A Project Report on Polypropylene (PP) Co-polymer Manufacturing: PPCP is produced by polymerizing polymer grade propylene using Ziegler-Natta catalyst system and hexane as a solvent. The Vadodara (India) plant is designed to produce 25000Mt/year of co-polymer viz. 16500MT/year of block polymer and 8500MT/year of random co-polymer.

1. A
Project Report
On
Polypropylene Co-polymer Manufacturing
Submitted in partial fulfillment towards the bachelor’s
degree in the field of Chemical Engineering
Prepared By
Shreenath M. Modi
Ch- 22 (I.D.No. 104024)
Under the Guidance of
Dr. Vimal Gandhi
Department of Chemical Engineering
Faculty of Technology, Dharmsinh Desai University
College road, Nadiad – 387 001
April -2014

2. CERTIFICATE
This is to certify that Mr. Shreenath M. Modi durably submitted his Project
report on PolyPropylene Co-polymer as partial fulfilment of his graduation
in department of Chemical Engineering in D.D.U. (Dharmsinh Desai
University), Nadiad.
Dr. Vimal Gandhi Dr. PREMAL SHUKLA
Associate Professor (GUIDE) Professor& HOD,
Chemical Engineering Department, Chemical Engineering Departement,
DDU, Nadiad. DDU, Nadiad.
Date: Date:
PREFACE
Theory of any subject is important but without its practical knowledge it becomes useless
particularly for the technical students. A technical student can’t become perfect in his field without
practical understanding of the branch.
Visual observation of actual chemical plant operations is one of the best ways of learning
what goes on in a typical chemical industry. It is essential that chemical engineering student should
have a comprehensive picture of the chemical industries.

3. For this reason, the industrial training is necessary addition to reading assignments and
classroom discussions.
The principle objectives of the plant training is to get details about the operations, which are
carried out in the industry and more about the working and details of equipment used in the
chemical industries. Another attractive feature is to learn industrial management discipline as well
as safety aspects which is equally important in life.
Hence this training provides golden opportunity for all teaching students.
Shreenath Modi
Sem – 8
Chemical Engg. Dept.
DDU, Nadiad.

4. ACKNOWLEDGEMENT
Any accomplishment requires the effort of many people. I
thank my professors & especially my guide Dr. Vimal Gandhi, whose
guidance & support was instrumental in accomplishing this task. I thank
my all colleague whose diligent efforts also made this training
successively progressive.
Many fundamental aspects, flow sheets, equipment details &
process fundamental are cleared during this training period. For this
much effective efforts, I am really very thankful to all industrial persons
who have given me the great experienced knowledge & guidance to me
for better understanding & to complete my training with higher
achievement.
Shreenath M. Modi
B.tech. Sem – VII
DDU.

5. INDEX
1. Introduction to Propylene
1.1 Properties ………………………………………………………………………………….1
2. Product Specification……………………………………………………………………….......2
3. Process Description of PPCP plant
Process Block Diagram……………………………………………………………………………3
 Area 100: Catalyst preparation & Utilities ……………………………………………….6
 Area 200: Polymerization section ………………………………………………………...6
 Area 300: Powder drying section …………………………………………………………6
 Area 400: Solvent recovery section …………………………………………………........6
 Area 500: Extrusion & palletizing ………………………………………………………..6
 Area 600: Bagging & dispatch ………………………………………………………........7
4. MSDS OF HAZARDOUS CHEMICALS USED IN PLANT ………………………………...8
5. Detailed Manufacturing process
 Area 100: Catalyst preparation & Utilities ……………………………………………….9
 Area 200: Polymerization section ……………………………………………................12
 Area 300: Powder drying section …………………………………………………….....15
 Area 400: Solvent recovery section …………………………………………………......18
 Area 500: Extrusion & palletizing ………………………………………………………21
 Area 600: Bagging & dispatch ………………………………………………………......23
6. Material Balance………………………………………………………………………………25
7. Energy Balance
7.1 Energy Balance of R201 & R202…....………………………………………………28
7.2 Energy Balance of Distillation column........................................................................29
7.3 Energy Balance of Extruder…............……………………………………………….30
8. Equipment Design
8.1 Shell & Tube Heat Exchanger…………………………………………………….....31
8.2 Centrifugal Pump…………………………………………………………………….40
8.3 Hexane Storage tank…………………………………………………………………44
9. Material of Construction………………………………………………………………………46
10. General safety………………………………………………………………………………..47

6. 11. Plant Location & Layout……………………………………………………………………..55
12. Utilities……………………………………………………………………………………….57
13. Cost estimation……………………………………………………………………………….58

7. List of Tables:
Name Page No.
MSDS of hazardous chemicals 8
Material Balance of equipment 27
MOC for Heat Exchanger 46
Direct cost calculation 58
Indirect cost calculation 59
Direct Production Costs 60
Fixed Charges 60
General Expenses 61
Selling Price of Products 61
Summary of Cost Estimation 63
List of Figures:
Name Page No.
Process Block Diagram 3
Area 100 9
Area 200 12
Area 300 15
Area 400 18
Area 500 21
Counter Current H.E. 32
Temperature correction factor 33
Temperature correction factor 34
Plant Layout 54

8. 1
CH – 1 – Propylene
Properties:
 Molecular weight : 42.08 kg/kmol
 Critical temperature : 365.57 K
 Melting point: 87.9 K
 Critical pressure: 4.6646 MPa
 Normal boiling point: 225.46 K
 Critical density: 223.4 kg/m3
 Normal vapor density: 1.91 kg/m3
(@ 273.15K; 1.0135MPa)

9. 2
CH- 2- Product Specification
PP is produced by polymerizing polymer grade propylene using Ziegler-Natta catalyst system
and hexane as a solvent.
The polymer exist as in 3 strucutral forms viz.
1. Isotactic
2. Syndiotactic
3. Atactic
In isotactic, the CH3 group is structured on alternate side of chain, while in case of atactic CH3
group is structured at random positions throughout the chain.
The isotactic is plastic in nature and insoluble in solvent while atactic (byproduct) is sticky in
nature and soluble in polymerization solvent.
Addition of polymer chain improves the impact strength of polymer for special end use.
Plant Capacity:
This plant is designed to produce 25000Mt/year of co-polymer viz. 16500MT/year of block
polymer and 8500MT/year of random co-polymer.
Product Competitors:
1. RTP company
2. Kolon
3. A. Schulman comallloy
4. BASF
5. Dow Chemical
6. SABIC
7. LyondellBasell
8.Samyong

10. 3
CH – 3 - Process description of PPCP plant:
Compressor
K-201
Dehexaning
Column
TO FPU
To 2nd
Degasser

11. 4
Propylene
Reactor
R-201
Reactor
R-202
1st
Degasser
Reactor
R-203
2nd
Degasser
Compressor
K-401
Compressor
K-202
H2
Hexane
H2
Centrifuge Powder
Prepolymeriztion Unit

12. 5
Powder drying area
Atactic + Hexane
Gummy Hexane
Separator
Flash hopper
Powder storage
Extrusion
Pellet storage
Hexane
Separator
Hexane
Scrubber
Atactic Packing
Hexane drying
Dry Hexane stoage
Pre Polymeriztion unit

13. 6
Area 100: Catalyst preparation & Utilities
 Refrigeration Brine solution
 Plant Blow Down
 Preparation of aqueous soda solution
 Recovery of condensates
 Co-catalyst dilution
 Preparation of catalytic suspension
Area 200: Polymerization section
 Reactors for homo polymer and random co-polymer
 Reactors for block co-polymer
 Degassers with compression and recovery
Area 300: Powder drying section
 Polymer centrifugation
 Predrying of powder with recovery of hexane
 Treatment of powder with vapor to decompose catalyst
 Final drying and powder transport
Area 400: Solvent recovery section
 Overheating of gummy hexane
 Atactic concentrator recovery
 Hexane distillation from heavies and light
 Hexane neutralization, drying and storage
Area 500: Extrusion & palletizing
 Powder storage
 Preparation and metering of additives
 Extrusion and additivated powder
 Drying, screening and weighing of polymer pallets

14. 7
Area 600: Bagging & dispatch
 Pellet storage
 Pallet homogenization and analysis
 Pallet bagging

15. 8
CH – 4 MSDS OF HAZARDOUS CHEMICALS USED IN PLANT:
CHEMICAL BOILING
POINT
˚C
AUTO
IGNITION
TEMPERATURE
˚C
HAZARDS EXTINGUISHING
AGENTS
CO -191.5 609 Flammable,
reacts with Na
& K to form
explosive,
sensitive to
shock, heat or
contact with
water
Spray H2O on
container if
exposed to fires,
Fog, DCP
C DONOR
(Cyclo Hexyl
Methyl
Diethoxy
silane)
198 235 Flammable,
reacts with
H2O, acids,
alkalies & SiO2
CO2 , DCP ,
alcohol foam,
Dry sand,
DO NOT USE
WATER
Ethylene -102.4 490 Fire Water, fog, DCP,
CO2
n-Hexane 69 225 Fire, explosion,
reacts
vigorously with
oxidizing
agents
Do not use water
jet,
Keep containers
cool by spraying
water
H2 -252.8 500 Fire, explosion,
easily oxidize,
violent reaction
with air+ other
catalysts Br2, I2
Spray water &
DCP for small fire
N2 -196 ---- N2 pipeline
condenses
liquid O2 out of
the atmosphere
& can create a
fire
Suitable for
surroundings
Propylene -47.7 497 Fire CO2 , DCP,
Halogenated
20% caustic 142.148 -- Fire Water spray
TEAL (Tri
ethyl
aluminum)
98 < -58 Fire, Highly
reactive
DCP, dry sand,
CO2 foam
NEVER USE
WATER
Table-1- MSDS of hazardous chemicals

16. 9
CH- 5- Detailed Manufacturing Process:
AREA- 100 - Catalyst Preparation & Utilities
Fig.-1- AREA 100 Catalyst prep. & utilities
 Refrigeration Brine solution:
Heat extraction for the process is supplied by calcium nitrate brine coming
from battery limit. Pump P101/s is provided for the circulation of brine in whole
plant with temperature control.
 Plant Blow Down:
The blow down V101 is provided to separate out the gaseous steam from
liquid and solid carried out in emergency discharge from the reactors R201, R202
and R203, before sending it to the flare.
Possible drains from equip. containing hexane are collected in same vessel
as well & neutralized with caustic (NaOH) solution if required.

17. 10
Now pump P102 transport them to atactic polymer &recovery unit in this
area.
 Recovery of condensates:
In vessel V104, HP (high pressure) condensate @ 40kg/cm2
is flashed with
recovery of medium pressure steam @15kg/cm2
. In vessel V105 all the condensates
are collected & flashed to reduce pressure (RP) steam @ 0.6 kg/cm2
& 112˚C which
is reutilized in plant.
 Catalyst preparation:
1. LYNX 1000 (Main catalyst):
The reaction is feasible because of this catalyst, the whole process depends on the
catalyst. This catalyst is made in Batch production.
This catalyst is TiCl3 placed on MgCl2. This provides active sites in polymerization
reaction. This is prepared in the vessel V110 in batch as per requirement, it first comes in
powder form and then fed in the prepolymerizer directly.
2. Co-catalysts:
1) TEAL – Tri ethyl aluminum
This Co-catalyst is required for killing poisonous substances for
this reaction like moisture & dust and providing perfect environment for
catalyst to act.
TEAL is also prepared batch wise as per requirement. They are
coming in cylinders of 1200kg weight. Then it is diluted in the Hexane in
vessel V108 before its use.
Special precaution is to be taken with TEAL is that it should not
come in contact with water, as it catches fire with an explosion.
2) C-DONOR- Cyclo Hexyl methyl diethoxy silane
The co-catalyst C-DONOR is required for controlling stereo
regularity of the product to get the maximum isotactic content in final
product. It comes in liquid form in drums and is diluted with hexane
first in surge vessel T101 & then transferred to prepolymerizer as
required.
Prepolymerization:
The prepolymerization is done to active the main centers of LYNX
catalyst for the polymerization reaction. Here the feed is propylene, hexane, main catalyst & co-
catalyst.
The prepolymerizer is kept at the temp of 15-16˚C, it helps controlling the
reaction to only 15% of final conversion (~75%). The temperature around the prepolymrizer is

18. 11
kept in control by circulating the brine solution @ 8˚C (which is cooled by NH3) in jackets and
baffles.

19. 12
AREA- 200 –Polymerization Section
Fig.- 2- AREA-200
The polymerization:
This reaction takes place in three reactors. These reactors are used as per requirement of
product. The sequence for the polymerization is shown below.
For homopolymer:
R201 R202 V202 V203
For block copolymer:
R201 R202 V202 R203 V203
The total volume of the reactors is 100m3
. Its operating conditions are as below:
I. Operating temperature: 70˚C, 70 ˚C, 60 ˚C respectively
II. Pressure: 10kg/cm2
, 7 kg/cm2
, 1-1.2 kg/cm2
III. Total conversion: 80%
IV. Heat of reaction: 480 kcal/kg
The catalyst suspension, cocatalysts solutions, polymerization grade propylene,
polymerization grade ethylene, recycled monomers and solvent as well as hydrogen,

20. 13
acting as a molecular weight regulator, are continuously fed to the reaction under flow
rate control.
Both homopolymerization and copolymerization reactions take place in
continuous hexane suspension, under specific conditions for each type of polymer. In all
cases they are exothermic reactions and give rise to partial conversions of monomers into
polymers, ranging between 75 and 90% of the monomers fed to the reactors. Generated
heat and unreacted monomers are to be removed from the hexane polymer slurry.
The reaction heat is removed under temperature control by demineralized water
circulating in a closed loop within jackets and baffles of all the reactors. Demi-water
circulation is assured by pump P201/S, its cooling is done by E201 PTFE (plate and
frame heat exchanger) and expansion by V201 vessel, where demi-water spilling or make
up can occur under level control.
At start-up the required heat on contrary is supplied by steam injectors J201, J202,
J203 to the demi-water and hence to the reactors. Reaction shut down in each reactor can
be carried out, if necessary, by introducing a killer: CO mixed with N2.
The unreacted monomers are removed downstream, by degassing the in-hexane
polymer slurry by means of pressure decrease and heat supply. The two degassers V202-
V203, of agitated vessel type, have a total volume of 70m3
about and operate at
decreasing pressure between 2 and 0.2kg/cm2
and at temperature of 60˚C approximately
inside them, heat to slurry is supplied directly by mixing it with hot hexane recycled from
solvent distillation section, under temperature or flowrate control.
The in-hexane slurry is always discharged by pressure difference from the
primary reactor R201 to the secondary R202, as well as from this one to the first degasser
V202. Hence the pump P203 transfers pre-degassed polymer slurry to the second
degasser V203, during homopolymer or random copolymer operations. Instead, when
operating on block copolymer, pump P203 recycles the homopolymer slurry to the third
reactor R203, where from the block copolymer slurry is discharged by Pump P202/S
pump into V203 final degasser. All discharges occur under level control.
UNREACTED PROPYLENE COMPRESSION AND RECOVERY:
The vapors degassing from 1st
degasser V202 are partially condensed in E202,
separated from condensate in V204, compressed by K201/S and finally condensed in
E203, where from condensate is discharged into V205, also the partial condensate from
V204 is delivered through pump P205/S (and E203), into the same vessel V205 under
level control, hence totally recovered stream is recycled by pump P206/S to primary
reactor R-201.
The vapors degassing from 2nd
degasser V203 are condensed and collected into an
equipment sequence as above, but at lower pressure levels: condenser E204, separator
V206, compressor K202/S, pump P207/S, final condenser E205 and separator V207.
From here, uncondensed vapors are recycled either to 3rd
reactor R203 during block co-
polymer production, or on the suction of higher pressure compressor K201/S for
subsequent condensation and recovery, during homopolymer and co-polymer production.

21. 14
The condensed fraction from V207 is recycled the same way either to reactor R203 or
K201/S delivery through pump P208/S.
Purge streams from R201, R202 are necessary to eliminate the inert introduced
with the monomers are continuously spilled under flowrate control and conveyed to the
small dehexaning column C201, where it is recovered as the bottom product and
discharged by pressure difference into 2nd
degasser V203 or up to the dry hexane storage
in AREA-400 (after cooling in E403). Top product is partially condensed in E206 by
means of flashing propylene, the uncondensable fraction is purged to flare. While the
condensate is recovered in reflux drum V208 and conveyed by pump P209/S to
purification inside feed processing unit (FPU).
C-201 bottoms discharge, top condensation and reflux are managed by level,
pressure and flowrate controllers respectively, purging and condensate discharge by
temperature and level controllers respectively from V208.
Purge stream from reactor R203 is conveyed to partial condensation (E408 or
E409) for hexane recovery in AREA 400, before sending it to the flare.

22. 15
AREA – 300 – CENTRIFUGATION AND DRYING:
Fig.-3- AREA 300
The polymer slurry from 2nd
degasser consists of both isotactic and atactic polymer. The
atactic polymer is dissolved in hexane and isotactic polymer remains in suspension form. This
slurry is fed to the centrifuges X301 A/B, where the copolymer in powder form gets separated,
from the atactic polymer. From here, the co-polymer powder is sent to the drying section and the
atactic polymer to the hexane recovery unit and then atactic polymer is taken out as a BY-
PRODUCT.
The polymer powder drying is carried out in 3 stages:
1. Flash dryer
2. Steam 3rd
bed dryer
3. Final 3rd
bed dryer

23. 16
FLASH DRYER (D302):
Hexane wet polymer is fed to the flash dryer D302 through polymer-agglomerates
breakers X304 A/B. Hot Nitrogen stream which is recycled to the flash dryer bottom, dries the
polymer and conveys it to cyclone X305. The polymer powder drops into the small hopper X306
below, from which it is discharged to the steaming fluid bed D303, under level control.
Hexane enriched Nitrogen, released from the top of cyclone, goes to the scrubber C301
where hexane is condensed and Nitrogen is deduced, by means of cold hexane recirculated to the
scrubber through pump P303/S and cooler E303 in a closed loop. The condensed hexane with
polymer powder entrainments, accumulating in the scrubber bottom, is recycled to the
polymerization reactors by high-pressure pump P304/S.
The Nitrogen is coming out of the scrubber is recycled to the flash dryer bottom by fan
B301/S, after heating in the exchangers E301 and E302.
A purge gaseous stream is spilled from the fan delivery to avoid an excessive concentration, in
the Nitrogen closed cycle, of in-hexane dissolved propylene introduced in the flash dryer. An
equivalent amount of pure Nitrogen is fed to the cycle under pressure control.
STEAMING FLUID BED DRYER (D303):
The polymer powder is discharged by gravity to the top of the fluid bed dryer D303 &
fluidized by live steam at about 0.5kg/cm2
which is fed at the dryer bottom below the main
distributing plate of conical form.
A supplementary fluidization is taking place in the powder’s discharge leg, extending
downward from the center of the main distributing plate. In this lag, the fluidization is given by
the same steam or by Nitrogen, both being fed through a secondary distributing plate of conical
form at the bottom of the leg.
The fluid bed vessel is completely jacketed and steam heated to minimize the
condensation of fluidizing steam on polymer particles.
The steam with eventual Nitrogen used for fluidization leaves the dryer top through the
inertial cyclone X307, where polymer powder is separated and redischarged back to fludized
bed.
Steam operated ejector J302 connected directly to the cyclone bottom, & discharging the
polymer powder. Eventual condensate droplets, which could disturb the powder discharge J302,
are separated in knock-out drum V303 from steam entering the ejector.
Steam and eventual Nitrogen, containing hexane vapors with traces of polymer dust are
sent from the dryer top to flash hopper V403 for preliminary dedusting and hence to scrubber
C402 for final dedusting, neutralization and hexane recovery in AREA 400.

24. 17
3. FINAL FLUID BED DRYER (D304/S):
Water wet polymer discharged under level control from the previous “Steamer” D303 is
conveyed by pneumatic transport, with hot nitrogen in closed cycle, to the final fluid bed dryer
D304 where it is dried from water by hot Nitrogen in closed loop. Rotary valve X313, feeds
pneumatic transport with powder.
The cyclone X314, on the top of dryer, separates powder entrainments from the wet
nitrogen stream leaving the dryer top.
The stream is dehumidified in the scrubber C302/S, acting both as condenser and as a
guard-separator for polymer entrainments. The condensed water is recycled to the scrubber
through pump P308/S and cooler E304/S and purged to sewer by an overflow level control
provided at scrubber bottom. NaOH solution is also sent to the bottom to neutralize traces of HCl
coming from the previous steaming stage.
The dehumidified Nitrogen leaving the scrubber top is separated from liquid
entrainments, in knock-out drum V304, and allowed to divide into two streams:
1. 1st
is sucked by compressor K301 A, heated in heat exchanger E308 and delivered
back as medium of pneumatic transport between steamer & dryer.
2. 2nd
is sucked by compressor K301 B and delivered back fluidizing medium of final
dryer, after heating in heat exchanger E305.
K301/S is placed as a common reserve to both above said compressors.
At last the dried polymer powder discharged under level control from D304/S final
dryer is conveyed by X303 pneumatic transport to extrusion section in AREA 500.

25. 18
AREA 400 – Atactic polymer recovery & solvent distillation:
Fig.- 4- AREA 400
The gummy hexane coming from centrifuge (via V301 and P301/S) is preheated
in E401 by means of C401 tops, heated by HP steam in E404/S and E405/S with intermediate
flash and at last fed as vapor-liquid mixture to V402.
Hexane vapors released as V402 top product, are fed to the distillation column
C401 where hexane is separated from heavy tails.
These ones are discharged under level control by P402/S pump and recycled to
V402. The required heat is supplied to column by E402 reboiler, steam heated under flowrate
control. Rectified hexane is condensed in E403, accumulated in V401 and recycled by pump
P401/S both to the column, as a reflux under flowrate control, and to the degassers of AREA
200. From the last stream the exceeding part is diverted, under V401 level control, up to storage
on T402 after cooling in E413.
In condensing hexane within kettle type exchanger E403, most of the heat
previously supplied to gummy hexane is recovered by generating L.P. steam from condensate in

26. 19
an amount controlled by C401 top pressure/E403 level. A fraction of hexane vapors @ about
160˚C is always used as heating medium for C201 dehexaning column (under temp. control in
AREA 200) and sometimes used as regeneration medium for D401 A/B molecular sieves, at the
time when their regeneration is required. In hexane concentrated atactic polymer, obtained as
V402 bottom product, is transferred under level control by pressure difference into flash hopper
V403, where it is fuher concentrated and exhausted from the residual hexane.
In order to improve the atactic polymer quality and to face heat requirements of
flashing, a small injection of live steam and respectively a steam heated exchanger E406 are
provided, at upstream of V403. The two streams are fed under flowrate and temperature control
respectively.
Final atactic polymer at molten state is discharged by pump P403 into small
containers on a paved area below, where it is allowed to cool before displacing the containers
onto a larger free area. V403 volume can contain more than one day’s production.
The wet hexane vapors coming from D303 (steaming fluid bed dryer) are mixed
with freeing ones, inside flash hopper V403, and all together are conveyed to the following
scrubber C402.
SOLVENT NEUTRALIZATION, DRYING AND STORAGE:
In C402 scrubber, wet hexane vapors are desuperheated, dehumidified, neutralized and
scrubbed from polymer entrainments (if any).
NaOH added water is recirculated under flowrate control to the scrubber, through pump
P404/S and cooler E407 in a closed cycle. An equivalent amount to steam condensate (from
hexane vapors) is at the same time wasted from the cycle.
Dehumidified hexane vapors leaving C402 top, is mixed with C403 tops, R203 and C3
rich vents, and are conveyed to water cooled condenser E408 and after the noncondensing
fractions to brine cooled exchanger E409 through V404.hence the remaining uncondensables are
sent by K401 compressor to the flare.
Condensed fractions from E408 & E409 are collected into settling vessel V404, wherein
water and hexane separated wherefrom they both are under level control directly to waste and the
latter through pump P405 up to 1st
storage tank T401 (wet hexane).
Upstream T401 make-up hexane from the B.L. is added and the whole stream is passed
through separator V405 where further water settling may occur, water wasting in this case is
provided manually once in a while.
Dehydration completion is performed in the small dehydrating column C403, on the top
of which wet hexane from storage is fed under flowrate control through pump P406/S and
preheater E410 reutilizing condensates as heating medium. Heat balance is supplied to the
column by E411 reboiler, steam heated under flowrate control.

27. 20
Wet hexane vapors, released as C403 tops, are recycled to E408 condenser, while
dehydrated hexane liquid obtained as bottom product is discharged under level or flowrate
control and sent by pump P407/S to drying unit D401 A/B.
This small drying unit especially acting as a guard in case of any malfunctioning
upstream is made up of two molecular sieves adsorbers, D401 A and B with related equipment
for regeneration. One absorber is to be regenerated when the other is on liquid hexane to be
dried.
During regeneration, hot hexane vapors top condenser E403 are used as regeneration
medium, after superheating in E412, flowrate and temperature of the medium are automatically
controlled.
At last dry hexane in liquid phase from D401 A/B is fed to the distillation column as a 2nd
feed for final purification. Rectified dry hexane, can reach the 2nd
storage tank T402 (dry hexane
tank). From here hexane is distributed to all users by high pressure pump P408 to the continuous
users and by low pressure pump P409 to the discontinuous ones. Pump P408/S is placed as a
common reserve to both said pumps.

28. 21
AREA 500 : ADDITIVES FEEDING & EXTRUSION:
Fig.-5- AREA 500
1. ADDITIVES FEEDING:
Polymer powder from drying section D304/S final dryer is discharged to the silo T501
conveyed by Nitrogen in a closed loop, as feeding silo extruder X511 and having a volume of
300m3
. Hence the powder is continuously proportioned by means of X505 metering device, to
the continuous mixer X509 and from this to the extruder.
High melting additives are loaded by whole containerfuls into X502 discharging device
and then into slow mixer X503, where mixing is carried out. In case of very sticking additives a
certain amount of polymer powder coming from pneumatic haulage X303 can be added to the
additives within X503 to improve their flowability.
After mixing completion, homogenized mass is discharged into bridge breaker equipped
hopper T507, acting as feeding hopper X506 metering device which continuously proportions
additives mixture with polymer powder if any, to the extruder through X509 mixer.
Low melting additives are loaded by whole containerfulls into a jacketed melting tank
T502, through X504 discharging device. On completion of melting and mixing (by agitator
A501), molten mass is discharged into jacketed surge tank T503 wherefrom, through the
metering unit X508, is fed directly into extruder body.
PP pellets are loaded manually in the silo T506, acting as feeding silo of X508 metering
device which proportions and feeds them to the same continuous mixer X509.

29. 22
The various components like polypropylene powder, powdered and pelletized solid
additives etc. are thus continuously mixed and fed to the extruder X511.
EXTRUSION:
PPCP is in powder form, which is mixed with various additives and powder/additives
mixture goes to Extruder for melting, mixing and pelletizing. By mixing with additives and
pelletizing, product get stability during handling, processing and storage and its life increases. it
is a twin screw extruder and polymer is melted by electric heater. The homogeneous mixture of
molten polymer passes through die and converted into pellets by under water pelletization
system. Then pellets are dried in centrifugal dryer goes to vibrating screen, where
undersize/oversize pellets are separated out. The normal sized pellets are transported to analysis
Silo by pneumatic conveying system. Extruder outlet pellets are analyzed for MFI & ethylene
content at every 2hrs. The analyzed pellets are transferred to homogenization silo and after the
receipt of 12hrs to 16hrs pellets, pellets are homogenized & bagged into 25kg PP raffia bags.
In the extruder X511 polymer powder and additives are homogenized, gelled, extruded
and granulated by an under-water pelletizer. Downstream X511 PP pellets are conveyed to
dewatering and drying system D501 A/B 501, where water separation occurs, and then to the
screen X514.
After screening for coarse elimination (these are the pellets recycled via silo T506 to the
extruder and thus recovered), PP pellets are fed to pneumatic haulage X415 which sends them to
analysis silos in AREA 600. Demineralized water collected in T505 and cooled in E501, is
recycled by means of pump P501/S to the extruder head with the aim of cooling the produced
pellets as well as of carrying them to D501 dryer.
Suction system B502/S ensures a suitable air suction from various hoods, where Nitrogen
or dusts could be released.

30. 23
AREA 600:
PELLETS ANALYSIS, HOMOGENIZATION STORAGE &
BAGGING:
PELLETS ANALYSIS, HOMOGENIZATION & STORAGE:
X515 pneumatic haulage conveys dried pellets alternatively to three analysis silos T601,
T602, T603 each one having a volume of about 70m3
and a capacity of storing approximately
5hrs. Production at maximum flowrate. By that time, completion of any routine analysis is
allowed through silos turnover.
Silo T604 receives off-grade pellets produced during start-up and possible off-grade
pellets from analysis of silos.
On-grade pellets are sent by X601 pneumatic haulage to 5 homogenizing and storage
silos, T601 A to E, each one having a volume of 210m3
.
Pellets homogenization occurs in the storage silos by means of the pneumatic haulage
X602 along with the static homogenizers X603 A to D. The last mainly consisting of tubes
outside of silos , take the product at various levels and collect it to mixing chambers, wherefrom
it is fed to the pneumatic haulage X602 that recycles the product to the same silos. X602 is also
used for conveying the homogenized pellets from storage to bagging silo T606.
BAGGING, PELLETIZING AND SHIPMENT:
Bagging machine X604 is fed by silo T606 having a volume of 30m3
.
X604 consists of an electric weighing that sends the pellets alternatively into two separate
filling devices. The bagging machine is suitable for gusseted open-mouth bags (made of either
PE or paper, to be defined) that are manually positioned to the two filling devices. As an
alternative, an automatic bags placer X605 can be applied.
Bags filled with 25kg product are then sealed by means of a suitable sealing device
(either welding X612 or sewing device X614, depending on the selected bag material) and
conveyed by X615 belt conveyer to a control system consisting of X606 metal detector and
X607 scale, mounted on the own belt conveyers.
The metal detector is meant to detect presence of any metal particles whether magnetic or
not. Any bags containing such particles are printed automatically with a mark distinguishing said
bags from off-weight ones.
The scale X607 is meant continuously to measure the bags weight. Weight control is
performed by setting the scale to two values, corresponding to plus & minus tolerance admitted

31. 24
in respect of theoretical 25kg weight of bags, on weigh bags are counted by a counter, the scale
is provided with.
Belt conveyer X609 conveys the bags to X610 completely automatically pelletizing unit,
having a capacity of 15 pallets/hr, each pallet being made up of 40 bags distributed on 8 layers of
5 bags each.
Pallets are then sent to X613 roller conveyer, having capacity of 3 pallets and acting as a
short facility.
At last the pallets are removed by operators from X613 onto fork lifts X611 A/B and
transferred to finished products warehouse.

32. 25
CH - 6 - GENERAL SAFETY
Safety is essentially meant for protecting human life and property. Elimination of unsafe
condition in all the operating area and prevention of unsafe practices are given prime
importance by the top management.
Goals in respect of safety, health and environment (S.H.E.) are:
To prevent injuries and personnel illness.
To maintain work place and surrounding area safe and healthy.
To eliminate any foreseeable occupational and environmental hazard that may result
in fire and damage to property.
To ensure that the ministry of labor, health, safety and welfare regulation are fully
met with.
6.1. General safety awareness:
Smoking and consumption of tobacco is strictly prohibited.
Do not run or jump on ladder.
Wash hands and rinse mouth properly before eating. Take bath before going home.
Do not eat anywhere in the plant except in canteen.
All employees should wear helmet and shoes in the plant.
Do not spill any oily substance on the floor.
Use safety belts while working on high altitudes.
Do not repair any machine/equipment when it is in operating condition.
Use flameproof lamp near Ammonia and methanol.
6.2. Use of PPE (Personal Protective Equipment):
There are two types of PPE. They are:

33. 26
 Respiratory PPEs
o Breathing Apparatus (B.A.) set: Used while handling gas leakages.
o Canister Mask (Organic/ Inorganic / Acids / Ammonia): Used while cleaning vessels
or reactors internally.
o Air Supply Mask: Used while internal cleaning of vessels.
o Dust Mask: Protection against dust.
 Non-Respiratory PPEs
o Helmet : Protection of head.
o Ear Plug/ Ear Muff : Protection against noise.
o Face Seal : Protection of face.
o Safety Goggles : Protection of eyes.
o PVC Suit : Protection of body and clothes.
o Hand Gloves : Protection of hands.
o Apron : Protection of clothes.
o Safety Shoes/ Gum Boot : Protection of legs.
o Safety Belts : Used while working on height.
6.3. Fire Engineering and Control:
1. Requirements for fire :
 Heat
 Fuel
 Air/ Oxygen
2. Types of fire
There are five types of fire. They are as follows:
‘A’: The cause for this fire is organic combustible solids like paper, plastics, wood,
grass, clothes, etc... The best remedy for this type of fire is cooling by water.
'B': The cause for this fire is flammable liquids or solids which can be liquefied like oil
petrol, paint, etc... The best remedy for this type of fire is blanketing.
'C': The cause for this fire is combustible compressed gases like L.P.G., ammonia. This
type of fire can be extinguished using D.C.P.

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'D': This includes fire due to metals like aluminum, zinc, potassium, sodium, and
magnesium. The best remedy for this type of fire is D.C.P.
'E': This includes the fire due to electrical appliances. This fire can be extinguished
using CO2 etc.
6.3.1. Types of fire extinguishers
a) D.C.P. type
b) CO2
c) Foam
i. Mechanical foam
ii. Chemical foam
d) Soda ash
e) Halon type
The temperature of the flame is at least 450°C. While controlling fire, the fire at lower levels
should be first extinguished.
6.4 Gas Leakage
 Wind direction is observed by seeing wind direction indicator. It is advised to go into the
transverse (90°) or opposite direction and reach the safe assembly point.
 Only trained and persons equipped with B.A. set should go to the place of emergency.
 Make way for the rescue team or first aid team or emergency vehicle.
 If a person inhales gas take him to open place. Loose his clothes. Remove shoe and
helmet. If he becomes unconscious, send him immediately to hospital.
10.5 Chemical Spillage
If there is contact with face or eyes immediately wash below safety shower for at least 15
minutes.
If chemical goes in mouth rinse properly with water.
Contact the safety department for treatment.
10.6 Emergency Preparedness
Water should be readily available at every point by means of fire hydrant line.

35. 28
Fire extinguishers should be easily accessible in every plant.
There should be wind direction indicator and siren.
10.7 Safety Work Permit System
Work permits are given to maintenance workers. There are four types of work permits.
They are as follows: -
Hot Work Permit
Required for welding of reactors or vessels.
Cold Work Permit
Height Work Permit
Given for working on height.
Vessel Work Permit
Given for working inside vessel/reactor.
10.8 Accident Occurrence Reporting System:
In case of fire a siren is blown twice at an interval of 15 seconds.
In case of gas leakage a siren is blown continuously four times for 15 seconds
duration.
When situation comes under control a siren is blown for 1 minute.
10.9 First Aid:
Following are the objectives of first aid:
To keep the person alive.
To improve his condition.
To prevent deterioration in his condition.

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10.9.1 First aid for some common accidents is as follows:
Burn
Pour cold water on the bum portion. Do not apply any ointment.
Shock
Remove the person from the place of danger. If respiration is stopped give C.P.R.
Injury or Cut
Stop the blood flow. Clean the cut with sterilized cloth. Wash the wound with water. Apply
bandage.
Suffocation
Remove the person from the place of danger. Inspect and clean his respiratory tract if
necessary. If respiration is stopped give C.P.R.
Eye Injury
If there is foreign bodies in the eye try to remove it. If the eye infected with chemical, wash
it with water for 15 mill11tes. Do not apply ointment or oil. If the eye is burnt use
sterilized bandage after washing with water.
Poisoning
Remove the person from the place of danger. Make the person to lie down. Remove
the infected clothes and wash the infected skin with water.
Fracture
Tie splints on the upper and lower part of the fractured body part. Take the person to the
hospital on a hard frame. In case of neck fracture summon the doctor on the place of
incidence.
10.8 Process Safety
Inspection, Testing and Maintenance of Process Equipment and Accessories.

37. 30
Important industrial maintenance includes mechanical, electrical and civil maintenances.
If the production is properly scheduled but there is improper maintenance of the machine,
it may lead to delay in deliveries and production loss.
Maintenance of the machine means efforts directed towards the upkeep and repair of the
machine.
Inspection, testing and maintenance of process equipment are generally done when it is not
in operation.
Maintenance helps in improving the productivity and keeping the machines in a state of
maximum efficient with economy.
Inspection and testing are essential function of the preventive maintenance program
External inspection means to watch for defects from abnormal sound, vibration, heat,
smoke, etc. when the machine is in operation.
Internal inspection means inspection of internal parts such as gear bushes, bearings
tolerances, lathe parts, etc. during the period when the machine is under planned shut down.
Two maintenance activities are carried out
i. Activities that directly contribute to prolonging life of the machine.
ii. Activities that are carried out to assess the performance of various
components at any particular point of time.
Preventive Maintenance
a) Weekly confirmed activities :
b) Tentative inspection, testing and maintenance plan

38. 31
c) Activity recording control
d) Exception reports
 Management may know the status of various maintenance activities by using "Query
System", where the system answers specific queries of the user.
 Files handled
a) Preventive maintenance master file
b) Spare master file
10.6. Runaway reaction (Thermal explosion):
It's the consequence of the loss of control of the temperature of a chemical compound or a reaction
mixture in an enclosure.
Consequence of a runaway reaction: -
 It results in the emission of a two-phase mixture of gas and liquid to the atmosphere giving
an aerosol.
 In open air aerosol can ignite due to oxidation of hot gases and droplets with air or possibly
to the Occurrence of electric sparks.
 The emission of reaction mixture in a housing area can cause serious problems.
Causes of Runaway Reaction:-
 Any deviation from process condition.
 Lack of experimental information necessary for risk assessment, choice of safe choices.
 Lack of consequences of runaway reactions

39. 32
CH -11- PLANT LAYOUT & LOCATION
Fig-9- Plant Layout
Plant Location: at VADODARA, GUJARAT (12 kms away from Vadodara railway station)
The location of the plant can have a crucial effect on the profitability of a project suitable
site, and only a brief review of the principal factors will be given in this section.
The principal factors to be considered are:
 Vadodara location is benifitial, with respect to the marketing area.
 Transport facilities is provide for employees.
 Easily availability of utilities like water, power, etc.
 Availability of large suitable land.
 Provision for environmental impact and effluent disposal.
 Local community considerations.
 Climate.
 Political strategic consideration.
MARKETING AREA: For materials that are produced in bulk quantities, such as beads of
polypropylene copolymer, even though for LDPE, LAB, where the cost of the product per ton is

40. 33
relatively low and the cost of transport a significant fraction of the sales price, the plant should be
located close to the primary market. This consideration will be less important for low volume
production, high-priced products; such as pharmaceuticals. In an international market, these may
be an advantage to be gained by locating the plant within an area with preferential tariff.
RAW MATERIAL: Raw Material Propylene comes from FPU (GOP-NCP)
The availability and price of suitable raw materials will often determine the site location. Plants
producing bulk chemicals are best located close to the source of the major raw material; where
there is also to the marketing area.
TRANSPORT: The transport of materials and products to and from plant will be an overriding
consideration in site selection. RIL, VADODARA a site should be selected that is close to major
forms of transport road, rail and airport. Road transport is being increasingly used and is suitable
for distribution from a central ware house. Rail transport will be cheaper for the long-distance
transport of bulk chemicals.
Air transport is convenient and efficient for the movement of personal and essential equipment
and supplies and the proximity of the site to a major airport should be considered.
AVAILABILITY OF LABOUR: RIL provides bus facility and residential township for
employees, qualified engineers and experts who are easily obtained from Vadodara city. Skilled
tradesmen will be needed for plant maintenance.
UTILITIES (SERVICES) : The word ‘utilities’ is now generally used for the essential services
needed in the operation of any production process. These services will normally be supplied from
a central facility and will included.
ELECTRICITY: Power required for electrochemical processes, motors, lightings and general
use. GTTP (gas turbine thermal power plant) is in the complex for generating electricity.
STEAM FOR PROCESS HEATING: The steams required for the process area generated in the
tube boilers towers are generally used to provide the cooling water required on site.
WATER FOR GENERAL USE: The water required for the general purpose will be taken from
local MAHISAGAR River.

41. 34
DEMINERALIZED WATER: Demineralized water from which all the minerals have been
removed by ion-exchange is used where pure water is needed for the process use, in boiler feed
water. DM water plant is there in complex.
REFRIGERATION: Refrigeration is done by the brine and cooling water circulation.
EFFLUENT DISPOSAL FACILITIES: Facilities must be provided for the effective disposal of
the effluent without any public distance.
ENVIRONMENTAL IMPACT, AND EFFLUENT DISPOSAL: All industrial process
produce waste products and full consideration must be given to the difficulties and coat of their
disposal. The disposal of toxic and harmful effluents will be covered by local regulation, and the
appropriate authorities must be consulted during the initial site survey to determine the standards
that must be met.
LOCAL COMMUNITY CONSIDERATIONS: The proposed plant must fit in with and be
acceptable to the local community full consideration must be given to the safe location of the plant
so that it does not impose a significant additional risk to the community.
Sufficient available for the proposed plant and future expansion. The land is ideally flat,
well drained and have load-bearing characteristics
CLIMATE: Adverse climate conditions at site will increase costs. Abnormally low temperature
will required the provision of additional insulation and special heating for equipment and piping.
Stronger locations will be needed at locations subject to high wind loads or earthquakes.
POLITICAL AND STRATEGIC CONSIDERATIONS:
Capital grants, tax concessions and other inducements are often given by governments to direct
new investment to preferred locations; such as area of high unemployment. The availability of
such grants can be the overriding consideration in site selection.

42. 35
CH-12-Utilities:
 High press. Steam
 Medium press. Steam
 Low press. Steam
 Reduced press. Steam
 Electricity
 Cooling water
 Plant air, instrument air
 Nitrogen
 Brine

43. 36