Polysynaid® 8000 Raises PE Production Run Profits for Foodservice Packaging Supplier

Polysynaid 8000

Problem

A major Canadian Polyethylene manufacturer with product lines tailored to the foodservice industry had been watching costs rise on its main process run. Over time, a measured drop in production yield was accompanied by increasing amount of down time dedicated to inspecting the reactor and mitigating the effects of sheeting. Additionally, the manufacturer was experiencing inconsistent quality issues with its final product, which put its main foodservice customer relationship at risk.

Analysis

Along with the increased costs associated with reactor shut down and maintenance, the customer was also dealing with quality control issues with the finished product. The process fouling (“sheeting”) resulted in an agglomeration of polymer deposits and gels on the inner surface of the reactor. When released from the reactor surface, the gels and polymer deposits frequently contaminated the final polymer and made it difficult to produce a polymer of consistent and reproducible quality.

Solution

The customer contacted Cestoil Chemical to find out about Polysynaid® 8000, and a member of Cestoil’s Chemical Engineering staff consulted with the customer about the particulars of their PE run process and about how Polysynaid® 8000 could improve their process efficiency. After an initial consultation, the customer decided to switch antifoulants and give Polysynaid® 8000 a trial run.

Result

The customer reported an immediate improvement on its PE process run, with longer run times without having to shut down due to sheeting, loss of yield, and time spent cleaning the reactor. Additionally, the customer realized a 10% decrease in loss of active catalyst, an unexpected benefit. Most importantly, the PE manufacturer enjoyed an immediate improvement in the consistency of its final product.

About Polysynaid® 8000

Polysynaid® 8000 is used to stabilize Liquid Slurry and Gas Phase processes allowing higher polyolefin production rates and production efficiencies. In the polyolefin reactor fluid bed polymer particles are very close together and can generate static. Static charge causes particles to stick together and to reactor walls. Larger and heavier polymer particles are difficult to suspend and cool. As they become hotter, they add to process fouling. Blockages require long production shutdowns to clear the problems.

Elimination of static helps avoid fouling in the form of agglomeration of particles, fines build up on the wall, or fines accumulation on the angled top disengagement section of the reactor. Polysynaid® 8000 is currently used by a number of multinationals in polyethylene production on a global basis to prevent reactor fouling and increase yield and throughput.

When compared to other antifoulants on the market, Polysynaid® 8000 has fewer catalyst poisons, a lower concentration of H2O, and only trace amounts of benzene, toluene, and xylene. Further, as it is a processing aid (not a polymer or additive), Polysynaid® 8000 requires no indirect food contact notification or FDA approval.

About Cestoil Chemical

Toronto-based Cestoil Chemical is a global leader in specialty chemicals, including fuel additives, process additives, and advanced materials. Cestoil Chemical embraces disruptive technologies to introduce new products to our customers ahead of the industry curve and in front of established trends in the refining, petrochemical, and automotive industries. For over 20 years we’ve provided products and services that have delivered bottom line results for our clients.