EPDM (ETHYLENE PROPYLENE DIENE MONOMER) PROCESS DESCRIPTION 1 INDEX 1 PLANT DESCRIPTION 3 2 INSTALLATION DESCRIPTION 4 2.1 INGREDIENTS PREPARATION (PFD FE414763-FE414764FE414765) 4 2.1.1 VAA IN OIL 4 2.1.2 CO-CATALYST 4 2.1.3 DCPAE STORAGE 4 2.1.4 ETA STORAGE 4 2.1.5 ANTIOXIDANT IN EMULSION 4 2.1.6 SODIUM HYDROXIDE (SODA) 4 2.1.7 MASTER 4 2.1.8 SBC07 4 2.1.9 POTASSIUM HYDROXIDE 5 2.2 POLYMERIZATION (PFD FE414766) 5 2.3 STRIPPING SECTION (PFD FE414767- FE414768- FE414769- FE414770) 6 2.4 MONOMER PURIFICATION AND STORAGE (PFD FE414771- FE414772) 7 2.5 FINISHING AND PACKAGING (PFD FE414773, FE414774, FE414775) 7 2.6 ENB-VNB RECOVERY SECTION (PFD FE414776) 8 2.7 ENB-VNB PURIFICATION SECTION (PFD FE414779) 9 2.8 TOLUENE RECOVERY (PFD FE414778) 9 2.9 TANK FARM (PFD FE424510) 9 2.10 FACILITIES (PFD FE424511) 10 2.11 UTILITIES (UFD FE414760 – FE424504) 10 2 1 PLANT DESCRIPTION The new plant, composed of one production line, will be used for the production of standard grades, already in portfolio VE, and experimental grades. The new plant will be independent from existing production lines, in detail new plant will composed by: Ingredients preparation section: new storages and dosages loop for VAA in oil, Master, SBC07, AO in emulsion, KOH, ETA, DCPAE, located in the new plant. Additional soda tank and dedicated feeding pump located in common storage tank area. New feeding pump for DEAC located close to common DEAC unloading and storage area (PFD FE414763-FE414764-FE414765); Polymerization section: configuration similar to line C with capacity of 5 t/h for DRY product (PFD FE414766); Stripping section: configuration similar to line C with capacity of 5 t/h for DRY product and 6.7 t/h for OE product (PFD FE414767-FE414768-FE414769FE414770); Finishing and packaging sections: configuration similar to existing lines with finishing machines capable to ensure 6.7 t/h connected to three balers and a bale packaging package equipped with two wrapping machines and two packaging stations (PFD FE414773, FE414774, FE414775); Monomer purification and storage section: configuration similar to line C with capacity of 28 t/h of mix C3 (PFD FE414771-FE414772) ; ENB-VNB recovery and purification section: dedicated to ENB-VNB mixture. This section is totally innovative and dedicated to ENB-VNB mixture purification and recovery (PFD FE414779); Toluene recovery (PFD FE414778): recovery system is completely independent from the production line. Dry toluene for cleaning reactor will be supplied to the new plant from the tank located in common tank area; Facilities: new blow-down, process water sump, steam condensate recovery, refrigeration package will be dedicated to the new plant (PFD FE414760, UFD FE424511, FE424504). The existing common storage area will be independent from the existing lines shut down, new and independent utilities supply headers will be provided. 3 2 INSTALLATIONS DESCRIPTION Below are described the installations in the new plant. 2.1 INGREDIENTS PREPARATION (PFD FE414763-FE414764-FE414765) 2.1.1 VAA IN OIL VAA (vanadium acetylacetonate) is supplied in pressurized vessels of 2 m3 containing VAA in oil at 8%(w/w) concentration. It is provided a dedicated storage V-7101, that is able to contain two tanks of 2 m3 reducing the number of discharges and to ensure an hold up of at least 3 days. VAA in oil is discharged by lobe pump P-7104 into a stirred storage tank V-7101, that is maintained at 40°C with electrical tracing and Cooling water jacket. A metering pumps P-7101 (P-7101S) assure a continuous handling of fluid in a pressure loop. A metering pump P-7108 (P-7108S) guarantee a constant flow rate of VAA (in oil) to reactor. Vents from tank V-7101 are sent to organic vents collection header. (PFD 1082).the maximum temperature and the associated higher / lower pressures 2.1.2 CO-CATALYST The co-catalyst (DEAC) is received as pure component from cylinders of about 7.5 m3. The discharge will be made in existing common area unloading station in field SM properly adjusted. The increase of discharges associated with a greater production capacity is high, therefore the current unloading will be modified and tanks of double volume will be discharged. A metering pumps P-7110 (P-7110S), directly connected to the tank located in the existing common area (field SM), regulate the flow of co-catalyst to reactor. 2.1.3 DCPAE STORAGE The activator DCPAE (Dichlorphenylacetate) is received as pure component in atmospheric IBC and discharged with pneumatic pump to the storage vessel V-7109. The centrifugal pumps P-7119 and P-7119S guarantee a pressure loop which allows a continuous recirculation of the activator. The metering pumps P-7106 (P-7106/S) guarantee the right flow rate to the reactor. In order to avoid contact with atmosphere and prevent flare corrosion due to Chloride compounds presence, the vessel is blanketed with nitrogen at a slight pressure and the vents are sent to the hydraulic seal V-7110 to neutralize the acid compounds by a scrubbing with water and KOH and then discharged to atmosphere. 2.1.4 ETA STORAGE The activator ETA (ethyl trichloroacetate), is received as pure component in atmospheric IBC and discharged with pneumatic pump to the storage vessel V-7111. The centrifugal pumps P-7122 (P-7122/S) guarantee a pressure loop which allows a continuous recirculation of the activator. The metering pumps P-7109 (P-7109/S) guarantee the right flow rate to the reactor. In order to avoid contact with atmosphere and prevent flare corrosion due to Chloride compounds presence, the vessel is blanketed with nitrogen at a slight pressure and the vents are sent to the hydraulic seal V-7110 to neutralize the acid compounds by a scrubbing with water and KOH and then discharged to atmosphere. 2.1.5 ANTIOXIDANT IN EMULSION Antioxidant in emulsion is supplied in IBC of 1 m3. Due to critical stability of this chemical, an atmospheric, stirred storage tank is provided (D-7107). The temperature is kept at 30°C using a cooling water/Low pressure steam condensate jacket and electrical tracing. 4 The unloading is made by a lobe pump (P-7103) and a second lobe pump P- 7107 (P7107S) assures a continuous feeding to stripping section. In order to avoid contact with atmosphere the vessel is blanketed with nitrogen at a slight pressure and vents are sent to the hydraulic seal D-7102. 2.1.6 SODIUM HYDROXIDE (SODA) The caustic soda is received from tank trucks already diluted at 50% (w/w), then diluted with demineralized water till 25% (w/w) and stored in F809B (new storage tank, in existing common area storage tanks). The diluted solution is continuously recirculated with the centrifugal pumps H-810A/B (dedicated to the new plant) and fed to stripping section by a side draw. 2.1.7 MASTER MASTER is a mixture of 5 components, 4 are received in bags and 1 is received in drum: velamin antiadhesive, hydrophilic colloid thickener, antifoaming, trisodium phosphate and talc. Due to high frequency of preparation and the critical fouling of this additive a dedicated storage tank is provided. MASTER is diluted with pressurized water at 1.5% and it is stored in the stirred tank D-7103. Then, the additive is moved in the stirred tank D-7104 with the centrifugal pumps P-7113 (P-7113S) from which it is charged to stripping section with the centrifugal pumps P-7114 (P-7114S). In order to avoid contact with atmosphere the vessel is blanketed with nitrogen at a slight pressure and vents are sent to the hydraulic seal D-7102. 2.1.8 SBC07 The emulsion, already diluted at 10% (w/w), are received in IBC and unloaded by lobe pump P-7105 in an atmospheric stirred tank (D-7105). The fluid is continuously recirculated with the lobe pump P-7115 and it is sent, in flow rate control, to the atmospheric stirred tank D-7106 for a further dilution till 1% with pressurized water. In order to avoid formation of foam inside D-7106, an antifoaming chemical is added: the pump P-7126 takes the antifoaming agent from the drum and discharge it into stirred tank D-7105. In this way, two products should be better mixed avoiding foam phenomena. The centrifugal pumps P-7116 (P-7116S) bring in discontinuous through a sequence the product till the atmospheric stirred tank D-7601 that is used as run tank during preparation of diluted mixture. From D-7601, SBC07 is transferred by gravity to die plate by the ejectors J-7601A/B. 2.1.9 POTASSIUM HYDROXIDE The potassium hydroxide, additive used in monomers distillation, is received already diluted at 30% (w/w) in IBC of 1 m3 and further diluted till 1.5% (w/w) with pressurized water in the atmospheric vessel D-7112. The centrifugal pumps P-7125 (P-7125/S) are used to recycle the diluted solution in a pressure loop while the metering pumps P7118 (P-7118/S) guarantee the right pressure and flow rate to monomer purification column. In order to avoid contact with atmosphere the vessel is blanketed with nitrogen at a slight pressure and vents are sent to the hydraulic seal D-7102. 2.2 POLYMERIZATION (PFD FE414766) The product line is provided with a continuous polymerization reactor equipped with an agitator (R-7201). It is an ethylene-propylene co-polymerization with the presence of third-monomer as ENB o ENB-VNB mixture depending on produced grades. C3 mixture (propane, propylene but also ethylene), ENB (or ENB-VNB mix) are continuously fed to reactor. The continuous feeding of VAA, DEAC and ETA (or DCPAE, in accordance with grade needed) guarantees the start of reaction. The quality of rubber is controlled by a continuous monitoring of pressure and vapor composition in the top of reactor. Since the reaction is exothermic and temperature and pressure must be kept constant in the reactor, a thermostatic system is provided. This system compresses (in Y-7201) and condensates (in E-7202) vapors from reactor and collect them into a tank (V-7202) ready to be recycled into reactor, cooling down the polymer suspension. Before being compressed vapors passes through filters, S-7201 5 (S-7201S), that keep fines entrained. Hydrogen is added as polymer molecular weight controller. V-7202 is equipped with process vent to discharge light-ends destined to off-gas treatment (FGH). From the reactor’s bottom, the crumb slurry is continuously discharged in level control from reactor to the stripping section by a pressure water loop that allows to control the C3 mixture evaporation due to the pressure drops passing from reactor to stripper. The exchanger E-7203 is only used at start-up to have the right gas composition in vapor phase from reactor before the start of reaction. The reactor is moreover equipped with a cleaning fluid line that uses toluene, in flow rate control, previously heated by E-7204. 2.3 STRIPPING SECTION (PFD FE414767-FE414768-FE414769-FE414770) Unreacted monomers (mainly C3 mixture) and ENB are separated from rubber by high and low pressure strippers. High pressure stripping section, that receives slurry from reactor (rubber, unreacted monomers and propane), is composed by the stirred tank V-7301 in which medium pressure steam is injected. Additives and process water (from finishing line) are also continuously charged. Milling pumps P-7301A/B (P-7301/S) are used to keep constant the shape of crumbs and to guarantee slurry recycle that leads an effective mixing of system. Vapors from high pressure stripper are condensed in EA-7301,under-cooled in E-7302 and collected in V-7302 where monomers C3 are separated as gas phase from water. Also aqueous streams coming from V-7501, from the bottom of C3 purification column and from the coalescer S-7501 are conveyed in V-7302. Gas phase (C3 vapours) is continuously compressed by package Y-7303 and then it is fed to the monomer distillation section (PFD 1051) while liquid phase containing ENB is sent to V-7403. The crumb slurry is pumped from the high pressure stripper to low pressure strippers, two stirred tank (V-7401 and V-7402) in which low pressure steam are injected to remove residual monomers completely and ENB in particular. The milling pumps, P7401 (P-7401/S) and P-7402 (P-7402/S), keep constant the crumbs size by recycling and feeding slurry to finishing line. Low pressure strippers are equipped with centrifugal pumps P-7404 (P-7404/S) and P-7405 (P-7405/S) that move slurry towards small cyclones able to concentrate in case of short finishing shut down; recovered water is sent to process water recovery system in finishing section (PFD 1062). Steam and monomer vapors leaving both low pressure strippers pass through filters S7401 (S-7401S); then they are condensed by air-cooler (EA-7401) and cooling water exchanger (E-7402) and collected into phase separator V-7403. Aqueous phase, containing ENB, is sent to water purification section (PFD 1081). Gas phase from V-7403, mainly composed by C3, is compressed by package Y-7403 and sent to monomer distillation section (PFD 1051). For production of oil extended grade, paraffinic oil is added to low pressure strippers by the lobe pumps H-801 D/E (yellow extensor oil) and H-801 F (white extensor oil) and process water is fed in order to keep the right polymer concentration. During draining of stripping section the shaker screen SD-7602 is used to separate rubber (third choice) from aqueous phase discharged to the organic sump (PFD 1091). 6 2.4 MONOMER PURIFICATION AND STORAGE (PFD FE414771-FE414772) Compressed monomers recovered by strippers have to be distilled in order to remove lights (as ethane, CO, CO2) and heavies (water, ENB) impurities before being recycled into reactor. Into the column C-7501 potassium hydroxide is also fed to neutralize acidic catalytic residues. The column is conducted at pressure of about 19 barg and it obtains: Organic stream at column head rich in propane and propylene; Aqueous stream with ENB at column bottom. The condenser E-7501 is connected to a three phase separator V-7501 and another heat exchanger system (E-7504) that uses refrigerated water in order to reduce monomer losses. Vents are sent to off-gas treatment. Aqueous phase is separated and sent to stripping section (PFD 1031). Organic phase (the flow rate is 3 times compared to the feed flow rate) is sent, in flow rate control, to the column as reflux by the centrifugal pump P-7501 (P-7501S). The purified monomer is kept from reflux stream and sent to monomer storage section (PFD 1052); it is refrigerated in E-7505 and sent, through the coalescer S-7501, to molecular sieve column package (Y-7502) in order to reduce water content before being stored in the buried tank V-7502. This tank is refilled with propylene and propane in order to have the right composition for a good polymerization. From the storage tank, monomers are sent to polymerization section by the centrifugal pumps P-7502 (P-7502S) passing through the alumina column package (Y-7503) in order to drop down residual water and polar component presence. Two filters, S-7502 and S-7503, are installed on propane/propylene recycle line; the first is collocated before the coalescer S-7501 in order to prevent the fouling and the second one is collocated after package Y-7502 to avoid alumina’s entrainment into the process. A static mixer is installed before vessel V-7502; it guarantees a good mixing between propane/propylene recycle stream and make-up streams. Alumina and molecular sieve packages are equipped with high temperature nitrogen regeneration system. 2.5 FINISHING AND PACKAGING (PFD FE414773, FE414774, FE414775) The polymer slurry discharge from the third stripper is fed to extruding line. Finishing line is equipped with only one package that guarantees the right (specification value <1%) humidity in final product. The primary shaker screen Y-7601-SD-1 separates most of water contained in the slurry, then water and fines are drained into fines tank D-7603 while the crumbs are sent to the feed hopper of dewatering press Y-7601-K1 containing about 20-30 % w/w of water. The crumbs are compacted and pressed by dewatering press, so that most of water is squeezed out from the crumbs: the crumbs discharged from the dewatering press contains about 5 % w/w of water. In the feed hopper, in accordance with polymer grades produced, is also fed zinc stearate, in order to increase the drying performance of the dewatering press. The dewatering press has external shells with slots of various thickness that allow to drain water squeezed by screw rotation against the shell. In the head of the dewatering press a counter-pressure system is provided; it allows to lighten the machine with the variation of the pass by hydraulic moving of chokes. The extruded polymer is cut into small pieces and falls into the mechanical dryer Y7601-K-2. The mechanical dryer consists of a barrel (completely closed), heated with steam for warming the product at the start-up, and a die plate equipped with different hole depending of the kind of product: in 7 this machine the mechanical energy is given to polymer and the generated heat warms crumbs and water, that flashes as the polymer coming out from the die plate; so the polymer becomes porous. Anti-sticking SBC07 is sprayed on the pellets by the air induced injectors J-7601A and J-7601B in order to avoid sticking at the end of expander. The polymer almost completely dewatered is sent to the Hot-box that is an horizontal vibrating conveyor and it is used to keep warm the product and reduce the content of water up to the final specification value by hot air feeding (Y-7601-K-4). The pellets discharged from the hot-box are fed to an FBD (fluid bed dryer, Y-7601-K5), that is first heated (first and second zones) and then cooled (third zone), to obtain more control of temperature and residual humidity of discharged product. Two blowers equipped with own heater/cooler provide hot/cold air to the FBD. The polymer is fed for gravity from FBD to the distributor Y7701K3 and three balers with own vibrating conveyor. To achieve a fine tuning of the weight control, the vibrating conveyor is design to feed each weighter that allows to weight bales of about 25 kg; after the balers, rubber passes through metal detector and then in-line scale which is enable to discharge automatically metal affected or out-of-weight bales from the roll conveyors. The bales are then wrapped with a film of polyethylene in the bales wrapping machine and sent to the packaging. To produce 6.7 t/h of bales two bales wrapping machine in parallel are provided. The plant is equipped with a treatment system for waste air from finishing section: the wet air coming from hoods (shaker screens Y-7601-SD-1 and SD-7602, expeller and atmospheric vessel D-7603) is sent to wet scrubber in order to remove fines and powder. The dry air coming from hot-box and from FBD is treated with cyclones in order to remove fines and powder and then with activated carbons bed that eliminates 90% of ENB in input. All this flux of air are moved to the new stack X-7601. Water and fines coming from shaker screen and dewatering press are collected to the recycle fines tank, an atmospheric stirred tank D-7603 from which water and fines are recycled to stripping section with the pumps P-7603 (P-7603/S). Excess water is removed from the recycle fines tank by overflow and it is fed to the screen SD-7602 to reduce the fines content before being discharged to the finishing sump. 2.6 ENB-VNB RECOVERY SECTION (PFD FE414776) Process water contaminated by ENB coming from stripping section is sent to V-7807 in order to separate by density organic phase from water phase. Water phase are stored in TK-7801 while organic phase, if standard grade (VNB free) is produced, is sent to OSBL or, when experimental grade (containing VNB) is produced, it is stored in TK-7802. Water at ENB solubility stored in TK-7801 has to be purified in column distillation before being discharged to sump. The stream is fed to first plate of the column C-7801 that is conducted at 0.6 barg with a reflux of 15% (compared to feed stream). Vapors from the top of column are condensed in E-7801 and separated in V-7801; organic phase is sent to OSBL or, in case of VNB presence, to TK-7802. Water phase is recycled to column with the pumps P-7801(P-7801/S). From bottom, aqueous stream (with organic traces under law limitation) are discharged to water sump. Lights are eliminated from the top of column in control of pressure; the exchanger E7805 allows to 8 reduce vents emissions. 2.7 ENB-VNB PURIFICATION SECTION (PFD FE414779) The organic phase coming from TK-7802 is a VNB-ENB mixture with solubility water and heavies (the amount is depending on raw materials); so it has to be purified before being recycled to polymerization reactor. This section is dedicated to remove only water from VNB-ENB mixture; the separation of ENB from VNB isn’t reached in this column. In order to prevent VNB contamination of the ENB streams in case of standard grades production (VNB free), the ENB streams are sent to existing common area storage tank. The column C-7802 works under vacuum condition and receives the stream from TK7802 (wet VNB-ENB tank) by the pumps P-7804 (P-7804/S). Vacuum is guaranteed by the package Y-7801 provided with a liquid ring pump. The stream is fed to first plate of the column; from the top vapors are condensed in E7812 and separated in V-7802; the aqueous phase is sent to TK-7801 to the next treatment while the organic phase is recycled (four time compared to the feed) to the column by pumps P-7810 (P-7810/S). Dry ENB-VNB mixture is recovered from a side-draw in vapor phase in order to reduce heavy content. From the bottom a small amount of heavies (rich of ENB dimers) and ENB are sent to V-7904 for incineration. Lights coming from package Y-7801 are discharged to organic vents collection header. (PFD 1082). 2.8 TOLUENE RECOVERY (PFD FE414778) Toluene is the solvent used for polymerization reactor chemical cleaning. After the chemical cleaning, solvent called “dirty toluene”, due to the content of rubber, is moved to the toluene stripper V-7805. Into the stripper, containing water and toluene, medium pressure steam is injected. Toluene and water vapors are recovered from the top of the stripper, they are condensed in E-7808 and then collected in V-7806. Here toluene and water are separated for gravity; toluene is sent, through coalescer, to molecular sieve column for solubility water removal and then dry toluene is moved to existing common area storage tank. Water phase is recycled to stripper and the excess is sent to existing common area storage tank. The recycle from the mill pumps P-7815 (P-7815/S) is used to prevent rubber sticking in the stripper, keeping constant the shape of crumbs. After stripping, rubber falls into the toluene stripper shaker screen (SD-7801) and water is analyzed before being sent to organic sewer. 2.9 TANK FARM (PFD FE424510) The new tank farm is composed by: Process water storage tank, TK-7801: this tank receives process water from stripping section and feeds it to ENB recovery column C-7801 by P-7808 (P7808/S). Wet VNB-ENB tank, TK-7802: it receives organic stream rich of ENB, containing VNB, and feeds it to VNB-ENB purification column C-7802 by the pumps P7804 (P7804/S). Possible presence of water at the bottom of the tank is discharged in TK7801 by the metering pump P-7820. Dry VNB-ENB tank, TK-7803: it receives purified VNB-ENB mixture from C-7802 and feeds it to VNB-ENB storage tanks (TK-7804A/B) by the pumps P-7805 (P7805/S) in order to prepare the loading batch for polymerization; 9 VNB-ENB storage tank, TK-7804 A/B: for standard grades these tanks are filled with ENB coming from OSBL (existing common area storage tank) by the pumps H-804A/B. For experimental grades, containing VNB, a loading batch of VNB-ENB mixture must be prepared, the content of VNB has to be controlled with on-line analyzer in order to obtain a right value of VNB in VNB-ENB mixture to reactor. VNB-ENB mixture is fed to polymerization reactor by the pump P-7807 (P-7807/S); VNB storage tank, TK-7805: it receives VNB from tank trucks and feeds it to VNBENB storage tank (TK-7804A/B) by the pumps P-7809 (P-7809/S) in order to prepare the loading batch for polymerization; All tanks are atmospheric; they are equipped with internal floating roof and vents are conveyed to D-7804 and then to organic vents collection header by fans F-7801 (F7801/S). In case of general plant shut down the vent are sent to an activated carbon system. 2.10 FACILITIES (PFD FE424511) Facilities section includes: Low and medium pressure steam condensate section: low and medium pressure steam condensate are conveyed into the atmospheric tank D-7901 in order to recover steam condensate. The condense is cooled in E-7901 and collected in D7905, this water is used as pressurized water in the plant. Water overflow from D7905 is sent to process water sump N-7903. Blow-down: organic vents and purging gas are conveyed in V-7903 to remove traces of liquid and sent to existing gasometer. High pressure vents rich of C3 coming from reactor and monomer distillation column are sent to existing off-gas treatment . Emergency vents are collected in two different headers, one of high pressure (reactor + monomers distillation column) and the other one of low pressure (stripping and other section). The first is connected with V-7901 to remove liquid before discharging to existing high pressure flare B50, to be revamped in order to treat this additional load. The second one is connected with V-7902 to remove liquid before discharging to new smokeless flare. Waste liquid vessel V-7904: C-7802 bottom column stream is conveyed to heated vessel V-7904 to keep a right value of viscosity in order to be moved and transferred to tank-car by the lobe pump P-7904 to next disposal. The vessel is blanketed with nitrogen and vents are sent to activated carbon system before emission in atmosphere. Fines and water sump: there are three water recovery sumps, a different height between them allows the water to move for gravity. N-7901 receive in continuous water with fines (discharge from finishing section, lines cleaning), then the fines are separated by gravity and water is conveyed in N-7903. N-7902 receives in discontinuous water possibly contaminated with organic and plant cleaning washing. Organic phase is separated by gravity and water is conveyed in N-7903. N-7903 receives water from N-7901 N-7902 together with process water from C7801 bottom and overflow from pressurized water vessel and sends waste water by P-7902/S to OSBL water treatment. 2.11 UTILITIES (UFD FE414760 – FE424504) The new plant requires utilities that are not presents in site: Refrigerated water: made by two refrigeration system in parallel in order to be able to handle normal and peak loads. Refrigerated water at the temperature of 6 °C is stored into atmospheric tank D-7902 and sends by the pumps P-7901A/B/C to refrigeration package in order to obtain refrigerated water at 2 °C to be distributed in the plant. Compressed air: in finishing section compressed air at the pressure of 7 barg is necessary to be used in vibrating machinery; it is produced by two compressors in parallel that use ambient air. 10
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