🧴 PE/PP — Polyethylene + Polypropylene

Модуль #302. КазМунайГаз GPC Атырау — план polypropylene 500 кт/год + polyethylene HDPE 400 кт/год (после ethylene cracker). Технологии: INEOS Innovene G gas-phase fluidized bed (HDPE) + LyondellBasell Spheripol or Hostalen (PP). Catalysts — Ziegler-Natta (Ti-Al organometallic) + metallocene Mt-Cp2 single-site high-tacticity. Polymer grades — HDPE blow-molding (Hostalen ACP6541), LLDPE film extrusion, PP injection moulding (Borealis BJ300MO), PP fiber (Borealis HC205TF) для нетканых масок и автомобильных тканей. EU IED BAT Polymers + ASTM D1898 + ISO 1872 + СН РК 4.04-15.

1. Состав HDPE plant 400 кт/год Innovene G

Feed preparation: ethylene 99.95% + comonomer (1-butene или 1-hexene) для LLDPE, hydrogen для molecular weight control;
Catalyst preparation: Ziegler-Natta TiCl4/MgCl2 на silica support OR metallocene Cp2ZrCl2 со MAO co-catalyst (methylaluminoxane), prep в N2-glove box;
Polymerization reactor: fluidized bed gas-phase Ø4.5 м H=12 м UCC Innovene G design, 80-90 °C × 25 бар, ethylene partial pressure 8-15 бар, gas velocity 0.5-1.0 м/с;
Bed inventory: 30-50 т polymer powder в fluidized bed, residence time 1-3 h, productivity 25-40 кг PE/g catalyst;
Heat removal: external loop heat exchanger + recycle gas cooler 40 МВт thermal (heat of polymerization 3500 кДж/кг ethylene);
Powder discharge: rotary valve + cyclones separate polymer powder from recycle gas, transfer к degassing column;
Degassing column: N2 stripping removes residual hydrocarbons + comonomer от polymer powder, output к extrusion;
Extruder/Pelletizer: twin-screw Coperion ZSK 350 mm + underwater pelletizer Gala UMP 1000, output PE pellets Ø3-5 мм производительность 100 т/час;
Additive package: antioxidant Irganox 1010 + Irgafos 168 + stearate carrier + slip agent + UV stabilizer Tinuvin, dosed via Diosna gravimetric blender;
Dryer + silo: centrifugal dryer для surface water + 4-6 storage silos × 2000 т каждый, N2 blanket для prevent dust explosion;
Bagging line: automated 25 kg bag filler + palletizer + stretch wrap для container shipment к customers;
Bulk loading: railcar rotary loader 100 т/час + truck bulk loader для domestic delivery;
QC lab: melt flow index MFI Tinius Olsen + density Mettler + GPC Agilent для molecular weight + DSC Mettler для crystallinity;
Flare + emergency relief: elevated flare 80 м для emergency relief при reactor runaway (high-MW polymer fouling);
DCS Honeywell Experion + emergency stop: reactor isolated через 6 SS valves в 30 sec при abnormal pressure/temperature.

Упражнение 1 — Process selection HDPE

Solution polymerization в hexane — устарелоSlurry polymerization в loop reactor — для HDPE narrow MWDТолько bulk autoclave high-pressureGas-phase fluidized bed Innovene G UCC/INEOS для HDPE/LLDPE: (1) Ziegler-Natta TiCl4/MgCl2 или metallocene catalyst на silica, productivity 25-40 кг PE/g cat, (2) fluidized bed Ø4.5 м H=12 м 80-90 °C × 25 бар gas-phase, no slurry/solution = no solvent recovery = simpler + cheaper, (3) heat of polymerization removed via external recycle gas cooler 40 МВт, (4) residence time 1-3 h, granular polymer 0.3-0.5 мм size, (5) Innovene G supports multi-modal MWD через staged reactors (bimodal HDPE для pipe applications), (6) capital cost 30-40% lower than slurry, (7) operational simplicity + reduced solvent inventory = safer EHS profile. Licensed by INEOS Technologies, deployed >50 plants worldwide; alternative Spherilene LyondellBasell или CB-Stamicarbon. EU IED BAT Polymers + ASTM D1898

Упражнение 2 — Ethylene conversion

HDPE plant 400 кт/год @ ethylene conversion 95% per pass + 99% overall (recycle). Расход ethylene (кт/год)?

Упражнение 3 — Капекс HDPE 400 кт/год

Polymerization reactor Innovene G Ø4.5 H=12 м + cooler = 75 млрд
Catalyst prep + feed system + comonomer = 22 млрд
Degassing column + N2 stripping + recycle = 35 млрд
Extruder/Pelletizer Coperion ZSK 350 + Gala underwater + dryer = 65 млрд
Additive package blender Diosna + 4× silos 2000 т + N2 blanket = 35 млрд
Bagging line 25 kg automated + palletizer + bulk loaders = 25 млрд
QC lab MFI Tinius + GPC Agilent + DSC + density = 12 млрд
DCS Honeywell + safety + flare 80 м + EU IED BAT + проект 4% + PNR + insurance = 110 млрд

Упражнение 4 — Dust explosion prevention

Только обычная пыль — не взрываетсяТолько sprinkler без N2Multi-barrier dust explosion prevention per NFPA 654 + 484: (1) PE/PP fine powder MIE Minimum Ignition Energy 20-50 mJ → static + spark explosion risk, (2) all silos N2-blanket continuous (O2 <8% vol) prevents combustion, (3) ATEX Zone 22 classification all powder handling areas, electrical Eex tD A21 IP6X, (4) explosion vents Erie Defraf на крыше silos 0.1-0.3 м² per м³ space, (5) explosion isolation valves Ø250 mm rotary chemical valves Pneumat KEM, (6) deflagration suppression Fenwal HRD chemicals 50 ms response, (7) grounding all conveyor + bagging line <10 Ω, (8) static dissipative shoes ESD + cotton clothing for operators, (9) housekeeping ≤1/4 inch dust accumulation rule OSHA per NFPA 654, (10) annual DHA Dust Hazard Analysis OSHA NEP combustible dust; NFPA 654 + NFPA 484 + IEC 60079-10-2 + OSHA NEP CPL 03-00-008 + СН РК 4.04-15Только вытяжная вентиляция

Нормативная база

EU IED BAT Reference Polymers (POL BREF) 2007
ASTM D1898 — Sampling of Plastics
ASTM D1238 — Melt Flow Rate of Thermoplastics
ISO 1872 — Polyethylene molding compounds
ISO 1873 — Polypropylene molding compounds
NFPA 654 — Prevention Fire/Dust Explosions in Manufacturing
NFPA 484 — Combustible Metals
OSHA NEP CPL 03-00-008 — Combustible Dust National Emphasis Program
IEC 60079-10-2 — Explosive Dust Atmospheres
СН РК 4.04-15 — Цветная + нефтехимическая
API RP 752 — Management of Hazards Associated with Location of Buildings