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1、UNIPOL PP Process DescriptionUNIPOL PP工艺过程描述1Description of the Contract Plant 合同工厂描述2UNIPOL PP Process Unit UNIPOL聚丙烯工艺装置3Auxiliary Process Facilities 辅助工艺装置UNIPOL PP PROCESS DESCRIPTIONUNIPOL PP工艺过程描述1 Description of the Contract Plant 合同工厂描述The Contract Plant consists of a polypropylene process u
2、nit designed to produce 400 KTA of pelleted polypropylene from propylene based on UNIPOL PP Technology licensed by Union Carbide Chemicals & Plastics Technology LLC, a subsidiary of The Dow Chemical Company. The UNIPOL PP Process is a low-pressure gas-phase fluidized bed process for the manufacture
3、of PP resins.合同工厂包含一套基于UNIPOL PP 技术的生产40万吨/年的聚丙烯工艺装置，该技术转让自陶氏化学公司下属的联合碳化物（联碳）化学和塑料技术公司。 UNIPOL PP 工艺技术是一项用于生产聚丙烯树脂的低压气相流化床工艺。In addition to the UNIPOL PP Process, resin handling and blending facilities are also included in the Contract Plant battery limits. Other auxiliary facilities include utility
4、 distribution, flare and plant infrastructure systems. The PDP provides adequate information to allow these systems to be easily designed by the Engineering Contractor, resulting in savings to the Licensee. The product bagging area is outside the Contract Plant battery limits and will be designed by
5、 the Licensee. 在UNIPOL PP 工艺之外，树脂处理和掺混也包括在本合同工厂范围之内. 其他辅助工艺设施包括公用工程分配，火炬，工厂基础设施。工艺包提供了足够的信息使工程承包商能很容易的设计这些系统,从而使专利受让方节省投资. 产品包装区域是在合同工厂之外，由该技术买方设计。2UNIPOL PP Process Unit UNIPOL聚丙烯工艺装置The UNIPOL PP plant ISBL is comprised of the following process areas. UNIPOL聚丙烯工厂界区由下列工艺单元组成：A.Raw Material Supply a
6、nd Purification 原料供应和精制B.Propylene Purification丙烯精制C.Reaction聚合反应D.Resin Degassing树脂脱气E.Vent Recovery尾气回收F.Resin Additive Handling添加剂的加入G.Pelleting造粒Each is described in detail in the following sections. No catalyst preparation is necessary SHAC catalyst is delivered to the plant ready to use. No ga
7、s/solid separation is needed due to the unique design of the reactor and product discharge system. The process units listed above are included in the Licensors Process Design Package (PDP). 每一单元都将在下面的章节详细描述催化剂制备是不需要的，因为卖方会将直接可用的SHAC催化剂运到工厂。由于特殊的反应器和产品下料系统的设计，也无需单独的气固分离装置以上所列的工艺装置都包含在专利商的工艺设计包(PDP)中A
8、.Raw Material Supply and Purification (Part 1) 原料供应及精制（第1部分）Ethylene, nitrogen, and hydrogen are delivered to the battery limits by pipeline. Co-catalyst, T2, is received from vendor shipping containers with these shipping containers stored in the ISBL area.乙烯，氮气和氢气通过管线送至界区边界。助催化剂三乙基铝则来自储存在界区内的厂商运输过
9、来的储罐。Ethylene from Battery Limits is compressed to 635 psig in the Ethylene Compressor (K-1003) and heated to 100C in the Ethylene Preheater (E-1006) before passing through the CO Removal Vessel (C-1008). The ethylene is then cooled down to 40C in the Ethylene After-Cooler (E-1010) before being fed
10、to the Ethylene Dryer (C-1012) for removal of water, miscellaneous polar compounds and carbon dioxide. Finally, ethylene is passed through the Ethylene Filter (Y-1002) to remove particulate contamination before it is sent to the reaction area.从界区外来的乙烯先经过乙烯压缩机(K-1003)压缩至635 psig，然后通过乙烯预热器(E-1006)加热至1
11、00C，再进入脱一氧化碳床(C-1008)。然后乙烯通过乙烯后冷却器(E-1010)冷却至40C， 再通过乙烯干燥器（C-1012）以除去水、各种极性成分和二氧化碳。最后，乙烯再经乙烯过滤器（Y-1002），去掉颗粒杂质，而后才被送至反应系统。Nitrogen is received from the boundary limits and the flow is split between different end users. Nitrogen not requiring purification is passed through a Filter (Y-1101) before be
12、ing sent to the process. Purification bed regeneration nitrogen is fed directly to the N2 Regeneration Heater (E-2114) without purification or filtration. Nitrogen for both Purified and High Pressure Purified end uses is passed through the Nitrogen Dryer (C-1112) to remove water. From the Dryer outl
13、et, Nitrogen passes through the Nitrogen Filter (Y-1115) to remove particulate contamination. A portion of this filtered nitrogen is fed to a small booster Compressor (K1102) which is used to increase the pressure of the nitrogen to its normal operating pressure of about 660 psig (4,551 kPag) for fe
14、ed to the PP reaction system. High pressure nitrogen is passed through a Filter (Y1116) to remove particulate contamination prior to being fed to the process. 由界区外来的氮气分流至不同的最终用户。不需要精制的氮气，只需在送至工艺区之前通过过滤器(Y-1101)。 精制床再生氮气不需要经过精制或过滤就可直接送到氮气再生加热器(E-2114)。 需要精制的氮气和高压精制的氮气会经过氮气干燥床(C-1112)去除水。从干燥床出来的氮气经过氮气
15、过滤器（Y-1115）去除颗粒杂质。 这股过滤氮气的一部分会进入一个小的压缩机(K-1102)， 升高氮气的压力至进入聚丙烯反应系统的正常操作压力 660 psig (4,551 kPag)。 高压但其在进入工艺系统之前通过一个过滤器(Y-1116)去除颗粒杂质。 Hydrogen from the boundary limits is passed through the Methanator Heater (E-1204) which increases the Hydrogen temperature to between 100C and 150C. At that temperatu
16、re, the Hydrogen enters the Methanator (C-1205) for the removal of carbon dioxide and carbon monoxide. The catalyst contained in the Methanator converts the CO and CO2 to Methane and Water. Methane is an inert in UNIPOL Reactor. The Hydrogen leaving the Methanator is cooled in the Methanator Afterco
17、oler (E1206). From the Aftercooler, Hydrogen passes through the Hydrogen Dryer (C-1207) for the removal of both the water contained in the incoming Hydrogen and that formed through the Methanation reaction. The hydrogen then passes through the Hydrogen Filter (Y-1211) to remove particulate contamina
18、nts before it is sent to the reaction system. 来自界区的氢气通过甲烷化预热器（E-1204）将氢气温度升至100C至150C之间。 在此温度下，氢气进入甲烷转化器(C-1205)去除二氧化碳和一氧化碳。在甲烷转化起中的催化器将一氧化碳和二氧化碳转化成甲烷和水。 甲烷在UNIPOL反应器中是一种惰性气体。离开甲烷转化器的氢气在甲烷化后冷却器(E-1206)中进行冷却，然后氢气通过氢气干燥器(C-1207)去除进料氢气中所含的水和在甲烷化反应中生成的水。 脱水后的氢气然后通过氢气过滤器(Y-1211)除去颗粒杂质， 然后进入反应系统。 Liquid T
19、2 is fed under nitrogen pressure from its respective shipping containers to the liquid full T2 Feed Pot (C-1505). The feed pot has a two hour hold time and is equipped with level indication to indicate when T2 container change out is required. From the T2 feed Pot the liquid T2 flows to the Alkyl ch
20、arge pumps (G-1503/G-1504). The pumps build pressure to roughly 3.9 MPag for feeding the H/R Reactors and 3.1 MPag for feeding the Impact Reactor. All vents from the system are routed to seal pot (C-1502) equipped to trap emissions for later disposal. 液态三乙基铝在氮气压力下从其运输罐进入烷基铝进料罐（C-1505）。该进料罐有两小时的保持时间并
21、装有料位计以便了解何时容器排空。三乙基铝从进料罐进入烷基铝送料泵（G-1503/G-1504）。送料泵将压力增至3.9 MPa（表压）以进入抗冲共聚反应器，增至3.1 MPa（表压）以进入均聚和无规共聚反应器。系统中的排放物都收集在密封罐（C-1502）中，等待将来进一步处理。A mineral oil system consisting of a drum pump (G-1514) and blow tank (C-1512) is provided for flushing elements of the Alkyl system prior to maintenance. Waste
22、mineral oil/Alkyl is collected in the Seal Pot (C-1502). Periodically, the Seal Pot is drained and recharged with fresh mineral oil. The drained mineral oil/Alkyl mixture is transferred to disposal tanks for offsite disposal. 在进行维修之前，会使用一个由回转泵（G-1514）和矿物油卸料罐（C-1512）组成的矿物油系统来冲洗烷基铝系统。废矿物油/三乙基铝收集在密封罐（C
23、-1502）中，密封罐定期的排放并重新注入新鲜的矿物油。 排放的废矿物油/三乙基铝混合物将转移到处理罐送到界区外处理。B.Propylene Purification (Part 2) 丙烯精制（第2部分）Facilities are provided to purify and pump propylene to the Reactor. Trace amounts of catalyst poisons, such as water, oxygen, carbon dioxide, carbon monoxide, alcohols, and ketones are reduced to
24、acceptable levels in the Purification System. 这部分包括精制液态丙烯以及将丙烯泵入反应器的设施。微量的反应毒物例如水，氧，二氧化碳，一氧化碳，乙醇和酮等在精制系统内被减至聚合反应可以接受的水平。Liquid propylene from the battery limits feeds directly into the Propylene Degassing Column (C2008). The column is equipped with a water-cooled Condenser (E2009) and a steam-heated
25、 Reboiler (E2010). Cooling water pressure for the Condenser is boosted with the Degassing Column Condenser Water Pump (G-2007). A small stream of overhead gas, containing propylene and stripped light contaminants (O2, CO, CO2, etc.), is vented to battery limits. The bottom product passes through the
26、 Propylene Cooler (E2011). From the cooler the propylene passes through one of two Propylene Dryers (C-2016 and C-2018) for removal of any trace water and other remaining polar compounds.液态丙烯从界区边界直接进入丙烯脱气塔（C-2008）。塔上装有一台水冷的冷凝器（E-2009）和一个蒸汽加热的再沸器（E-2010）。冷凝器的冷却水靠脱气塔冷凝水泵（G-2007）泵出。一小股含有分离出的轻组分杂质（氧气、一氧
27、化碳、二氧化碳等）的塔顶馏出气体被送出界区。塔底排出物则流经丙烯冷却器（E-2011）。经过丙烯冷却器后，丙烯直接进入两台丙烯干燥床(C-2016, C-2018)中的一台去除任何残存的痕量水和其它残留的极性化合物。Following polar impurity removal, the propylene pressure is boosted by the Propylene Charge Pump (G2012). The propylene is then filtered through the Propylene Filter (Y2020) for removal of par
28、ticulate contaminants and flows forward to the Reaction System. 在脱除了丙烯中的极性杂质后，接着使用丙烯加料泵（G-2012）增加丙烯压力。丙烯然后通过丙烯过滤器（Y-2020）以去掉颗粒杂质，进入反应系统。Nitrogen from the supply header is heated by the Regeneration Heater (E2114) to the required temperature for regeneration of the purification beds in Part 1 and Par
29、t2. 从供应源头来的氮气由再生加热器(E-2114)加热至第一和第二部分的精制床再生需要的温度。 The Propylene Purification area design will include a drain line from each purification bed which will allow propylene in the purification beds to be drained back to the degassing column prior to regeneration, prior to removing a bed from service, or
30、 for other operational/maintenance reasons. The degassing column (at the outlet of the Propylene Cooler) will also have a drain line to the OSBL to also allow the draining of propylene from the column for similar operational/maintenance reasons. The Licensors standard practice for draining propylene
31、 from equipment uses high pressure nitrogen. 丙烯精制区的设计将为每个精制床安装一条排放线，这样就可以将精制床里所含的任何丙烯在再生、床层停止操作、或任何其他操作/维护活动之前送回到脱气塔。基于同样的原因，（位于丙烯冷却器输出端的）脱气塔本身也会配有一条排放线，以便把丙烯排向界区外。专利转让方的标准操要求在排放设备中的丙烯时使用高压氮气。C.Reaction (Part 4A) 聚合反应（第4A部分）The polymerization reaction takes place in a fluidized bed Reactor (C4001) a
32、t a nominal pressure of 3.38 MPag and a nominal temperature of around 67C. Catalyst and reactants are fed continuously to the Reactor, and the granular product is removed intermittently. Reactants in the vapor phase are continuously cycled from the reactor through a centrifugal Cycle Gas Compressor
33、(K4003) and water-cooled Cycle Gas Cooler (E4002) and back through the reaction bed. This cycle gas flow serves to fluidize the reaction bed for good back mixing, supply raw materials to reaction sites, and remove heat generated by the exothermic polymerization reaction.聚合反应是在流化床反应器（C-4001）内在3.38 MP
34、a （表压）的公称压力和约67C的公称温度下发生。催化剂和反应物被连续加入反应器，而产品粉料则以批次的方式被移出反应器。气相中的反应物不断地离开反应器，经过离心式循环气压缩机（K-4003）和水冷的循环气冷却器（E-4002）， 再回到反应器。这股循环气的功能包括对反应器中的固体床层进行流化以达到充分的返混、将原料带入反应器，并移走聚合反应放出的反应热。Resin properties are controlled primarily by the type of catalyst used and by cycle gas composition. The computer can main
35、tain closed loop control of the resin properties in the Reactor by making instantaneous predictions of the resin properties in the reactor and adjusting variables as necessary. Resin properties do not vary with production rate.反应器所生产的树脂的性质主要是由所使用的催化剂种类以及循环气组成来决定的。计算机可以通过即时地对在反应器中的树脂性质进行预测并在必要的情况下对反应
36、器变量做出调整来维持对树脂性质的闭环控制。树脂性质并不随产率的变化而变化。The Reactor is a skirt-supported vessel with an expanded top section for disengagement of solids from the cycle gas stream.反应器有塔裙支持，顶部有一个扩大段，用于更好地分离循环气流中的固体。The Cycle Gas Compressor is a single-stage, constant-speed, centrifugal compressor with a double dry mecha
37、nical seal. The typical outlet pressure from the cycle gas compressor is 3.48 MPag. The cycle gas circulation flow rate is controlled by either inlet guide vanes or discharge throttling on the discharge piping of the machine. The Cycle Gas Compressor maintains the optimal superficial gas velocity fo
38、r all products through the cycle gas loop. 循环气压缩机是单段、定速、离心式、使用双层干机械密封的压缩机。该压缩机的典型出口压力为3.48 MPa （表压）。循环气的循环速率是由压缩机的进口阀门或是出口管节流阀来控制的。对所有产品床层，循环气压缩机可保持最佳的表观气体速度。 The Cycle Gas Cooler is a single pass shell and tube heat exchanger. Cycle gas flows through the tubes and cooling water circulates through t
39、he shell side. A pump back water system provides reactor temperature control by recirculating hot cooling water discharged from the shell of the Cycle Gas Cooler and recycling it back to mix with the fresh incoming cooling water supply to the exchanger using the Cycle Water Pump (G4004). The Cycle G
40、as Cooler is also used as a heater for reaction start-up by injecting steam through a sparger into the cooling water inlet of the Cycle Gas Cooler.循环气冷却器是单程的管壳式换热器。循环气从管内流过，而冷却水则从壳层流过。反应器的温度由一个泵回流水系统控制，从循环气冷却器壳层出来的热水与新鲜的冷却水混合，一起通过循环水泵（G-4004）再泵入冷却器。在反应器启动开车时，循环气冷却器也可为加热器。此时将蒸汽从循环气冷却器的冷却水入口喷入。Reactor
41、 pressure is controlled by varying the propylene feed rate. The concentrations of hydrogen, ethylene, and propylene in the cycle gas are measured by an on-line cycle gas analyzer, and flows are automatically controlled as necessary to maintain the required cycle gas composition.反应器压力是通过改变丙烯进料速度来控制的。
42、循环气中氢气、乙烯和丙烯的浓度由一台在线循环气分析仪来测量，而它们的流量在必要时会自动调节，以满足所要求的循环气组成。The polymerization catalyst is received in drums as a slurry in mineral oil. A Drum Tilter (S-4046) is used on the end of a fork-truck to handle and tilt the drums. To prevent catalyst solids from settling, the drums are rolled on the Drum T
43、umbler (S4045). The drums are unloaded using the Unloading Pump (G4054) into the Slurry Feed Tank (C4040), which has an agitator (Y-4041). The catalyst is pumped from this vessel to the Reactor by the Slurry Feed Pump (G4043). The production rate is controlled by varying the amount of catalyst pumpe
44、d to the Reactor by controlling the speed of the Slurry Feed Pump. A Mineral Oil Drum Pump (G-4055) is provided to unload mineral oil from shipping drums to flush out the system. Mineral oil is stored in the Mineral Oil Storage Tank (C-4056).聚合催化剂与矿物油混合为淤浆状，成桶装运。叉车的尾部安有一个桶罐翻转装置（S-4046），帮助倾斜和搬运这些桶。为防
45、止催化剂沉淀，用滚桶器（S-4045）不停地转动这些桶。通过卸料泵（G-4054）将催化剂卸至带有搅拌器（Y-4041）的淤浆进料罐（C-4040）。催化剂再由淤浆进料泵（G-4043）打入反应器。产率的控制是通过控制淤浆进料泵的速度（进而控制进入反应器的催化剂的量）来实现的。使用一个矿物油回转泵（G-4055）将矿物油从运输用桶中卸出，用来冲洗该系统。矿物油储存在矿物油储存罐（C-4056）中。Provisions are also made for addition of donor to the cycle gas system through the Additive Feed Pot
46、s (C4060 and C-4062). Donor is unloaded from shipping drums using the Additive Drum Pump (G-4069). The donor is pumped from these vessels to either reactor by the Aditive Pumps (G-4061 and G-4063).给电子体可以通过给电子体添加罐（C-4060，C-4062）加入到循环气系统中。首先用给电子体回转泵（G-4069）把给电子体从运输桶中卸下。再将给电子体通过给体泵（G-4061，G-4063）打入各个反应
47、器。The reactor has two pairs of Product Discharge Systems, which can be operated in an alternating mode or independently. Each system consists of two Product Chambers and two Product Blow Tanks. The granular product drops sequentially from the Product Chamber (C4101, C-4105, C-4106, and C-4107) to th
48、e Product Blow Tank (C4103, C4108, C-4110, and C-4112) from which it is conveyed directly to the Product Purge Bin (C-5009), during Homopolymer/Random production, or directly to the Transfer Tank Filters (Y-4312 and Y-4322), during Impact production.反应器有两套产品卸料系统，可以交互运行，也可以独立运行。每套系统包括两个产品仓和两个产品卸料罐。产品
49、粉料依次从产品仓（C 4101，C-4105, C-4106 和C-4107）进入产品卸料罐（C-4103, C-4108, C-4110和C-4112）。从那里，产品直接被送进产品接收器 （C-5009， 当生产均聚物和无规共聚物时）或是送往输送罐过滤器（Y-4321， 当生产抗冲共聚物时）。During a process upset, the polymerization reaction can be stopped or slowed down with the kill system. The kill injects hundreds of times more CO than the required stoichiome
