Popcorn polymer formation is a known process safety risk in ethylene processing units with relatively high butadiene concentration (e.g. butadiene purification units).
This presentation will summarize a 2019 loss of containment event involving popcorn polymer plugging a unit with relatively lower bulk butadiene concentration, namely an olefins purification unit in a depropanizer tower system.
As part of the event investigation, it was determined that popcorn polymer can form in units at lower butadiene concentrations when combined with initiators such as oxygen, peroxides or rust, particularly in areas with restricted fluid circulation. A characteristic of popcorn polymer (vs. other forms of butadiene-related polymer) is growth which can result in mechanical damage, unit plugging and possible loss of containment if not mitigated.
This presentation will provide a broad overview of popcorn polymer fundamentals, highlight the risks associated with popcorn polymer via an incident summary and suggest mitigation ideas to address this process safety risk.
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