Plant Capacity: 150,000 MTPY
Commissioned: February 2001
Shut Down: January 2013
Associated with the 4000,000 MTPY VCM Plant -IPP Stock #600847
This 150 kmta PVC Plant uses licensed technology from Ineos Vinyl. The process employs “closed-lid” and VCM stripping technology. The reactors are designed to remain closed in between batches and unreacted VCM is removed with a stripping column for recycle.
Engineering was by Technip and the plant started up in 2001. The last major turnaround was in September, 2012 and the plant was shut down in December, 2012.
The plant produces K57, K66-R-G-F, and K70 grades
Complete EDC/VCM plant available as well.
All field instrumentation is electronic. Redundant Micromotion flow meters are used for critical fluid measurements, even on lines up to 6” diameter.
Utility systems include instrument air compressors (3), nitrogen booster compressor, major electrical transformers (11), thermal oxidizers (2), waste water treatment facility, and fire water pumps (3).
This 150 kmta PVC Plant uses licensed technology from Ineos Vinyl. The process employs “closed-lid” and VCM stripping technology. The reactors are designed to remain closed in between batches and unreacted VCM is removed with a stripping column for recycle. Engineering was by Technip and the plant started up in 2001. The last major turnaround was in September, 2012 and the plant was shut down in December, 2012. The plant produces K57, K66-R-G-F, and K70 grades
The reaction section of the PVC plant uses four batch reactors feeding a single, continuous stripping and drying train. The reaction process is carried out by polymerizing VCM in water and producing PVC slurry. The reactor temperature ranges from 45oC to 75oC depending on produced grades. The in-situ catalysts and initiators are equipped with a fully automated dosing system.
After the VCM polymerization step is completed, the slurry is discharged into a blow-down vessel and unreacted VCM is stripped from the slurry in a stripping column. This ensures that the PVC product has less than 1 ppm VCM after final processing.
The unreacted VCM from the stripping column is further recovered in a VCM recovery unit. It is recycled and charged back into the reactor together with the fresh VCM. The inert gas along with trace amounts of VCM are sent to the incinerator. The waste water is treated in the waste water stripper and the waste water treatment ponds before being discharged.The slurry is then sent to two centrifuges where the polymer slurry is dewatered to produce a wet cake where the water content is reduced to between 15% and 30% depending on grades. The two centrifuges are Tomoe model TRH074 Super-D-Canter (P-V13600). They have 150 kW Toshiba drive motors turning the input side of the Nico hydraulic couplings at 1480 rpm with a final output speed of 2260 rpm. The centrifuge measurements are 4.4 meters long by 3.9 meters wide by 1.6 meters diameter.The wet cake is fed to the dryer system using two vibrating conveyors manufactured by Rhewum of Germany. The units are model RIU 1000 x 4500 which measure 1.7 meters by 2.0 meters by 4.5 meters long. They are rated for 14,500 kg/hr each with bulk densities ranging from 460 – 600 kg/m3. Each unit is driven by four 2.0 kW electric motors.The wet cake is fed into a fluidized bed drier where the moisture content is further reduced to less than 0.2% water. The fluid bed dryer system was designed and constructed by VA Tech Wabag GmbH in Austria. It is designed to continuously dry 22 mt/hr of S-PVC (bulk density of 460 – 560 kg/m3 and specific heat of 1.4 kJ/kg-oK) at 45oC from an initial moisture content of 28% to a final content of 0.2% water. The total designed water evaporation rate is 7,700 kg/hr with the final PVC product temperature of 60oC. Heat is provided to the fluid bed dryer by hot water flowing through internal heat exchangers. Ambient air is filtered and blown through the system with two-stage drying air blowers manufactured by Piller of Germany. The blower capacity is 103,400 m3/hr with a 110 kW drive motor. Post drying, dust in the air is collected in a high-efficiency cyclone, passed through rotary air-locks, and into the final PVC product stream. The total air flow exiting the system is 92,360 m3/hr. The hot water is heated in a “low-pressure boiler” rated for 6.0 bar at 100oC. The maximum heating capacity is 7,700 kW with 170 m2 of heating surface area. The boiler can use heating oil or natural gas for heating. The total hot water flow is 570 m3/hr, heated with 6,500 kW of natural gas.The polymer product is sized using Rotex series DX2000 vibrating screeners to remove the oversized polymers and then sent to the silos via a series of pneumatic conveying systems. The specific Rotex model number of the screeners is 342DA-S6SL. There is a color additive system included which was used for adding the blue tint to some PVC pipe products. This Mitsui system includes semi-automatic debagging systems, mixing tanks with heavy-duty agitators, and injection pumps.The polymer is then bagged in one metric ton super-sacks or 25 kg bags using Taro Packaging systems. The product can also be shipped in bulk.
Specification Sheets, Maintenance Records and Photographs of all equipment are available upon request.
Utilities & Miscellaneous Systems
Instrument Air:Three electrical power driven instrument air compressors (Ingersoll Rand Centac) having a capacity of 1,500 NM3/hr. Air dryer included.
Nitrogen:One electrical power driven nitrogen booster compressor (Ingersoll Rand) having a capacity of 200 NM3/hr.
Electrical:Incoming electricity is 33kV, stepped down to 11kV using two transformers. The 11 kV is further stepped down to 3.3kV using two transformers, 415v using seven transformers. All transformers are by ABB. The other electrical equipment are by TAMCO and ABB.
Thermal Oxidizers:Two fuel gas fired thermal oxidizers with a capacity of 16.5MM KJ. System includes a caustic scrubber.
Fire Water:One electric and two diesel engine-driven fire water pumps.
Instrumentation:All field instrumentation is electronic. Redundant Micromotion flow meters are used for critical fluid measurements, even on lines up to 6” diameter.
The raw material and utility consumptions to produce one metric ton (mt) of PVC are shown in the table below:
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