Description Overview Inventory number: E-6371 Continuous polymerization plant Plant capacity is 100 tpd on PTA route and 70 tpd on DMT route Plant has dual feed facility Originally designed for pureterephthalic acid as a feedstock Plant has two identical lines each producing 45 tpd of polymer Based on Monsanto, USA technology Flexibility of using DMT as a feedstock Necessary changes and technological upgradation for DMT conversion done with help of Fischer Inventa, Germany After modifying for DMT, rated capacity is 70 tpd Common trans-esterification section designed for 70 tpd caters to two CP lines DMT used in solid or molten form Byproducts methanol and glycol are distilled and reused for the process Plant currently running with best possible material and energy ratios Efficiency can further be improved by changes in process and equipment Plant has separate utilities like HTM heaters, boilers, DG sets, and other utilities PET produced in chips form and packed in jumbo bags, then stored in a godown Methanol stored in underground storage tanks with dedicated loading station Separate fire pump house with provisions for facing emergency Sprinkler systems and fire detection systems installed at critical locations Plant normally run on MSEB load Plant running continuously in 3 shifts Except raw material feeding and finished goods handling, all operations are automatic Process Description PTA Route PTA in solid form charged through screw conveyor in a slurry preparation tank In this tank, MEG and catalysts and additives are also added as required for the process Slurry after homogenisation fed to pre-reactors at 2 bar pressure and 260 deg C Further transferred to reactor at 1 bar pressure and 270 deg C Water taken out as byproduct from overhead vapours through distillation column and condenser Esterified product fed to post reactor operated at 75 mbar pressure and 275 deg C Then transferred to PP column operating at 20 mbar pressure and 285 deg C Product again transferred to finisher operated at 295 deg C and 1.5 mbar pressure Finisher has cage drive for surface renewal Final product cooled, cut, dried, screened and conveyed to storage area for packing All processes automatic and transfer done through level controller of reactors Reactors heated with external jacket and coil having HTM fluid circulating at 335 deg C in liquid or vapour phase Steam ejectors used for vacuum applications DMT Route Trans-esterification section for DMT route consists of 3 esterifiers: R1, R2 and R3 R1 operated at 1 bar pressure and 200 deg C Raw material DMT and glycol along with catalyst fed to R1 Product from R1 transferred to R2 and R3 by pressure and level difference R2 operated under atmospheric pressure at 220 deg C R3 operated under atmospheric pressure at 250 deg C Product then transferred to monomer hold vessel operated under 600 mbar pressure at 265 deg C Additive additions done in these reactors as per need of product MHV onwards polycondensation takes place in post reactor, PP column and finisher similar to PTA route Equipment Summary Mechanical Equipments Reactors: 15, make Monsanto, jacketed Auxiliary tanks: 75, make Monsanto, including storage tanks, additive tanks, water tanks, day tanks Pumps: 115, make Goulds, Maag, KSB, including oil pump, polymer pumps and water pumps Heat exchangers: 35, make Monsanto, Ganson, Recon, including all plant heat exchangers, radiators, vapourisers Filters: 40, make Monsanto, Barmag, Alok, including air, water, polymer and oil filters Pneumatic conveying system: 3, make Waschle Ideal, DPC Agitators: 20, make Monsanto, Lightning, Ekato, for reactors and additives vessels Scrubbers: 10, make Monsanto, for services Instruments Control valves: 80, make Masoneilan, IL, Dembla, for hot oil, product, steam etc. Safety valves: 65, make Farrise, Fainger, Leser, for product, steam and services Converters (I/P): 80, make Rosemount, ABB Level gauges: 25, make Techtrol, for oil, water Pressure gauges: 100, make H. Guru, Waaree, for all services Transmitters: 150, make Rosemount RTD: 250, make Radix Actuators: 40, make Automax Nucleonic gauges: 10, make Berthhold Intl., for product services U.P.S. for DCS: make Tata Liebert DCS: 1, make MCS 1000, for process operation Electricals Electrical control panels: 20, make Telecon Motors: 250, make Kirloskar, Siemens, BBL DG sets: 1, make Cummins AC drives: 12, make Siemens, Eurotherm Air circuit breakers: 20, make GEC
