2 to0.35
kg/cm2 G and approximately 1070c through the steam cooler 7E-1304 (7E-2304). The operating
pressure of this system is about 400mmAq.

3) DRYER GAS CIRCULATION SYSTEM:The mixed recycle gas from 7E-1302 (7E-2302)
containing a small amount of fine polymer particles goes into the dryer gas scrubber 7V-1302(7V2302).The fine polymer entrained with the mixed gas is collected by the circulation liquid in the
dryer gas scrubber pump 7P-1302A or B (7P-2302A or B). The collected polymer is recovered
through 7P-1302A or B (7P-2302A or B) into 7v-1223 (7v-2223), while the liquid level of 7V1302 (7V-2301) is controlled by LC. The mixed recycle gas cooler in 7E-1301(7E-2301) is
pressurized by the dryer gas blower 7B-1301A or B (7E-2307) is heated to decrease hexane content
in it. The recycle gas from 7E-1307 (7E-2307) is heated to approximately 1000c by the dryer gas
Header 7E-1302 (7E-2302) with low pressure steam under TC control. The non-condensable gas
which leaves the outlet of the purge gas condenser 7E-1303 (7E-2303) is pressurized to 3kg/cm2
G by the off gas compressor 7K-302 and part of it is supplied to the gland of 7SE-1302 (7SE-2303)
for flushing while surplus is discharge to the flare system.

EXTRUDER SECTION

ME 1409

BN 1402
BN 1403
ME 1408
W 1405

W 1412

V 1403
DMW
V 1402
LSB

Homogenizer

Extruder

Drying and extruder section

Model : CMP-300X-12AW

Purpose : To convert HDPE powder in to sellable pellets

Make: Japan Steel Works

Design Capacity : 20 TPH

Installed qty : 2 Nos.

Details:
Make :

JSW

Model :

CMP 300X-12AW

CMP :

Continuous Mixer Pump

300 :

Nominal Screw Diameter

Twin Screws/co-rotating / Intermeshing

12

L/D Ratio

Electric Heating

W :

Water Cooling

M/C Capacity :

20 MT/Hrs

Product Pellet Size : Lentoid Shape [2.5 to 3.0mm

3.00mm ]

4. PELLETIZING, STORAGE & PACKING SECTION

Powder hopper:
The product powder which has left 7SE-1302 is transferred to the nitrogen gas pneumatic powder
conveying system through the powder rotary valve 7ME-1303 the product which is forwarded by
the powder transfer blower 7B-1401A/B is contentiously separated in the powder cyclone 7SE1401 from nitrogen and dropped into powder hopper 7BN-1402. Nitrogen gas is filtered through
back filter 7SE-1402 to be recirculated.

Bulk powder loading:

From the powder hopper 7BN-1402 the polymer powder can be transferred by means of pneumatic
transport 7X-1403 to the powder bulk loading silo 7BN-1405 .Below this silo a truck bulk loading
station is provided. This facility is available only for line 1.
Powder and stabilizer feed system:

The powder stream which has left the outlet of 7BN-1402 is metered by the powder measuring
feeder 7W-1405 & is fed to 7EX-1425 through 7ME-1406.
Solid stabilizer mixture in accordance with the stabilizer recipe predetermined for product type is
prepared in 7ME-1409 & discharged batch wise into 7BN-1403 by gravity. Stabilizer mixture from
7BN-1403 is metered by 7W-1412 & fed to 7ME-1406. Liquid stabilizer & W-stabilizer are fed
into 7ME-1406 by the liquid stabilizer feed pump 7P-1402A/B & W-stabilizer feed pump 7P1403A/B respectively.
Polyethylene powder & stabilizers are fed to 7EX-1425. The pelletizer is a twin screw type
continuous mixture with gear pump where PE powder & stabilizers are mixed & kneaded. Molten
polymer are pushed towards the dye by gear pump system, then the molten polymer is extruded
through the dye hole into the cutter box through which pellet cooling water is circulated. The
extrudate is cut into pellets by revolving cutters. The resin in the pellet form is transferred to the
pellet separator 7SE-1404 with circulated PCW.
For protection of 7SE-1404 a grid PW strainer 7SE-1427 is provided, to remove any fused blocks
of pellets. The pellets which pass the grade are sent to 7SE-1404 after they are drained on the
perforated plate screen. Product pellets are classified by the pellet-vibrating screen 7SE-1428, into
oversized, normal & undersized products. Normal sized pellets which flow in the pellet separator
hopper 7BN-1404 are pneumatically conveyed to the specified silo through the pellet rotary valve
7ME-1431 by the pellet transfer blower 7B-1451A/B.

Pellet blending and transfer system:

Pellet silos 7BN-1451A/B/C/D/E have a capacity of 500 each. In order to rectify such fluctuations
of quality due to possible variance in operating conditions of process control, the pellet blending
is carried out through transferring the pellet to the bagging hopper.
Packing:

Each plant is supplied with two bagging lines, 7X-901, fed from independent silos 7BN-1901A/B.
Each bagging line includes the bagging matching 7ME-1901A/B-X, the check weighers 7W901A/B/C/D-X, the metal detectors 7W-903A/B/C/D-X and bag rejecter devices 7ME904A/B/C/D-X.

5. HEXANE RECOVERY SECTION

FLOW DIAGRAM OF HEXANE RECOVERY SECTION

Butene
Hydrogen
Ethylene

Reactor 1 & 2

Hexane

Catalyst Section

Dilution Drum 1 & 2 Flash Drum

Centrifuge
Powder Dryer

Mother Liquor Holding Drum

Powder Silo
Hexane Holding Drum
Crude/Imported Hexane Storage
Pure Hexane Storage

C-703

Hexane De-hydrator
Hexane Stripping Column

Pellet to Silo
Extruder

Low Polymer

Caustic soda washing:

Mother liquor is transferred to HE and NAOH separator V-721 through HE and NAOH contactor
7M-721 together with 20% (weight) caustic soda, demineralized water and low pressure steam
which is fed in to the system to maintain its temperature at 60 degree C. the pH of the fluid
circulated through 7M-721 is more than 12. Then caustic washed crude hexane is transferred to
HE and water separator 7V-722 through HE and water contactor 7M-722, where processes water
is fed to wash out caustic soda. The PH of the fluid circulating through 7M-722 is approximately
7~8.

Hexane stripping:
Hexane containing low polymer and coming from crude hexane feed drum 7V-701 is fed to 7C703 by the crude hexane feed pump P-702A/B. Hexane vapor generated in 7C-703 is depressurized
to 0.2 kg/cm2 g, condensed and cooled in hexane overhead condenser 7E704. Molten low polymer
in hexane concentrated in the bottom of 7C-703 is pressurized to 22kg/cm2g by the flash drum
feed pump 7P-711A/B and heated from 120 degree C to 220 degree C in the flash preheated 7E711. The heated solution gets its pressure reduced to 3kg/cm2g as it enters in the flash drum 7V711.The solution is cooled to approximately 160 degree C ,while hexane vapor so generated is
recycled to 7C-703.The low polymer solution in 7V-711 is kept from cooling of, from the steam
coil provided in it and is fed to the low polymer preheater,7E-712,where the solution is heated up
to 180 degree C. the solution then flows in to the second flash drum 7V-712 whose is kept at 300
mm Hg, by the LP vacuum pump 7B-701.Hexane vapor generated in 7V-712 is condensed in the
vent gas cooler 7E-713 and stored in the 7V-713 bottom ,then transferred to 7V-701. The LP
solution, from which hexane is removed in 7V-712 is transferred to LP holding drum, 7V-717 by
low polymer transfer pump 7P-713A/B.

Low polymer flaking:

Molten low polymer of LP holding drum 7V-717 is transferred by LP storage bottom pump 7P-717 to the

drum flaker, 7X-701 LP is cooled and solidified on the drum of 7X-701, which is cooled with a
circulating water system .Flaked LP is collected in the flaker hopper ,7BN-704 and manually
packed

Hexane purification:
Hexane vapour from 7C-703 is condensed and cooled in 7E-704, then flows into the stripper
receiver 7V-702 by gravity, during which DM water can be added. The mixture flows into 7V702, provided with rectifying plates for enhancing separation of water drops in hexane, in which
it is caused to undergo phase separation into hexane and water layers. The water layer in 7V-702
is discharged by LC. The hexane layer, saturated with water up to approximately 250 weight ppm,
is fed by the dehydrator feed pump 7P-706A/B to the top of the hexane dehydrator 7C-704. Low
press steam is supplied to the dehydrator reboiler 7E-705 installed in the 7C-704 bottom .The
bottoms of 7C-704, water content and temp of which are 10wt ppm or less and about 80 degree C
respectively, is forwarded by the dehydrated bottom pump 7P-707 A/B to the dehydrator bottom
cooler 7E-706 where the liquid is cooled to 40 degree C or lower & then transferred to the pure
hexane drum 7V-772.

Pure hexane distribution:

Purified hexane with a water content of 10wt ppm or less is pressurized to 12 kg/cm2 or higher by
the HP hexane pump 7P-708A/B, dehydrated to less than 5wt ppm water content by hexane dryer
7V-703A/B containing molecular sieves, and then forwarded to various process sections through
the hexane strainer 7Z-704A/B.

Processing Additives and Product Quality

Additives are essential ingredients added to the polymers to stabilize it and to obtain an optimum
combination of the desired properties and in the final product in most economical way.
The output from the processing equipment and the quality of the product are determined by the
resistances of the polymer to thermal degrading, the speed with which a solid feed can be converted
into melt and the fractional behavior of the melt on the surface of the processing equipment.
High thermal stability in polymers enables processing to be carried out at high temps and to
achieve a higher output through a reduction in melt viscosity. It also improves the product quality
as a result of elimination of the deleterious effect of degradation on physical properties and
appearance. Fast fusion of the particles is essentially to ensure that a homogeneous melt is
produced before it is resolidified into the required shape. Finally the frictional behavior of the
polymer melt on the metal surfaces determines the residence time of the polymer molecules in the
processing equipments.

Primary stabilizers or antioxidants:

This interrupt the chain reaction by combining directly with the propagating free radicals itself,
typical examples of antioxidants are hindered phenols and aromatic amines.

Secondary stabilizers or peroxide decomposer:

Their function is to react with hydro peroxide as soon as they are formed and converting them into
non-radical species. The most common type of additives that acts as peroxide decomposer is
organic thioesters, phosphides and metal thio carbamates.

Chelating agents/ Metal deactivators:

These protect the polymer against degradation (particularly where there is a danger of
contamination of a hydrocarbon polymer with metal ions like Ni, Cu, Mn, Fe, Co that take
catalyses the oxidation reaction) by immobilizing the metal ions through coordination reactions.
In fact they produce a cage effect around the metal ions so that they cant react with the peroxides
and dont allow the O2 to interact with the active free radicals. The most important chelating agents
are compound based on organic phosphates, ox amides and hydrazides. Sometimes di methyl
glyoxime also acts as a very good chelating agents.
Different stabilizers used for HDPE virgin polymer in the form of antioxidants are:

1. IRGANOX 1010:
Phenolic antioxidant for processing and long-term thermal stabilization.

Characterization:
IRGANOX 1010- a sterically hindered phenolic antioxidant is a highly effective, non-staining
stabilizer for organic substrate such as plastics, synthetic fibers, elsatomers etc. it protects these
substrates against thermo oxidative degradation.

Chemical name:
Pentaerythritol Tetrakis (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate.

2. IRGANOX 1076:
phenolic primary antioxidant for processing and long-term thermal stabilization.

Characterization:
IRGANOX 1076, a sterically hindered phenolic antioxidant, is highly efficient, non-staining
stabilizer for substances such as plastics, synthetic fibers, elastomers etc. it protects these
substrates against thermo-oxidative degradation. It is odorless, stable to light and has excellent

color retention. It has good compatibility with most substrates, low volatility and high resistance
to extraction.

Chemical name:
Ocadecyl-3- (3, 5-di-tert.butyl-4-hydroxy phenyl)-propionate.

3. P-EPQ:
A high performance phosphonite processing stabilizer

Characterization:
IRGAFOS P-EPQ is a hydrolytically stable phosphonite-processing stabilizer. As a secondary
antioxidant, IRGAFOS P-EPQ reacts during processing with hyroperoxides formed by auto
oxidation of polymers preventing process induced degradation and extending the performance of
primary antioxidants.

Chemical Name:
Tetrakis (2, 4-di-tert-butylphenyl) [1, 1-biphenyl]-4, 4-diylbisphosphonite

Lubricant & flow promoters:

There are three major friction problems encountered in polymer processing---1) Inter particle friction between the polymer powders, or granules, which impair their
free flowing characteristics and hence creating difficulties in conveying operation such as feeding
into the processing equipment and advancement within it.
2) Friction between the polymer melt and the metal surfaces of thee processing
equipment, which can seriously impair the flow of the melt and produce undesirable effect such as
low output and poor surface quality of the finished product.
3) Friction during finishing operations and in conveys e.g. printing, packaging and
transportation.

External lubricants used to aid processing are high molecular weight fatty acids, alcohols,
and amines having 12-18 carbon atoms in their backbone.
In solid layer lubrication the surfaces of the rubbing members (polymer granules) are
coated with lamellar solids e.g. graphite, MoS, CoS etc, and are normally used under
extremely high friction conditions where by very high temperatures are developed and
which would render both fluid and bonding lubrication sometimes ineffective.

Different lubricants and flow promoters used for HDPE are Calcium Stearate, Glycerol Mono
Stearate, and Oil etc.

Surface Property Modifier:

Anti static agent:
Anti-static agents normally consist of one N-compound such as long chain amines, amides, or
quaternary ammonium slats
E.g. 1.Stearamide-propyl dimethyl 2-hydroxyl ethyl ammonium nitrate.
2. Sulphonic acid and alkyl aryl sulphonates.
3. Polyhydric alcohols and derivatives.

Acid Scavengers:
The inclusion of an acid scavenger is necessary because of the catalyst resides. Even though the
amount of catalyst residues is in the low ppm range, the need to neutralize acid residues persists.
The potential for the corrosion of a mold surface or die tip can be a very costly proposition. By
adding the appropriate antacid, any acidic species will be neutralized or scavenged, eliminating or
reducing the potential for corrosion. Antacids include metallic stearate, including sodium, calcium,
and zinc.
The use of metal stearate will give a resin a certain amount of lubricity, which has the potential for
providing small amount of mold release or slip properties.
Calcium-stearate is used as acid scavenger.

Cooling Procedures:
1. Overhead condenser.
2. Slurry cooler.
3. Jacket cooling.
Here the reactor is fitted with 3-stage turbine agitator where ethylene, co-monomer & recycle gas
are fed to the reactor bottom by eight injector system. Here the reactor used is following type:

Designed by:
Design Pressure:
Design Temperature:
Capacity:
Operating Fluid:
Test Pressure:

Sinko-Pantech Co.Ltd.
143/107 psig.
221/212 F.
89.9/3.63 m3.
Polyethylene.
220/165 psig.

OVERHEAD CONDENSER:
Heat generated during polymerization reaction is taken by the solvent hexane which comes out
from top of the reactor & this hexane is cooled in overhead condenser by cooling water system.
The operating fluid is fed to the accumulator & then recycles back to the reactor by a centrifugal
blower. During this operation theoretically 60% of total heat generated is removed.

SLURRY COOLER:
Here slurry cooler is used to remove heat upto 30% of total heat. Here slurry & water is passed
counter currently to cool the slurry & recycle back to the reactor.

JACKET COOLING:
Reactor is jacketed by a cooling system in which cooling water is circulated to remove heat upto
10% of total heat.

REFRIGERATION SYSTEM
A refrigeration system consists of a throttling valve, a condenser, an evaporation
column and a compressor. This full system comprises to form a Refrigeration
cycle.

CONDENSATION

THROTTLING

REFRIGERATION CYCLE

EVAPORATION

COMPRESSION

Refrigerant: propane
Fluid that is cooled: brine water (MEG +water)
Equipments:
Receiver/Economizer (7E-843-X) :
It is an open pressurized vessel serving as refrigerant buffer drum for primary refrigerant (R1270)
and as an economizer to increase the intermediate pressure side of the system.

Flooded Evaporator (7E-843-X):

It is a component on the low pressure side and is a flooded evaporator working with Propylene as
the primary refrigerant. The secondary refrigerant is a 20% MEG+ water.

Compressor unit (7K-821-X):

It is screw type compressor

Condenser (7E-841-X) :
This is water cooled condenser. In operation it will condense refrigerant vapour and sub cool the
liquid by 2 deg C. It is a component on HP side.
Oil separator (7V-841-X) : It separates oil and Primary refrigerant

Product quality and specification

Mode

R1

R2

Density

Catalyst/Teal
Conc in
Reactor

Slurry
Con.

Cat.Conc. in
vessel

E5201/5300B

series

110130

0.52-0.60

0.950-0.953

R1- 0.039/1

400/350

4 gmPZ/L-HE

E5201S/6200B

series

120150

0.50-0.55

0.956-0.959

R1- 0.04/1

400/350

4 gmPZ/L-HE

F5600/7000F

series

0.05-0.06

0.954-0.957

R1- 0.085/1

400/350

7.5gmPZ/L-HE

F5400/7700F
B5500/8200B

series
series

0.08-0.1
0.48-0.55

0.954-0.957

R1- 0.085/1

400/350

8gmPZ/L-HE

@ 5kg

0.953-0.956

R1- 0.02/1

400/350

2.2 gm PZ+RZ/ l
HE

2.2 gm PZ+RZ/ l
HE

Grade

700900
650850
14-17

HDT-6

P-B

12-14

0.0450.065

0.961-0.964

R1- 0.024/0.5
R1- 0.017/0.5

400/400

B 6401/5200B

P-B

12-14

0.03-0.05

0.961-0.964

R1- 0.024/0.5
R1- 0.011/0.5

400/400
a

R5801/5000SF

PB

12-14

0.05-0.06

0.961-0.964

R1- 0.024/0.5
R1- 0.011/0.5

400/400

2.2 gm PZ+RZ/ l
HE

P5300/6366M

Series

0.05-0.06

0.954-0.957

R1- 0.085/1

400/350

8gmPZ/L-HE

P5200

Series

800900
650850

0.095-0.2

0.953-0.955

R1- 0.085/1

400/350

8gmPZ/L-HE

P5200UV

Series

650850

0.095-0.2

0.953-0.955

R1- 0.085/1

400/350

8gmPZ/L-HE

M5818/ 1600J

P-A

18-21

0.952-0.956

R1- 0.022/5

400/400

3gmPZ/L-HE

Y5401/ 5000S

P-A

0.7-1.0

0.953-0.956

R1- 0.011/0.5

380/380

1.8gmPZ/L-HE

18-21
0.81.05

2.2 gm PZ+RZ/ l
HE

DIFFERENT INSTRUMENTS USED IN HDPE PLANT:

Pump :
The pump section is the most important section of the workshop. The refinery requires so
much movement of different materials, starting from crude oil to the final processed
diesel and gasoline, from cooling water to the reactor effluents, across the length and
breadth of the plant that pumps are inevitably of the greatest importance. As in the valve
section, the pumps, as and when reported to be malfunctioning are brought to the
workshop and are repaired accordingly.
The different kinds of pumps used in the industry are :
1) Centrifugal Pump (single stage): It is used for circulation of R.W. in precontacting pot,
jacket water circulation in the reactor. It has
a) high capacity, b) low discharge pressure

2) Sun dyne Pump: It is a special type of centrifugal pump, which has a) high capacity, b)
High discharge
pressure, c) high
impeller speed (14500
rpm), d) Compact
design.

3) Gear pump: It is
used for highly viscous
fluids. It is used as an a)
oil pump, b) Antistatic
Atmer metering pump.

4) Diaphragm pump: It is used as a)

catalyst metering pump, b) donor loading
pump

Various Valves:
CLASSIFICATION ACCORDING TO FUNCTION:

: ON-OFF VALVE: Handle the function of blocking the flow or allowing it to pass. Example:
gate, plug, ball, pressure-relief valves.

: NON-RETURN VALVE: Allow the fluid to flow only in the desired direction. The design is
such that any flow or pressure in the opposite direction is mechanically restricted. All check
valves are non-return valves.

: THROTTLING VALVES: It is used to regulate the flow, temperature, pressure of the

service. They can move to any position within the stroke of the valve and hold the position
including the full open or closed position.

Various types of valves used in this plant are given below.

1. Gate valve:
With rotation of the hand wheel of the valve the bush attached to it also rotates. Accordingly,
the threaded portion of the spindle moves either upwards or downwards with the wheel. The
spindle is slotted to the gate and the gates moves according to the spindle. Here min pr. drop

and bi-directional on-off service is required. Some of the valves are rejected here due to
pitting in the valve seats and body seats.

2. Globe valve:
Unlike the gate valve the globe valve can obstruct the fluid fully. Here the spindle rises along
with the wheel. Thus by rotation of the hand wheel and observing the movement of the
spindle we can differentiate globe valve and gate valve.

3. Butterfly valves :
These valves are mainly used as an onoff valve. It is
mainly a rotary motion valve that uses a rotating
round disk as a regulating element. There are two
types of butterfly valves concentric and eccentric
butterfly valves. These valves can be directly installed
between two flanges without any special end
connections owing to their very narrow face-to-face
dimensions. It has a large flow coefficient and due to
rotary motion of shaft the friction forces generated are
less than a linear motion valve. They have a high-pressure recovery factor.

These valves are used in low-pressure applications. Cavitations and choked flow can
occur easily with these valves when installed in an application with high-pressure drop.

4. Plug cocks and ball valves

For temperature below 250 C, metallic
plug cocks are useful in chemical process lines.
As in laboratory stopcock, a quarter turn of the
stem takes the valve from fully open to fully
closed, and when fully open, the channel
through the plug may be as large as the inside of
the pipe itself, and the pressure drop is minimal.
In a ball valve the sealing element is spherical,
and the problems of alignment and freezing of
the element are less than with a plug cock. In
both plug cocks and ball valves the area of
contact between moving element and the seat is large, and both can therefore be used in

in

far

throttling service. Ball valves find occasional application in flow control.

5. Non-return (check) valves

Non-return valves allow the fluid to flow only in the desired
direction. The design is such that any flow or pressure in the
opposite direction is mechanically restricted from occurring. All
check valves are non-return valves.

Non-return valves are used to prevent back flow of fluids, which could damage equipment or
upset the process. Such valves are especially useful in protecting a pump in a liquid application
or compressed gas application from back flow when pump or compressor is shut down. Nonreturn valves are also used in process systems that have varying pressure that must be kept
separate.

There are two types of check (non-return) valves, swing types and spring types.

In the swing type, the pressure of the water forces the valve gate to 'swing' open, but once the
flow stops, gravity causes the gate to fall closed, preventing a reversal of the flow. This type of
valve must be mounted vertically or horizontally to work properly.

In contrast, the gate in a spring check valve is spring loaded. Water pressure forces the gate open
just as in the swing type, but when the flow stops, the spring, not gravity, forces the gate closed.
This enables the valve to be mounted in any position and at any angle.

6. Solenoid valves
Solenoid valves are best
suited for
small, short-stroke on-off
operations requiring very
high
speed of response. These
valves
can open or close in 8 to 12
milliseconds. However, they
are
limited to pressure drops
below
20.7 bars although when
pivoted
with pilot levers or double
seats,
they can handle higherpressure
drops. A solenoid valve contains a valve body, a magnetic core attached to the stem and disc, and
a solenoid coil. A small spring assists the release and initial closing of the valve. The valve is
electrically energized to open. When an electrical signal is input to a solenoid valve (magnetic
changeover valve), the drawing force of the solenoid moves the spool, changing the direction of
flow. Because the electrical signal is switched at the valve, remote control and automatic control
are simple. Stronger springs are used to overcome the friction of the packing when it is required.
Reversing the valve plug causes reverse action (open when de-energized). These valves are quite
expensive.

HDPE FROM TOP VIEW

Dryer in HDPE plant:

Dryer is used to dry powder by removing volatile materials (steam / hexane).

It is inclined equipment & rotates at max 3 rpm.Inside there are steam tubes which carries
steam.Wet powder comes in touch with steam tubes in counter flow design. Hexane comes out
from the wet powder while comes in touch with steam tubes. It is a rotary type dryer. HDPE has
two dryers.

Heat exchanger in HDPE plant:

Heat exchanger is the equipment used to exchange heat between two fluids with different
temperatures, through a fixed wall, without mixing them.
Their names are based on the utilization.
Cooler/Heater: To cool or heat a fluid.

Condenser: To condense a vaporized material

Evaporator: To evaporate a liquid.
Waste Heat Boiler: To recover waste heat.
Different types of heat exchangers are
1) Shell & tube HE
2) Plate type HE
3) Double pipe HE

Blowers in HDPE plant:

Blower is a gas motive device that operates at a low pressure. For sticky nature of the polymer,
blower is not used for conveying the polymer as it generates low flow rate. As a result there
remains a possibility of chocking. So to avoid this problem compressors are used.
Blower is used for re-circulation of hot nitrogen in the dryer in HDPE plant. Here blowers are
also used for re-circulating instrument air for conveying HDPE pellets to pellet storage silos.

HPL FLARE GAS REMOVAL

HPLS MOTHER PLANT

STORAGE TANKS

Compressor in HDPE plant:

Compressor used in this plant is Screw type
compressor. It is a unique type of compressor. It is
for high compression ratio & high flow. Here two
two screws (referred to as male & female) are
in opposite direction with a very small allowance
between them (0.001mm). It is capable of handling
the phases - liquid & gas. It is very costly device &
distance between the screws is very carefully
maintained.

used
gear or
rotated
both
the

The screw compressors are widely used today in industrial refrigeration for compression
of refrigerants like ammonia, here in HPL, propylene.

Note: different types of compressors are:

Centrifugal compressor
Screw compressor
Reciprocating compressor
Diaphragm compressor
Polytropic compressor
But in HPL screw compressor is used mostly. Others are not used normally.
Because
1.
2.
3.
4.

Rotary screws reduce or eliminate pulsations resulting in reduced vibration.

High speeds and compression ratios help maximize available production.
Its compactness reduces package costs.
Absence of reciprocating inertial forces allows the compressor to run at
high speeds which results in more compact units.

Different Grades of HDPE and its Application

Grade

MFI

Density

Product attributes

Applications

F5400

0.06

0.954

Thin films

F5600

0.04

0.956

R5801

0.66

0.958

Easy processability,
Good strength and
Sealability.
High strength and
Impact strength.
Easy processability,
High tenacity.

P5300

0.55

0.954

Very
easy
processability, High
tenacity.

HDT6

0.5

0.960

B5500

0.35

0.955

.
Easy
processability, High
tenacity
Easy
process
ability,
High
stiffness and Impact
resistance

B6401

0.3

0.964

E5201

0.36

0.952

E5201(S)

0.36

0.952

Tissue films and

Liners.
Raffia for woven
sacks
and
Tarpaulin.
Monofilament
yarn for Nets,
Twines
and
Ropes.
for woven sacks
and Tarpaulin.

Blow
molded
parts
and
Containers,
Large Containers
and Chemicals.
Easy processability, Blow
molded
Excellent
parts
and
Impact/Stiffness
Containers.
ratio
Easy processability, Blow
molded
Excellent
parts
and
Impact/Stiffness
Containers
ratio
Easy processability, Blow
molded
Excellent Impact parts
and
ratio
Containers

CONCLUSION

The In-Plant Training carried out at Haldia Petrochemicals Ltd., has provided us a much-needed
exposure into the industrial world of Chemical Engineering. During the course of the training,
we gained an insight into the overall manufacturing process of High Density Poly-Ethylene
(HDPE). From this training we have got an idea about manufacturing, processing, testing and
molding of HDPE.
on the contrary it is reasonable to experience the plant operations but would just be a mare joke if
this HPL wouldnt gave us a chance to visit its plant and we thus come across many bookish
things and its live experimentations.
Like to mention the equipments that we all come to know which are used in the plants such
pumps, compressors, valves, blower, heat exchangers, condensers, reboilers, dryers, loop
reactors, bag filters, cyclone etc. in operation.
The Live experience of Fire & Safety and its better prevention lead us to make us believe in
taking safety measures and by that we come to know across many useful safety terms and sirens
and its use in this industry.
We are sure that the experience gained here will stand us in good stead in future.