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This document describes a project to produce high density polyethylene (HDPE) via solution polymerization. It was submitted by three students - Hafiz M. Waseem, Furqan Nayyar, and Khalid Hussain - to the Department of Polymer and Process Engineering at the University of Engineering and Technology in Lahore, Pakistan. The project is advised by Mr. Asif Ali Qaisar and Mr. Tariq Bashir. The document includes sections on the HDPE manufacturing process, material balance calculations, design of process equipment like the reactor, phase separator, heat exchanger, centrifuge and dryer, as well as instrumentation and control, hazard analysis, safety data, and cost

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Ali Ahsan
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39 views

Table of Contents

This document describes a project to produce high density polyethylene (HDPE) via solution polymerization. It was submitted by three students - Hafiz M. Waseem, Furqan Nayyar, and Khalid Hussain - to the Department of Polymer and Process Engineering at the University of Engineering and Technology in Lahore, Pakistan. The project is advised by Mr. Asif Ali Qaisar and Mr. Tariq Bashir. The document includes sections on the HDPE manufacturing process, material balance calculations, design of process equipment like the reactor, phase separator, heat exchanger, centrifuge and dryer, as well as instrumentation and control, hazard analysis, safety data, and cost

Uploaded by

Ali Ahsan
Copyright
© © All Rights Reserved
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
You are on page 1/ 13

Production of High Density

Polyethylene (HDPE)

Session: 2003-2006

Project Advisors
Mr. Asif Ali Qaisar
Mr. Tariq Bashir

Group members
Hafiz M.Waseem 2003-POLY-1071
Furqan Nayyar 2003-POLY-1057
Khalid Hussain 2003-POLY-1059
DEPARTMENT OF
POLYMER&PROCESS ENGINEERING
UNIVERISITY OF ENGINEERING & TECHNOLOGY
LAHORE-PAKISTAN
Production of High Density
Polyethylene (HDPE)

This project is submitted to department of Polymer $


Process Engineering, University of Engineering &
Technology
Lahore- Pakistan for the partial fulfillment of the
Requirements for the
Bachelor’s Degree
In

Polymer & Process Engineering


Internal Examiner: Sign: _______________
Name: ______________

External Examiner: Sign: _______________


Name: _______________
DEPARTMENT OF
POLYMER&PROCESS ENGINEERING
UNIVERISITY OF ENGINEERING AND TECHNOLOGY
LAHORE-PAKISTAN
All praises to Almighty Allah,
Whose uniqueness oneness &
wholeness is unchangeable. All
respects are for His Holy Prophet,
Muhammad (peace be upon him)
who enabled us to recognize our
Creator.
Dedicated To
Our loving Parents & teachers,

their unreturnable patience &

guidance to bring us to this

position.
ACKNOWLEDGEMENT

All praise to ALMIGHTY ALLAH, who provided us with the strength


to accomplish this main project. All respects are for His HOLY
PROPHET (PBUH), whose teachings are true source of knowledge &
guidance for whole mankind.
Before anybody else we thank our Parents who have always been a
source of moral support, driving force behind whatever we do. We are
indebted to our project advisors Mr. Asif Ali Qaisar and Mr. Tariq
Bashir for his worthy discussions, encouragement, technical
discussions, inspiring guidance, remarkable suggestions, keen
interest, constructive criticism & friendly discussions which enabled
us to complete this report. He spared a lot of precious time in
advising & helping us in writing this report.
We are sincerely grateful to Prof Dr.G.M Mamoor, Dr. Shaukat
Rasool & Mr. Zaka-ur-Rehman for their profound gratitude and
superb guidance in connection with the project.
We are also thankful to librarians of National Library of Engineering
Sciences, Departmental Library & PU Library for their cooperation in
search of design material.

Authors
PREFACE

Polymer Composites are the most famous material through out the
world due to their better properties as compared to metals. Polyethylene
is the most consuming Polymer through out the world. Polyethylene has
many grades and HDPE is one of them.
The use of HDPE is increasing day by day at different levels. In
Pakistan HDPE is one of the most consuming plastic materials. Now the
pipes of HDPE are going to be used in transportation of Gas which is
the one of the biggest project in Pakistan.
Keeping these points in mind we urged to work & we are feeling
great to present our work on “Production of High Density Polyethylene
(HDPE) by Solution Polymerization”. This report is divided in different
sections. First of all the introduction of HDPE is given, which highlights
its importance. Different manufacturing processes for HDPE are also
described in chapter 2. Detailed description of “Production of High
Density Polyethylene” is also presented in chapter 2. Afterwards
Material balance is presented.
In preceding chapters introduction to different equipments of
plant along with their designing procedure and specification sheets are
presented.
Instrumentation & Control, Hazop Study, Material Safety Data
Sheet and Cost Estimation for this plant are also included in this report.
Chapter # 1 Pg#1

Introduction
1.1 Introductions to PE 1
1.2 World wide usage of most common plastics 2
1.3 Grades of PE 2
1.4 History of HDPE 4
1.5 properties of HDPE 6
1.6 Commercial application of HDPE 7
Chapter # 2
Manufacturing Process
2.1 Commonly used Processes 8
2.2 Process Selection 12
2.3 Process Flow Sheet 17
2.4 Flow sheet description 18

Chapter # 3

Material Balance

3.1 Basis 19
3.2 Overall material balance 19
3.3 Material Balance against each Unit 20
Chapter # 4

Reactor Design
4.1 General 21
4.2 Classification of reactors 22
4.3 Comparison of STR and TFR 24
4.4 Reactor selection 25
4.5 Designing steps 27
4.6 Impeller Selection 31
4.7 Impeller Design 32
4.8 Mechanical Design 34
4.9 Specification Sheet 38
Chapter # 5
Phase separator
5.1 Introduction 39
5.2 Types of separation 39
5.3 types of separator 40
5.4 mechanical configuration of separator 42
5.5 Designing 46
5.6 Specification Sheet 47
Chapter # 6
Heat Exchanger
6.1 Introduction 48
6.2 Selection Guide to Heat Exchanger types 49
6.3 Shell and tube heat exchanger 51
6.4 Design calculation 52
6.5 Specification sheet 58

Chapter # 7
Centrifuge
7.1 Introduction 59
7.2 Classification of Centrifuges 60
7.3 Selection of Centrifuges 61
7.4 Solid Bowl Centrifuge 64
7.5 Designing of Solid Bowl Centrifuge 68
7.6 Specification Sheet 72

Chapter # 8
Dryer Design
8.1 Introduction 73
8.2 Selection of Dryer 73
8.3 types of dryer 74
8.4 Dryers for HDPE 75
8.5 Selection Criteria 75
8.6 Desiging 76
8.7 Specification Sheet 80
Chapter # 9
Instrumentation and Control
9.1 Basic Concept 81
9.2 Temperature Measurement and Control 83
9.3. Pressure Measurement and Control 83
9.4 Flow Measurement and Control 84
9..5 CSTR Control Configuration 84

Chapter # 10
HAZOP Study
10.1 Introduction (Hazop) 85
10.2 Steps Conducted in Hazop Study 86
10.3.3 HAZOP Study Of Cyclohexnae 89
10.4 HAZOP Study of Storage Tank for Cyclohexane 94
10.5 HAZOP Study Of Eythylene 95
10.6 HAZOP Study Of HDPE 97
Chapter # 11
Material Safety Data Sheet 98
Chapter # 12
Cost Estimation
12.1 Cost Index 104
12.2 Purchase Cost of Major Equipments 104
12.3 Fixed Capital Cost 105
12.4 Operating Cost 106
12.4 Production Cost 107

REFERENCES 108
End Page
110

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