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Plant Types: Petrochemical
Subtypes: Butadiene Plant, High Density Polyethylene (HDPE), Linear Low Density Polyethylene (LLDPE), Polypropylene (PP), Butane Toluene Xylene (BTX), Aromatics
Capacity: 1mm+ tons per year
Raw Materials: Ethylene, Propylene, Butane, Pygas
Fully Integrated Petrochemical Complex
This facility is a fully integrated petrochemical complex centered on a large naphtha cracker and aromatics unit, with downstream polymer plants. It converts naphtha into light olefins and aromatics, which are further processed into high-volume plastics.
Naphtha Cracker & Aromatics:
Downstream Polymer Plants:
Polypropylene (PP): 300,000 t/yr
Linear Low-Density Polyethylene (LLDPE): 160,000 t/yr
High-Density Polyethylene (HDPE): 160,000 t/yr
New PE Plant: 250,000 t/yr (Started operations around July/Aug 2024, shutting by end of Feb 2025)
Total PE Capacity: 570,000 t/yr
The site integrates its olefins into 570 kt of polyethylene and 300 kt of polypropylene, making it a strong net consumer of its own ethylene and propylene production.
Plant Types: Chemical and Specialty Chemical, Petrochemical
Subtypes: Formaldehyde Plant
Capacity: 105mm lbs/yr at 40%-45% (capable of 37-51%)
Raw Materials: Methanol, Oxygen
Formaldehyde Plant (Reichhold Design using metal oxide catalyst).
Available for operation in-place (Allentown, PA USA) or relocation globally.
Process Description:
The Formaldehyde plant (P501) is designed to produce formaldehyde by the catalytic conversion of methanol and oxygen controlled recycle gas. Formaldehyde is produced by the direct oxidation of methanol from the Methanol Storage Tank and Piping (P502). Emissions from the methanol storage tank and piping, during truck unloading, are captured by the Methanol Vapor Recovery System (C502). Emissions not captured by the vapor recovery system are fugitive emissions (Z550). The catalytic conversion reaction is carried out with the aid of a catalyst, which consists of molybdenum and iron oxides. The process gas is passed through the catalyst, contained in a multiple tube unit called the converter. It both heats the air-methanol mixture to the reaction temperature in the upper part of the catalyst tube and removes the heat of the reaction in the lower part. The formalin gases, which leave the converter, are cooled in an after-cooler where low-pressure steam is produced. The cooled gases enter an absorber where the formaldehyde is absorbed into water to produce up to a 53.0% Formaldehyde solution. In order to reach desired production rates, it is necessary to operate the plant under recycle conditions. Part of the gas mixture leaving the absorber stack is returned to a recycle tank where it is mixed with fresh air, at a controlled rate, to maintain oxygen content of 10 — 10.5% by volume. The remaining unused gas mixture goes to the Natural Gas fired (FML541) Catalytic Oxidizer (C501) where it is preheated and oxidized, in the presence of a catalyst, to harmless byproducts. These byproducts are released to the atmosphere through the Formaldehyde Incinerator Stack (5501).
Notes: Shut down in 2024. Documentation is incomplete.
Plant Types: Petrochemical
Subtypes: Toluene
Capacity: separate and purify up to 18 mt/hr of toluene
This all stainless steel, dual-column distillation system was designed by Sabic to separate and purify up to 18 mt/hr of toluene from a complex mixture including isomers, Bisphenol-A, and water. The system consists of a feed tank, vaporizer, pre-flash vessel, upper column, lower column, two column reboilers, and two overhead condensers with vacuum jets.
Subsystem from Complete Bisphenol A (BPA) Plant, IPP Stock #600363
Plant Types: Petrochemical
Subtypes: Methanol Plant
Capacity: 275 TPD (82,500 TPY)
Raw Materials: Natural Gas, Carbon DiOxide (CO2)
The natural gas feedstock is first preheated and de‐sulphurized (382°C/25bar), absorption is carried out over Zinc oxide granules, and then reacted with steam to produce a reformed gas/steam mixture at 860°C temperature and 21 bar pressure.
The reforming reaction is basically the reaction between a hydrocarbon and steam to produce carbon monoxide and hydrogen. In the presence of excess steam these basic products are modified to produce quantities of carbon dioxide and methane, giving a reformed gas consisting of methane, carbon dioxide, carbon monoxide and hydrogen.
The reformed gas/steam mixture is then cooled, separated from process condensate and passed into the make‐up gas compressor where the gas is compressed (36°C /17bar) to a high pressure (113°C/49bar) to be injected into the methanol synthesis loop.
With Carbon Dioxide Additions, the external supply of carbon dioxide is mixed with the high pressure gases from the make‐up gas compressor before injection into the synthesis loop.
Synthesis gases are circulated at high flow rates through a methanol synthesis catalyst held at moderate temperatures (135°C/52bar) where hydrogen reacts with carbon monoxide and carbon dioxide to produce gaseous methanol.
Cooling of the circulated gas condenses crude liquid methanol which is bled from the system and sent to crude storage. The remaining gases are then replenished with make‐up gas before entering the synthesis gas circulator to pass round the loop again.
Inert gases (methane) present in the reformed gas accumulate in the loop and are bled from the system to be burnt as fuel.
The crude methanol contains small concentrations of other organic chemicals synthesized in the methanol converter.
The crude product is then taken from storage, fractionated in two distillation columns and the pure methanol passed to purified product storage tanks.