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USED APPROXIMATELY 120,000 TPY HIGH DENSITY POLYETHYLENE POLYMERISATION PRODUCTION PLANT. PLANT USES UNIVATION UNIPOL TECHNOLOGY. THE PLANT WAS ORIGINALLY DESIGNED AND BUILT ON 1986 FOR A CAPACITY OF 80,000 METRIC TON PER YEAR OF HIGH DENSITY POLYETHYLENE, “HDPE”. THE CAPACITY HAS BEEN RAISED TO 120, 000 TON PER YEAR ONLY BY OPTIMIZING THE PROCESS CONDITIONS RATHER THAN ADDING EQUIPMENT OR UPGRADING THE REACTOR. PRESENTLY PLANT IS OPERATING AT 110,000 TON PER YEAR CAPACITY IN LINE WITH THE DEMAND IN THAT AREA. THE MAJOR OPERATING AREAS OF THE PRODUCTION UNIT CONSIST OF: - FEED GAS PURIFICATION SECTION - COMPRESSION AND REACTION/ REACTOR - PURGE BINS AND VENT RECOVERY - EXTRUDER AND PACKAGING SYSTEM (THE PACKAGING SECTION WILL NOT BE AVAILABLE WITH THE PLANT). THE EXTRUDER IS PART OF THE PLANT. THE PROCESS DESCRIPTION: THE POLYMERIZATION HAPPENS IN THE REACTOR OVER A CATALYST OF ZEOLITE AT ABOUT 100 C AND 290 PSIG. THE REACTION IS IN THE GAS PHASE AND THE CATALYST INJECTION IS IN A POWDER STATE AND CONTINUOUS INJECTION. THE POLYOLEFIN MOLECULES DISCHARGE FROM THE BOTTOM OF THE REACTOR IN SOLID AND POWDER STATE. THE PROCESS TECHNOLOGY OF GAS PHASE REACTOR IS VERY CLEAN AND EASY TO CONTROL. THE PRODUCT FLOWS FROM REACTOR DOWN INTO THE PURGE-BIN , THEN TO THE STORAGE BINS WHERE AFTER ADDING ADDITIVES AND IN CASE ADDING COLOR PRODUCT FLOWS TO THE EXTRUDER AND ULTIMATELY TO BAGGING AND PACKAGING SYSTEM. THE MAJOR EQUIPMENT CONSISTS OF: 1- PURIFICATION OF ETHYLENE FEED. 2- FEED GAS BOOSTER COMPRESSOR 3- REACTOR / EGG SHAPE ON THE TOP 4- PURGE-BIN AND DRYER 5- CIRCULATING COMPRESSOR 6- RECYCLE GAS COOLER 7- ADDITIVE BINS AND MISCELLANEOUS BINS 8- EXTRUDER. 9- CONTROL SYSTEM IS FULLY COMPUTERIZED WITH DCS SYSTEM PROVIDED BY HUNTSMAN & BROWN. THE PROCESS HAS BEEN IMPROVED SIGNIFICANTLY SINCE INITIAL COMMISSIONING. THE PLANT HAS ADAPTED A DUAL CATALYST FEEDER, DUAL BIN SYSTEM AND DUAL PRODUCT DISCHARGE SYSTEM. THESE DUAL FEATURES HAVE IMPROVED THE ON STREAM TIME AND RELIABILITY OF THE PLANT. THE AVAILABILITY OF THE PLANT IS ALMOST IN THE RANGE OF 96-98%, WHICH IS A MILESTONE IN THE BENCH-MARKING THROUGH THE OLEFINS INDUSTRY. OPERATION PERFORMANCE AND UNIT CONSUMPTIONS: -FEED STOCK IS ETHYLENE AND MONOMER 1.014 TON/ TON PRODUCT -ELECTRICITY 383 KWH/ TON “ -COOLING WATER (CIRCULATION) 144 CUBIC METERS / TON PRODUCT - STEAM / 4 BAR 0.051 TON/ TON PRODUCT - CATALYST CONSUMPTION / BASED ON VALUE 2003 EU.15-20/ TON -MANNING , 20 OPERATORS, 5 FOREMEN AND ONE SUPERVISOR PRODUCT SPECIFICATION: HOMO AND CO POLYMERIC HDPE AND LLDPE POSSIBLE GRADE. PRODUCT APPLICATION: BLOW AND INJECTION MOLDINGS, FILM AND PIPE BLACK AND NEUTRAL COLOR.