POLYETHYLENE PRODUCTION TECHNOLOGIES

1 POLYETHYLENE PRODUCTION TECHNOLOGIESPOLYETHYLENE PRODUCTIONTECHNOLOGIES POLYETHYLENE PRODUCTION TECHNOLOGIESROUTES TO POLYETHYLENEPOLYETHYLENE PRODUCTION TECHNOLOGIESB yproducts(LPG or C4 s)EthyleneNatural GasEthylenePartialOxidationAcetyleneButa dieneButaneCondensateEthane/PropaneMetha nePropylenePolymerizationPolyethyleneSte am crackingPropyleneButadieneExtraction & DehydrogenationSteamCrackingNatural Gas Separation1. From Natural GasPOLYETHYLENE PRODUCTION TECHNOLOGIESC4 s forProduction of LPGFuel GasPropyleneButadieneGasolineFuel OilEthylenePolymerizationPolyethyleneSte amCrackingExtraction & DehydrogenationButaneNaphtha2.

2 From NaphthaPOLYETHYLENE PRODUCTION TECHNOLOGIES Routes to PE New Trends1. MTO ( Methanol to Olefins)2. Bio Petrochemicals (Ethanol Dehydration) POLYETHYLENE PRODUCTION TECHNOLOGIESPOLYETHYLENE POLYMERIZATION REACTION & TECHNIQUES POLYETHYLENE PRODUCTION TECHNOLOGIES PE Polymerization ReactionsA reaction in which polymer chain is formed bycombining large number of small molecules called Monomers . Polymerization Polymerization reaction steps:1. InitiationThe trick to get the reaction started is to use a catalyst,initiator or PRODUCTION TECHNOLOGIES2.

3 Propagation/GrowthThe new radical formed in the first step reacts withanother monomer molecule to give a new largerradical. This chain growth continue until propagationis terminated PE Polymerization Reactions (cont d)3. TerminationMechanism to stop the propagation- Dis-propagation- Recombination- Chain transferPOLYETHYLENE PRODUCTION TECHNOLOGIES PE Polymerization TechniquesThe route to PE falls into two categories:1. High pressure polymerization Produces LDPE Operating pressure ranging from 1000 to 3000 barg Operating temperature from 80 to 300 C Autoclave or tubular reactor Free radical catalysts using initiators (peroxides) Ethylene compression to the reaction pressure throughseveral compression stages with inter stage cooling is amajor PRODUCTION TECHNOLOGIES PE Polymerization Techniques (cont d)2.

4 Low pressure polymerization Produces LLDPE and HDPE Utilizes co-monomer (Butene-1, Hexene-1 or Octene-1) Operating pressure ranging from 10 to 80 barg Operating temperature from 70 to 300 C 3 types of Catalyst can be used Ziegler/Natta Cr/Mo oxide MetallocenePOLYETHYLENE PRODUCTION TECHNOLOGIES PE Polymerization Techniques (cont d)There are THREE different processes developed for lowpressure PE Process Bothcatalystandresultingpolymer remain dissolved in asolvent that must be removed toisolate the polymer.

5 Polymerizationreactiontakesplace in a CSTR (ContinuousStirred Tank Reactor).CatalystEthyleneSolventPolymer2 . Low pressure polymerization (cont d) POLYETHYLENE PRODUCTION TECHNOLOGIES PE Polymerization Techniques (cont d)II. Slurry Process Catalyst and polymer formed during productionremains suspended in a liquid medium but neverdissolving. Polymerization reaction takes place in CSTR ortubular Low pressure polymerization (cont d) POLYETHYLENE PRODUCTION TECHNOLOGIES PE Polymerization Techniques (cont d)III.

6 Gas Phase Process No solvent is used. Ethylene monomer and supportedcatalyst are blown into the reactor. Polymerization reaction takes place influidized bed Low pressure polymerization (cont d) POLYETHYLENE PRODUCTION TECHNOLOGIESR egional differences/similarities in the type of process utilized to produce linear POLYETHYLENE PE Polymerization Techniques (cont d) POLYETHYLENE PRODUCTION TECHNOLOGIESPE POLYMERIZATION TYPICAL PROCESS SCHEMEPOLYETHYLENE PRODUCTION TECHNOLOGIESPOLYETHYLENE PRODUCTION TECHNOLOGIESCo-monomerPurificationEthyle ne Purification & CompressionEthyleneH2 HydrogenPurification(If Applicable)Catalyst(s)PreparationSection PolymerizationRecycle gas recovery & coolingRecycle gas compressorDegassingGas recycle & RecoveryPolymer withdrawal & conditioning (drying)

7 ExtrusionAdditivesPelletizingStorage silos, bagging and palletizingProductSolvent Recover(if applicable) POLYETHYLENE PRODUCTION TECHNOLOGIESPOLYETHYLENE, GRADES AND PROPERTIESPOLYETHYLENE PRODUCTION TECHNOLOGIES PE is athermoplasticpolymer, which can bemelted to a liquid and remolded as it returns to asolid state. PE is chemically synthesized from moleculesthat contain long chains ofethylenemonomer. PE is the most widely used plastic with worldwide annual PRODUCTION of approximately 150million metric tons (2013).

8 POLYETHYLENE PRODUCTION TECHNOLOGIES Most Important PE Grades PropertiesHDPELLDPELDPED ensity, gm/cm , %80 905550 65 Melting Temp. C130125115 Yield Strength, MPa20 408 454 16 Melt index range (g/10 min) 100 150 POLYETHYLENE PRODUCTION TECHNOLOGIES Most Important PE Grades Properties (cont d)Melt indexPOLYETHYLENE PRODUCTION TECHNOLOGIES BIMODAL HDPE There is two types of HDPE with respect to molecularweight distribution1. Low Molecular Weight (LMW)2. High Molecular Weight (HMW)Both are calledUNIMODALHDPE which relates topossessing a unique mode per reactor.

9 BIMODALis the combination between LMW andHMW in one reactor. Why BIMODAL HDPE ?Light weight containers while maintaining good PRODUCTION TECHNOLOGIES UNIMODAL HDPEPOLYETHYLENE PRODUCTION TECHNOLOGIES BIMODAL HDPE (cont d) POLYETHYLENE PRODUCTION TECHNOLOGIESPOLYETHYLENE END USER TECHNIQUESPOLYETHYLENE PRODUCTION TECHNOLOGIES End User Processing TechniquesExtrusionPOLYETHYLENE PRODUCTION TECHNOLOGIESS heet ExtrusionThermoforming End User Processing Techniques (cont d) POLYETHYLENE PRODUCTION TECHNOLOGIESB lown Film End User Processing Techniques (cont d)

10 POLYETHYLENE PRODUCTION TECHNOLOGIESBlow Molding End User Processing Techniques (cont d) POLYETHYLENE PRODUCTION TECHNOLOGIESPOLYETHYLENE APPLICATIONSPOLYETHYLENE PRODUCTION TECHNOLOGIES LLDPE Heavy duty bags Covers Buckets and containers Stretch filmsPOLYETHYLENE PRODUCTION TECHNOLOGIES HDPE Hard hats Detergent bottles Natural gas and Water distribution piping Food storage containers Bottle capsPOLYETHYLENE PRODUCTION TECHNOLOGIES LDPE Plastic bags Dispensing bottles Film warps Cables insulation General purpose containersPOLYETHYLENE PRODUCTION TECHNOLOGIESPOLYETHYLENE MARKET