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					Topas® COC

Topas® COC Production Plant
International Conference: Topas® COC Your clear advantage for pharmaceutical packaging April 28th-29th, 2004 in Oberhausen, Germany Presented by Dr. Oliver Lüdtke www.ticona.com

Topas® COC

Overview
The Topas® COC production plant How we guarantee stable & highest quality > manufacturing process > general aspects Summary Safety Instructions

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Topas® COC

What are we talking about?

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Topas Production Plant

Tank farm PC-Room Silo farm & bagging area

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Topas® COC

What are we talking about?
Capacity, nameplate > Topas® COC production 30,000 tons/a Monomer production integrated: > Norbornene production 21,000 tons/a

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World biggest norbornene producer World scale plant

Topas® COC

How we guarantee stable & highest quality

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Topas® COC

TOPAS® COC Manufacturing Process

norbornene ethylene
norbornene solvent

distillation

metallocene catalyst

polymerization

catalyst separation

evaporation

TOPAS® COC

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Topas® COC

How we guarantee stable & highest quality
Polymerization

Metallocen

x

+ y H2C=CH2
MAO

Solution polymerization Ultra high purity of all incoming streams Monomer concentration in the reactor defines the ratio of monomers in the polymer (thermal properties)

Advantage: Metallocene-catalysts enable optimized process conditions “Taylor made” polymer properties Highest optical quality of polymer

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Topas® COC

TOPAS® COC Manufacturing Process

norbornene ethylene
norbornene solvent

distillation

metallocene catalyst

polymerization

catalyst separation

evaporation

TOPAS® COC

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Topas® COC

How we guarantee stable & highest quality
Catalyst separation Catalyst is deactivated and then precipitated with filter aid New developed continuos filtration step separates the catalyst from the viscous polymer solution > special candle filter type (each 130m2 filter area) Advantage Separation of catalyst higher than 99,9 % > excellent transparency and color > extremely low level of inorganic impurities (< 10ppm)

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Topas® COC

TOPAS® COC Manufacturing Process

norbornene ethylene
norbornene solvent

distillation

metallocene catalyst

polymerization

catalyst separation

evaporation

TOPAS® COC

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Topas® COC

How we guarantee stable & highest quality
Evaporation New developed effective two stage solvent separation step > Optimized residual time > Optimized inert conditions > Optimized equipment design Advantage Very low solvent residuals in the polymer possible (< 100 ppm) Low solvent residuals for polymer melts with viscosities from 0.1 to 1000 Pa s Excellent transparency and color

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Topas® COC

TOPAS® COC Manufacturing Process

norbornene ethylene
norbornene solvent

distillation

metallocene catalyst

polymerization

catalyst separation

evaporation

TOPAS® COC

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Topas® COC

How we guarantee stable & highest quality
TOPAS® COC

Two pelletizing systems for wide viscosity range On-line optical quality control systems > pellets & melt Closed pneumatic conveying & storage system for pellets > bagging under clean room conditions Advantage Pelletizing over an extreme wide viscosity range > 0,1 - 1000 Pa s melt viscosity On-line optical control systems > highest optical quality No contaminations

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Topas® COC

How we guarantee stable & highest quality
Production plant is completely controlled by a Process Control System (PCS)
> various computer programs run process steps automatically (programs with up to 1000 steps) > equipment and PCS are communicating via a bus system > for shift training an independent PCS simulation station is used

Data management system is installed
> storage of all process data and quality data (up to 400 values per sec.) > Continuous optimization of process control and product quality

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Topas® COC

How we guarantee stable & highest quality
Product is completely separated from impurities and contaminations > all incoming streams are filtered & cleaned = adsorptive and catalytic cleaning steps > multiple stage distillation > special equipment design = materials & surfaces & residual design Semi-stationary foam extinguishing system installed > smoke and fire detection system direct connected to the PCS-room and the site fire brigade > site fire brigade is in less than 3 minutes at the plant > frequent emergency drills with employees

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Topas® COC

How we guarantee stable & highest quality
Peoples excellence:
> high education level of shift employees
= more than 80h special training per employee per year

> unit specialists are specially trained in six sigma methods
= statistical methods for process and quality control “Show me the data”

> all shift employees have a basic understanding of six sigma methods

Strong cooperation with R&D and pilot plant

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Topas® COC

Summary

The Topas® COC Production plant is a state of the art production plant > Focus on peoples excellence > Focus on process excellence

Stable & highest quality of the product

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Topas® COC

Safety Instructions: Plant Visit

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Topas® COC

Safety Instructions: Plant Visit
KEEP IN MIND: YOU ENTER A PRODUCTION AREA !!! When you enter the plant, make sure you have > safety helmet and glasses! > shoes, for walking on a metal grid! 1st watch your steps, then the equipment! Walk only on solid ground or metal grids! Use handrails! Stay together! Don‘t touch apparatus or pipes! > You might be hurt by sharp edges! No electrical device (cellular phone) is allowed! > We are in an explosion proof area

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