I.

INTRODUCTION

A. MISSION/ VISION

MISSION:

 To sustain a steadfast commitment to highest quality products and most reliable

services.
 To endeavor as business partner of choice of its customers.
 To uphold an enduring dedication to employees development and advocate its
utmost care towards health, safety and environment.

VISION:

To be globally-recognized provider of premium quality polyethylene products and

services.

B. CORPORATE PROFILE

NPC ALLIANCE CORPORATION (NPCA)

was established in August of 2005 as a world-class
polyethylene plant in the Philippines. The Plant and
property presently occupy 187,200 square meters
within PAFC Industrial Park Barangay Batangas II
Mariveles, Bataan, Philippines.

Today NPC Alliance Corporation is a dynamic player

in the Petrochemical Industry, working hard and
providing high quality resin to meet the world’s
rapidly increasing demand.

C. TECHNICAL DESCRIPTION

NPCA produces premium quality, high-performance polyethylene resin employing the

safest and most environmentally sound polyethylene process in the world.

NPCA is composed of two identical trains, which use two types of catalyst. Each train
produces complementary products resulting in a diverse array of HDPE and LLDPE
grades.

Using the world-renowed and award- winning INEOS Innovene Gas Phase Technology,
The plant can produce 250,000 tonnes of polyethylene resins annually.
 D. PLANT FACILITIES

1. QUALITY CONTROL LABORATORY

This is where they conduct their quality assurance procedures and test samples.
This is also where they conduct experiments and research development samples.

2. MACHINES AND EQUIPMENT

Used in the production

3. RECEIVING DOCK / PORT

This is where ships carrying the imported raw materials are received.

4. PROCESS CONTROL ROOM

This is where they oversee all the processes going inside the plant while on
operation. All problems and technicalities can be seen through the control room.

III. MANUFACTURING PROCESS

A. RAW MATERIALS

Polyethylene (PE) materials are produced by the polymerization of ethylene which is

obtained from oil. PE describes a family of polymers ranging from low density to high
density materials, each with different performance characteristics. The first commercial
pipe materials were produced in the 1950s but these are very different to the high
performance polymers of today.

High quality HDPE compounds suitable for water pipe manufacture are produced by
combining all the necessary additives with the polymer powder in a very controlled
manner. The additives protect the polymer from degradation during manufacture and its
service lifetime. The compounds are then rigorously tested by the raw material producer
against the specification requirements.
B. PROCESS FLOWCHART

C. FINISHED PRODUCT

NPCA offers an array of products; each designed for

a specific purpose, from every household items to
large-scale industrial applications. generally supplied
in pellet form, these materials are carefully packed
and sealed in 25kg bags to downstream
manufacturers who transform these materials into
wide range of everyday applications.

Since every end-product calls for particular properties,

 the selection of the most suitable resin for each application is vital.

To this end, NPCA offers products that are designed for specific solutions, requiring end-
product properties.

III. QUALITY CONTROL

A. IN-PROCESS TESTING

NPC Alliance Corporation offers full range of laboratory services to the oil & gas,
petrochemical and other industries.

We are committed to deliver the premium standard quality to meet our customer’s diverse
analytical requirements by providing accurate, timely, impartial results with the strictest
level of confidentiality using state-of the-art equipment well-govern by best trained
personnel.

Item Test Methods Reference Method

A. Polyethylene and other Plastics
1 Melt Flow Rates of Thermoplastics by Extrusion Plastometer ASTM D 1238 / ISO 1133
2 Density of Plastics by Density-Gradient Technique ASTM 1505
3 Test Methods of Apparent Density, Bulk Factor, and Pourability of Plastic ASTM D 1895
Materials
4 Analysis of Elemental Content in Polyolefins by X-ray Fluorescence ASTM D 6247
Spectrometry
5 Particle Size (Sieve Analysis) of Plastic Materials ASTM D 1921
6 Calculating Yellowness and Whiteness Indices from Instrumentally ASTM E 313
Measured Color Coordinates
7 Volatiles BP Innovene Analytical
Handbook
8 Pellet Contamination BP Innovene Analytical
Handbook
9 Melt Flow Ratio BP Innovene Analytical
Handbook
10 Die Swell Ratio BP Innovene Analytical
Handbook
11 Powder Particle Size BP Innovene Analytical
Handbook
12 Tensile Properties of Thin Plastic Sheeting ASTM D 882
13 Tensile Properties of Plastics ASTM D 638
14 Determining the Izod Pendulum Impact Resistance of Plastics ASTM D 256
15 Environmental Stress-Cracking of Ethylene Plastics ASTM D 1693
16 Impact Resistance of Plastic Film by the Free-Falling Dart Method ASTM D 1709
17 Haze and Luminous Transmittance of Transparent Plastics ASTM D 1003
18 Specular Gloss of Plastic Films and Solid Plastics ASTM D 2457
19 Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting ASTM D 1894
20 Propagation of Tear Resistance of Plastic Film and Thin Sheeting by ASTM D 1922
Pendulum Method
 22 Enthalpies of Fusion and Crystallization of Polymers by Differential Scanning ASTM D 3417
Calorimetry
23 Compressive Properties of Rigid Cellular Plastics ASMT D 1621
24 Flexural ISO 178

B. Water and Wastewater

1 pH ASTM D 1125
2 Conductivity ASTM D 1126 / SMEWW 20th
Edition 2510 B
3 Turbidity ASTM D 1889 / SMEWW 20th
Edition 2130
4 Ammonia ASTM D 1426 / HACH Method
8038
5 Phenols ASTM D 1783 / HACH Method
8047
6 Surfactants, Anionic ASTM D 2330 / HACH Method
8028
7 Oil and Grease ASTM D 3921 / HACH Method
10056
8 Copper ASTM D 1688 / HACH Method
8506
9 Hydrazine ASTM D 1385 / HACH Method
8141
10 Nitrate ASTM D 3867 / HACH Method
8039
11 Nitrite ASTM D 3867 / HACH Method
8507
12 Sulfate ASTM D 516 / HACH Method
8051
13 Chemical Oxygen Demand ASTM D 1252 / SMEWW 20th
Edition 5220 D / HACH Method
8000
14 M Alkalinity ASTM D 1067 / SMEWW 20th
Edition 2320 B / HACH Method
8221
15 Total Hardness ASTM D 1126 / SMEWW 20th
Edition 2340 C / HACH Method
8226
16 Chloride ASTM D 1696 / SMEWW 20th
Edition 4500-Cl B / HACH Method
8113
17 Chromium ASTM D 1687 / SMEWW 20th
Edition 3500-Cr B / HACH
Method 8023
18 Zinc ASTM D 1691 / SMEWW 20th
Edition 3500-Zn B / HACH
Method 8009
19 Free Chlorine ASTM D 1253 / SMEWW 20th
Edition 4500-Cl G / HACH
Method 8021
20 Iron, Total ASTM D 1068 / SMEWW 20th
Edition 3500-Fe B / HACH
Method 8008
21 Silica, High-range ASTM D 859 / SMEWW 20th
Edition 4500-SiO2 C / HACH
Method 8185
22 Silica, Ultra-low range ASTM D 859 / SMEWW 20th
Edition 4500-SiO2 C / HACH
Method 8282
23 Calcium Hardness ASTM D 1126 / SMEWW 20th
Edition 3500-Ca B / HACH
Method 8222
 24 Color SMEWW 20th Edition 2120 C /
HACH Method 8025
25 Total Suspended Solids SMEWW 20th Edition 2540 D /
HACH Method 8158
26 Total Dissolved Solids SMEWW 20th Edition 2540 C /
HACH Method 8164
27 Phosphate,Reactive SMEWW 20th Edition 4500-P C /
HACH Method 8114
28 Phosphate, Total SMEWW 20th Edition 4500-P B &
E / HACH Method 8190
C. Others
1 Water in Organic Liquid by Coulometric Karl Fischer Titration ASTM E 1076
2 Moisture and Dewpoint BP Innovene Analytical
Handbook
3 Oxygen Analysis BP Innovene Analytical
Handbook
4 Hydrocarbon Impurities in Ethylene ASTM D 6159
5 Butylene Analysis ASTM D 4424
6 Ethylene, other hydrocarbons, and carbon dioxide in high-purity ethylene ASTM D 2505
7 Ash Content ASTM D 0482

B. FINISHED PRODUCT
NPCA offers an array of products; each
designed for a specific purpose, from every
household items to large-scale industrial
applications. Generally supplied in pellet form,
these materials are carefully packed and
sealed in 25kg bags to downstream
manufacturers who transform these materials
into wide range of everyday applications.

Since every end-product calls for particular

properties, the selection of the most suitable
resin for each application is vital. To this end,
NPCA offers products that are designed for
specific solutions, requiring end-product
properties.

IV. WATER AND WASTE TREATMENT

In the plant visit, pipes and equipment are used to avoid exposure or leakage of raw
materials that may cause harm to nature and human beings. They consume low energy
and are very strict on their production to conserve energy and to not waste raw
materials.
The plant uses high technology equipment to monitor all processes and ensure safety
not only to its employees but as well as to its environment. By these equipments they
can ensure that everything is under control and no harm is done. Also, to ensure that
 unnecessary things are not needed to take action if ever something went wrong in their
operating procedures.
They also conduct programs such as:
EHS MANAGEMENT PROGRAM
Subject: Waste management program
Aspect: Disposal of wastes ( dry fines from undersize, wet fines from PWC tank, pellets
from sampling points, used oil, slashed out FFS films, pellet sweeps, cartons, pipes,
used shrink films, ink containers, solvent containers, acetone)
Objective: Reduction of wastes.
Target: 10% reduction based on last year’s wastes by the end of 2014.

V. ROLES OF A CHEMICAL ENGINEER

Day-to-day responsibilities are extremely diverse and depend on the role and the
sector in which you work. In general, tasks may include:

 working closely with process chemists and control engineers to ensure the
process plant is set up to provide maximum output levels and efficient running of
the production facility;
 designing plant and equipment configuration so that they can be readily adapted
to suit the product range and the process technologies involved, taking
environmental and economic aspects into account;
 setting up scale-up and scale-down processes including appropriate changes to
equipment design and configuration;
 assessing options for plant expansion or reconfiguration by developing and
testing process simulation models;
 designing, installing and commissioning new production plants, including
monitoring developments and troubleshooting;
 optimizing production by analyzing processes and compiling de-bottleneck
studies;
 applying new technologies;
 researching new products from trial through to commercialization and improving
product lines;
 Ensuring that potential safety issues related to the project operator, the
environment, the process and the product are considered at all stages.

Examples of work activities in specific sectors include:

 undertaking small and intermediate-scale manufacturing and packaging activities

in product development for trial purposes;
  Developing new methods of safe
production, including projects such
as conceptual design, simulation
and construction of test rigs, and
detailed design and operations
support.

VI. RECOMMENDATIONS

The plant visit was very

interesting. The employees are
very friendly and approachable. The tour guide of the plant was very attentive to
us giving information and pointing out important details. The plant is vast. The
surroundings is clean and so is their facilities. The machines and equipment
they use are all in good conditions and ready for production.

VII. APPENDIX

DOCUMENTATION
REFERENCES:

http://www.parsethylene-
kish.com/separsekish/default.aspx?page=document&app=documents&docid=11516&do
cparid=0
www.npcac.com.ph/