PROCESS FLOW DIAGRAM: POLYETHYLENE. By: Cameron Shaw Daniel Couto Daniel LeClair Leigh Bedford Nicole Rich-Portelli
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1 PROCESS FLOW DIAGRAM: POLYETHYLENE By: Cameron Shaw Daniel Couto Daniel LeClair Leigh Bedford Nicole Rich-Portelli
2 Process Overview Compressor: initial compression of ethylene feed to 1500 bar Hyper-compressor: compensates for pressure loss in recycle stream and outlet feeds to restore reactor inlet pressure to 2000 bar Reactor: Plug Flow Reactor (PFR) inside a cooling jacket T = 70C, P = 2000bar Separator: main source of pressure loss polymer solids fall to bottom and are sent to extruder unreacted ethylene recycled back to reactor
3 PROCESS OVERVIEW Major safety concerns are around the plug flow reactor: Free radical polymerization of ethylene to polyethylene is a highly exothermic reaction Converts gaseous ethylene into viscous polyethylene melt Thus many constraints must be taken for a process that aims to be effective and safe: reactor temperature (prevent unideal and dangerous temperatures) reactor pressure (prevent pressure increases and decreases in reactor) flow rate in reactor (prevent unideal flow rates)
4 HAZOP
5 HAZOP LOW TEMPERATURE
6 HAZOP HIGH TEMPERATURE
7 HAZOP LOW PRESSURE
8 HAZOP HIGH PRESSURE
9 HAZOP LOW FLOW
10 HAZOP HIGH FLOW
11 HAZOP REVERSE FLOW
12 HAZOP - FINAL
13 CHEM ENG 4N04 SDL Project - The Production of Formalin from Methanol Group B4 Matt Galachiuk Kyle Kovacs Sana Shamsher Angela Zeinstra Honorable Mention: Jervis Pereira
14 Process Overview and Principles
15 Reaction Kinetics and Principles CH₃OH + ½O2 CH₂O + H₂O CH₃OH CH₂O + H₂ ΔH RXN = -156 kj/mol ΔH RXN = 85.0 kj/mol Operating temperature: 900 to 950K - resulting selectivity? - resulting conversion? Operating pressure: atmospheric Catalyst: silver Figure: G. A. Bowmaker, G. I. N. Waterhouse, J. B. Metson. Mechanism and active sites for the partial oxidation of methanol to formaldehyde over an electrolytic silver catalyst. Applied Catalysis A: General, vol. 265, no. 1, pp , June 2004.
16 Catalyst Regeneration Frequency of replacement: every 3 years Frequency of regeneration: every 1.5 years Process to regenerate catalyst: flood with cesium salt solution - catalyst remains in reactor Volume of catalyst needed: 2 m 3 - based on mass balances and a linearly deactivating catalyst Mass of catalyst needed: kg - based on a density of kg/ m 3
17 Production Losses Two shut downs in a 3 year period (lifetime of catalyst) Shutdowns last for 1-2 weeks each 1 st shutdown: full maintenance, catalyst regeneration 2 nd shutdown: full maintenance, catalyst replacement ITEM FREQUENCY COST Lost production Twice in 3 years $ Maintenance Twice in 3 years $ Replacing catalyst Once in 3 years $ Regeneration Once in 3 years negligible TOTAL $
18 Class Activity HAZOP Analysis Guide Word Deviation Causes Consequences Existing Protection Recommendations High Level in separator is too high Low Level in separator is too low None There is no liquid in the separator
19 Class Activity HAZOP Analysis
20 Janine Ho Jannany Srichandra Claudia Chan Kushlani Wijesekera Chris Paslawski November 22, 2012
21 [Diagram provided by the Burlington Water Purification Plant]
22 Overall Scope [Simplified from P&IDs provided by the Burlington Water Purification Plant]
23 Flocculation and Sedimentation Sludge to waste treatment Polymer Recycled microsand Alum Sulfuric Acid To ozone contactor Raw water from low lift Drain Drain Drain Fresh microsand Drain [Simplified from P&IDs provided by the Burlington Water Purification Plant]
24 Ozone Contactors To Ozone Destructors Hydrogen Peroxide Sodium Bisulphite Ozone recycle Settled water (From Settling tanks) To Filter Ozone Ozone Contacting Ozone Quenching [Simplified from P&IDs provided by the Burlington Water Purification Plant]
25 Operability: Requirements: 90% of 113ML reservoir capacity Water Quality constraints set by Ministry of Environment of Ontario: Turbidity ph Fluoride ion concentration Colour Ozone Mircoorganisms: Crypto, Giarda, Choliform Bacteria
26 Turbidity [NTU] Operating Window-Turbidity Output Flow rate [ML/day]
27 Concentration of Fluoride [mg/l] Operating Window -[Fluoride] Output Flow Rate [ML/day]
28 Reliability Reliability = Probability of failure = Availability =
29 Back-Up Equipment Ozone contactors (4 total, 2 currently in use) 3 Pairs each of low and high-lift pumps (55, 75, 97 ML/day) By-pass valve for raw water Diesel-run generator in case of power outage
30 Safety and Control Operation is controlled by the SCADA (Supervisory Control and Data Acquisition) system: Centralized monitoring and control for multiple inputs and outputs. Collects field data, transfers this data to a central computer through controllers (eg. PLC), and then displays information to the operator on a screen.
31 P&ID for Settling Section Sludge to waste treatment Polymer Recycled microsand LSHH ph Turb To ozone contactor Raw water from low lift Drain Drain Sand Drain Fresh microsand Drain
32 Sludge to waste treatment ph Recycled microsand LSHH Turb To ozone contactor Raw water from low lift LAH LC Drain Drain Drain FO Fresh microsand Polymer Drain
33 Sludge to waste treatment ph Recycled microsand LSHH Turb Raw water from low lift LAH LC To ozone contactor Turb Turb C Drain Drain Drain FO Fresh microsand Polymer Drain Recycle Stream
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Concentration mg/l TDS mg/l 10, ,000 Recovery 75% Waste TDS mg/l 44,000 COD mg/l 3,500 0 BOD NTU 1,250 0 Power Used kwh/m3 2.
1326 North Trinity San Antonio, TX 78207 1 Test Report Frac/Produced Water September 2012 A test was run in 2012 using model P-6 four stages in series. The test was run at 900 LPH (approx 4 GPM, 135 BPD).