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  • The Polystyrene Process facility will use the INEOS/Lummus technology for the manufacture of High Impact Polystyrene (HIPS) and General Purpose Polystyrene (GPPS) as well as certain ISBL support facilities.
  • The plant will have the capacity to produce 200,000 metric tons per year (MTA) of Polystyrene based on 8000 hours per year. The plant will consist of two (2) – 100,000 MTA parallel lines. The Swing line will be capable of producing HIPS or GPPS, while the HIPS line will produce HIPS only.


  • The process units of the plant are two (2) parallel lines, the Swing Plant and the HIPS Plant


  • Each of The HIPS Plant & The Swing Plant consists of processing sections .


The scope of work for this project covers basic process design of the facilities listed above under

Plant Elements. Utility Distribution P&IDs are to be supplied by Others in the detailed

engineering phase . Also all feeds and OSBL facilities   are provided by Others.

Detailed Design shall be performed by Others.

The Basic Design and Detailed Design of all other OSBL Storage, Utilities, Generation and

Distribution, Packaging, Warehousing, OSBL Wastewater Treatment, Emergency Power,

Laboratory, Maintenance and Administration facilities are provided by Others



  • Polystyrene is produced by polymerization of styrene monomer. When polymerized in the presence of rubber it is called High Impact Polystyrene (HIPS). When no rubber is present, it is called General Purpose or Crystal Polystyrene (GPPS).
  • Styrene monomer (vinylbenzene) (C8H8)

is a clear liquid with a distinct odor. Styrene monomer is also a flammable liquid whose vapor is heavier than air and therefore must be handled properly.

  • Polymerization consists of three steps: (1) initiation, (2) propagation and (3) termination. The

polymerization reactions are as follows:

  • M– >M


  • M + M– > MM· + M — > MMM· + M — > [MMMM·


     (3) — [MMMM·] + [·MMM] — — > [MMMMMMM] —

–    Step (1) – Initiation

In step (1) the double bond on the carbon atom is broken to form a free radical. This is

accomplished by the application of heat or by a catalyst.

  • Step ((2) – Propagation

The free radical, which is highly unstable, combines with another styrene molecule thus forming a new free radical. This process continues and the polymer chain continues to grow.

  • Step (3) – Termination

In the termination reaction, two free radicals can combine to terminate a chain or other chemicals can be used to terminate a chain.


  • The INEOS continuous polymerization process is a proven and efficient technology that controls these steps for the production of a wide range of crystal and impact polystyrenes.

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