Documente Academic
Documente Profesional
Documente Cultură
Overview on Polypropylene
Production and specification
Content
Polypropylene fundamentals
Polypropylene properties
Polypropylene technologies
Polypropylene process
Additives used in Polypropylene
Polypropylene application
Polypropylene producers
Polypropylene market
2
Polypropylene
fundamentals
3
Polymer - ?
What is PP ?
Polypropylene Development
Prof Giulio Natta and Prof Karl Ziegler synthesized
polypropylene in 1954.
Tacticity
Atactic
Polypropylene
Properties
8
Types of Polypropylene
PP
PP
Homopolymer
(PPHP)
PP Impact
Copolymer
(PPICP)
PP Random
Copolymer
(PPRCP)
C3-(C3-C3-C3)n-C3
High Stiffness
High Service Temp.
C3-(C3-C3-C2-C3-C3-C3-C2-C3)nC3
C3-(C3-C3-C3)n-C3
+
C3-(C3-C3-C2-C2-C3-C3-C3-C2-C2-C2-C3-C2-C3)n-C3
Properties of Polypropylene
Homopolymer PP
High stiffness
High crystallinity
High melting point
Low impact strength
Random Copolymer
High clarity
Low melting point
Reduced crystallinity
Reduced stiffness
Better impact
Enhanced clarity
11
Comparative Properties of PP
Optical properties
Melting point
HP
Impact strength
Modulus
HP
12
13
Molecular Weight
Crystallinilty
Polypropylene
Technologies
18
PP Polymerization Processes
- Bulk Processes
Spheripol
19
20
21
Reactor
1
Reactor Feed
Catalyst
Cocatalyst
Compressor
Cooler
Cooler
Reactor 2
Reactor Feed
Product
Discharge
System
Product
Discharge
System
Homopolymer Random
Copolymer
Impact Copolymer
22
23
24
25
Polypropylene
Process
26
27
Plant Areas
The different areas of PP plant area
PP Line 1
PP line 2
Common Area
28
1100
Catalyst Preparation
1200
1300
1500
1600
1800
1900
29
1100
Donor Metering
2100
1600
1700
Monomer Purification
30
Bagging /warehouse
Homogenization
Extrusion
Common Area
Battery
Limit
Main Substation
31
Mineral Oil
storage
TEAL SYSTEM
Extrusion Building
Loop Reactors
Recovery/Steaming
& Drying
32
Area 1100/2100
Catalyst, Co-catalyst & Donor
storage and metering
33
Natta
catalyst-
Titanium
34
catalyst
Catalyst:
Ticl4 catalyst supported on MgCl2 base.
A crystalline solid having a controlled particle size, is
dispersed in a mixture of mineral oil and grease.
The oil/grease mixture ratio is 70/30 by weight, and is
mixed with catalyst.
Catalyst concentration ranges from 200 to 260 grams of
catalyst per liter of mixture.
35
36
Catalyst technology :
TiCl4 ,Mgcl2 ( Carrier ) and internal Donor.
Polymer morphology and PSD are highly dependant on size and
structure of the catalyst.
Stereo regularity is controlled by internal donor.
37
38
Donor:
39
44
45
Area 1200/2200
Pre-contacting, Pre-polymerization
&
Bulk Polymerization
46
Catalyst
TEAL
Donor
Precontacting
pot
Propylene
Hydrogen
2nd loop
reactor
48
Pre-contacting:
Pre-contacting pot is a constantly stirred vessel of about 3 litres
volume & coupled with magnetic agitator.
Chilled water is circulated in the jacket to maintain a constant
temperature of about 10C.
The Catalyst paste, Donor, and TEAL are fed to pre-contacting pot.
Here the Catalyst activation takes place.
The overflow feeds the pre-polymerization reactor R2200.
49
Pre-polymerization:
Catalyst mixture leaving the precontacting pot is injected into a stream of cold
propylene, which feeds the pre-polymerizer reactor (R 2200); capacity- 1.1 m3
The slurry is fed to a pre-polymerizer reactor (R 2200) where reaction takes
place at low kinetics.
A small amount of propylene is polymerized under controlled conditions of
temperature (20C), pressure (34-35 bar) and residence time in the prepolymer
reactor.
Temperature control is by controlling chilled water temp in the prepolmer
reactor jacket.
Contd..
50
Bulk Polymerization:
The main polymerization reaction for homopolymer, random copolymer and
terpolymer (future) production takes place in two loop reactors in series.
The polymerization conditions are the same on both reactors,
Reaction Conditions.
Reaction temperature
:
70-73 C
.
Pressure
:
34 45 barg.
.
Slurry concentration
:
50% by weight
.
Propane concentration
:
not more than 40% by weight
51
52
Bulk Polymerization:
Each loop Reactor has its own circulating pump, which continuously recirculates
the contents of the loop.
The pressure is controlled by the reactors surge drum (V2202), which is a vessel
connected to the 2nd loop reactor R 2202. Surge drum is equipped with a steam
heated propylene vaporizer (E 2203).
The slurry is transferred from R2201 to R 2202.
The slurry is discharged from R 2202 through the valve LV 2301 (installed in
the bottom) to the flash line.
53
Bulk Polymerization:
Important Process variables/ Controls
Pressure control- Indirectly by controlling the Reactor surge drum pressure,
as reactors are floating with surge drum.
Temperature control- By controlling the jacket water temperature in the loop
reactor jacket.
Density Control- Ensures the amount of reactant and product balance and
thereby controls the flowability of the slurry. Density control is with the fresh
monomer feed into the reactors.
Discharge control- Is based on the level of the reactor surge drum.
54
Area 1300/2300
Polymer Degassing & Propylene
Recovery
55
LP C3 Scrubber
Flash Drum
Polymer slurry
from reactor
Recycle gas
compressor
Recycle gas filter
56
Recycle C3 Scrubber
To steamer scrubber
C3 Feed tank
57
The slurry discharged from the second reactor is heated in the flash pipe to
vaporize the un-reacted liquid propylene.
The gas and polymer mixture is discharged into flash drum where the operating
pressure is 18kg/cm2g.
58
59
Area 2400
Gas Phase Polymerization
&
Ethylene Striper
60
JW Circulation pump
Hydrogen
Ethylene
Propylene
From recycle C3 Scrubber
62
Area 1500/2500
Polymer steaming and drying
63
Steam/ Propylene to
steamer scrubber
3.
M
Polymer In
LP STEAM
Polymer Out
64
Wet Nitrogen to
Scrubber
Wet Nitrogen
Wet Polymer
Polymer Fines to
Conveying system
Fluidised Bed of
Polymer
Hot Nitrogen
65
Area 1700/2700
66
Coalescer
21V-1701
C3 from BL
26 kg/cm2(g)
35-45 deg C
Moisture
Phosphine/
Sulphur/ Arsine
Removal Column
21C-1702
67
Propylene Purification:
68
PP line 1
PP line 2
Ethylene
from BL
50kg/cm2g
30-45 deg C
Ethylene Dryingand
Unit
CO2 removal unit
21PK 2702
69
2. Ethylene Purification:
Since ethylene pressure is 50 kg/cm2 g, ethylene doesnt need to be
compressed .
Ethylene from Battery Limit is sent to CO and O2 removal towers.
After CO removal, ethylene is sent to drying and CO2 removal unit.
70
21V
2710
Butene
Feed
Tank
Coalescer
21V-2703
C4 from BL
8 kg/cm2(g)
35-45 deg C
Moisture
PP Line 2
71
21P 2701
Butene Feed Pump
Butene Purification:
72
Line 1
Hydrogen From BL
17 kg/cm2g
hydrogen filter
21PK2705A/B
Line 2
73
Area 1800/2800
Extrusion and Additivation.
74
Extruder:
Extruder
PP Pellets
75
76
77
78
79
The first numeric digit of the grade name denotes the family of the PP
resin.
1 - Homopolymer PP
2 - Random Copolymer
3 - Impact Copolymer
4 - Super High Impact Copolymer
The second, third and fourth numeric digit indicate the MFI of the
product (MFI X 10).
The fifth alphabetical digit indicates the Application of the grade.
o M: Molding
o E: Extrusion
o Y: Fiber and filaments
o R: Raffia
o F : Film
80
The Sixth alphabetical grade indicates the additivation package for the grade.
o S : Slip and antiblock
o G : General
o N: Nucleating Agent
o U : UV stabilizer
o C : High Clarity
81
Polypropylene
Additives used
82
83
Additives
Modifier
Processing Aids
Primary Antioxidant
Property Extender
84
eg
85
86
Polypropylene
Application
87
Applications - Film
PP is used extensively in the Film applications primarily because of its
high strength
High clarity
88
high strength
Good flowability
Low density
89
high strength
Good Chemical resistance
90
91
92
Applications - Fibres
PP is used extensively in the Fibre applications primarily because PP fibres are
Light weight
Rot Proof
Resistant to Fading
93
Applications Fabrics
PP is used in both woven and non woven fabric applications
94
Applications - Packaging
PP is used extensively in the Packaging applications both
Flexible packaging- metallized PP film
Containers- Food Grade
Rigid packaging
95
96
Polypropylene
Producers
97
Polymer
Homo &
Copolymers
Technology
Unipol, Dow (2 Lines)
Capacity, KT/Year
450
Reliance,
Jamnagar
IPCL, Nagothane
IPCL, Baroda
IPCL, Baroda
Homo PP
2130
Spheripol I, Basell
Montell
Adipol, Basell
140
40
100
300
600
98
Polypropylene
Market
99
100
22.6
25
24
20
15
10
5
0
India
China
101
World
102