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SC2 cracking furnace

SC2 cracking furnace. These chemical converter units are the Pyrolysis Furnaces. Long carbon chain molecules cracking to smaller parts in the special alloy tubes in the radiation zone (800 – 850 °C). SC-1 block diagram. Information about polymer units of TVK.

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SC2 cracking furnace

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  1. SC2 cracking furnace These chemical converter units are the Pyrolysis Furnaces Long carbon chain molecules cracking to smaller parts in the special alloy tubes in the radiation zone (800 – 850 °C)

  2. SC-1 block diagram

  3. Informationaboutpolymerunits of TVK „…locallylarge, butgloballysmall, …howcanwedoanymore? „

  4. Cyclical industry with frequent transitions on a dynamic market PP4 Basic behavior of polyolefin units PP3 * Transition grades were created in Q4, 2012

  5. TVK’s polymertechnologyreview The „troops” thatwehave

  6. PolyPropylene • PP: linearpolymerbuiltfrompropylene and insomecasescontainsalsoethylene • Tradename: Tipplen (TVK) • Three main types: homo PP, random copolymer PP (C2: 0.5-6.5%) and blockcopolymer PP (C2: 5-25%) • Properties: • Melt index: 0.2 - 80g/10 min (230oC/2,16 kg) • C2 content: 0.5 – 20wt% • Melting range: 140 – 165oC • Licensors: • PP3; PP4: LyondellBasell / Spheripol (loopRxwith monomer asdiluent)

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

  8. Bulk Loop vs. Gas phase reactor technology • Higher CAPEX • Easy Temperature Control at Reactors • Shorter Grade Transition Time • Narrower Product Portfolio (It means lower C2 content random PP, TPO grades) • Lower Volatile Content in PP (Just at CR grades) • Better Catalyst Activity Spheripol PP advantage-disadvantage

  9. LowDensityPolyethylene • LDPE technologies: autoclave/tubularreactor • LDPE-2 Plantstartedin 1991. • Annualcapacity: 65 kt • Product • Tradename: Tipolen • Density: 0.919 – 0.925 g/cm3 • Melt index: 0.2 – 4.6 g/10 min (190oC/2.16 kg) • Main application: film blowing • Licensor: LyondellBasell tubular autoclave

  10. LDPE tubular vs. autoclave

  11. Shematicprocess of LDPE-2 Plant • Polymerisationtype: free radical • monomer: ethylene • iniciator: oxygenradicalformation starting of chaingrowth • modificator: propionaldehydetransmittingradicalactivity termination • comonomer: n-Buthylacrylateplasticity, polarity, shining of theproduct

  12. High/Medium Density Polyethylene • HDPE/MDPE: Polyethylenehavingonlyshortchainbranchesonthelinear main chain • Tradename: Tipelin (TVK) • Properties: • Density: 0.935 – 0.965 g/cm3 • Melt index: 0.1 - 50 g/10 min (190 oC/2,16 kg) • Melting range: 125 – 135oC • Licensor: • PE1/ HDPE-1: ChevronPhillips (loopRxwithlightdiluent) • PE2 / HDPE-2: MitsuiChemicals Inc. (stirred tank Rxwithheavydiluent)

  13. Extruder (210°C) Continuous Intensive Mixer (CIM) PE-1/HDPE-1 Unit – 200KTA (1986) Loop Reactor (90 – 106°C; 42barg) Flash Tank (60°C; 0,3barg) Flash Gas to recycling system ethylene Treaters Cyclone Bag Filter isobutane hexene-1 hydrogen Dryer (70°C) HDPE fluff to powder silos Purge Column (75°C) Powder Silos (8pcs) Additives Homogenizer Dryer Repellet HDPE pellets Classifier Scales • Silo farm (28 silos) • Bagging machines (2 lines) • Truck loading facility

  14. Comonomer Centrifuge H2 TEAL Daily tank Mixing silo Pellet Silo Dryer / 105°C Homogenizer VOC: ~33 -> 0,1wt% Powder Silo 220°C R1: 85°C/7barg R2: 75°C/2.5barg Packa-ging Fresh solvent Termék Solvent tank 2/3 1/3 Low Polymer (LP) PE-2 / HDPE-2 Unit – 220KTA 2004

  15. PE-1/HDPE1 vs. PE-2/HDPE-2 Advantages, disadvantagesinthe HDPE units • Less rotationmaschine - Higherreliability • Excellentdiluentrecovery • Broaddensityrange (0,962-0,935) • Lowercatalystcosts • Less steamconsumption • Lowervolatilecontent (instead of MDPE) • MI correctionintheextrusionsection • Higherelectricityconsumption • Justmonomodalproducts • Longertransitions • Lowerflexibility • Widerproductrange (mono and bimodal) • Shortergradetransitiontime • Highflexibility • Lowerpressureinthereactor part • Start and stop withoutflaring • Lower ESP intheextrusionsection • Possibilitytouse C3- instead of purchasedco-monomer • Highersteamconsumptioninthediluentrecoverysection • Higherspecificdiluentconsumption • Highervolatilecontent • Highermaintenancecosts

  16. ProcessControl - Optimization Trytofind…. …keepit… …automateit.

  17. General processcontrolscheme

  18. Optimization 3 basic rules: 1 – Safety 2 – Quality 3 – Economic goals The economical situation forces the polymer producers to find „new operating region”, and they would be able to adopt new technics to remained there in every different workpoints. Weak demand

  19. The APC is not a „magicweapon”. This is thattoolwichcanhelpustokeeptheplantneartothe optimum continuouslyifthe operators arefamiliarewiththat. • The two most criticalbehaviors of a polymerplant: Non-linearity, multivariable APC the most commontoolforoptimization

  20. Thankyouforyourkindattention!

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