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(CP PLANT) Continuous Polymerization Plant

Reference No. 8675430
Assets (CP PLANT) Continuous Polymerization Plant
Description Continuous Polymerization Plant designed for using Pureterephthalic Acid as a feedstock but convertible to using DMT as a feedstock.
Year 1990s
Location INDIA
Details

Continuous Polymerization Plant (CP Plant)

 

The Company is producing polyester (PET) chips used for various applications leg. BOPET film, textile grade, etc.

 

The plant capacity is 100 TPD on PTA route and 70 TPD on DMT route.  This plant is having dual feed facility.   

 

 

PLANT DESCRIPTION

 

Continuous Polymerization Plant (CP Plant) is originally designed for Pureterephthalic Acid as a feedstock.   The plant is having two identical lines each producing 45 TPD of polymer.  The plant is based on Monsanto, USA technology.

 

This plant is also having a flexibility of using DMT as a feedstock. After modifying the process for DMT the rated capacity of the plant is 70 TPD.  The common trans-esterification section which is designed for 70 TPD is catering to two CP lines down the line. The DMT used is in the solid form or molten form. 

 

The byproducts i.e. Methanol & Glycol are distilled and reused for the process.  This plant is at present running with the best possible material & energy ratios and the efficiency can further be improved by doing some changes in the process, equipments. 

 

The plant is having a separate utilities like HTM heaters, Boilers, DG sets, and other utilities. 

 

The PET is produced in chips form and packed in jumbo bags and then stored in a go-down.

 

The Methanol is stored in underground storage tanks with a dedicated loading station. A separate fire pump house is there with all the provisions for facing the emergency.  Sprinkler systems, fire detection systems are installed at the critical locations. 

 

The plant is normally run on MSEB load.  The plant is running continuously in 3 shifts.  Except raw material feeding and finished goods handling all the operations are automatic. 

 

 

 

EQUIPMENT SUMMARY

 

A) Mechanical Equipments:

 

S.No.

Description

Quantity

Make

Remarks

 

1

Reactors

15

Monsanto

Jacketed

2

Auxiliary Tanks

75

Monsanto

Storage tanks, Additive tanks, water tanks, day tanks

3

Pumps

115

Goulds, Maag, KSB

Oil pump, polymer pumps & water pumps

4

Heat Exchangers

35

Monsanto, Ganson, Recon

All plant Heat Exchanger, Radiators, Vapourisers

5

Filters

40

Monsanto, Barmag, Alok

Air, Water, Polymer & Oil

6

Pneumatic conveying system

3

Waschle Ideal

DPC

7

Agitators

20

Monsanto Lightning Ekato

Reactors & Additives, Vessels

8

Scrubbers

10

Monsanto

Services

 

B) Instruments:

 

S.No.

Description

Quantity

 

Make

 

Remarks

1

Control valves

80

Masoneilan,IL, Dembla

Hot oil, product, steam etc.

2

Safety valves

65

Farrise, Fainger Leser

Product, steam & services

3

Converters (I/P)

80

Rosemount, ABB

--

4

Level Gauges

25

Techtrol

Oil, water

5

Pressure Gauges

100

H. Guru, Waaree

All services

6

Transmitters

150

Rosemount

--

7

RTD

250

Radix

--

6

Actuators

40

Automax

--

7

Nucleonic Gauges

10

Berthhold Intl.

Product services

8

U.P.S.

For DCS

Tata Liebert

 

 

9

D C S

1

MCS 1000

Process operation

 

C) Electricals:

 

S.No.

Description

Quantity

Make

Remarks

 

1

Electrical Control  Panels

20

Telecon

--

2

Motors

250

Kirloskar, Siemens, BBL

--

3

DG sets

1

Cummins

--

4

AC Drives

12

Siemens, Eurotherm

--

5

Air Circuit Breakers

20

GEC

--

6

LDB

35

MDS

--

 

 

PLANT LAYOUT & ASSETS

 

S.No.

Details

Area (SQM)

 

A)

Land

16780

B)

Building

 

1.

Main Plant

1000

2.

 Utility

600

3.

 Office

142

4.

 Design Office

36

5.

 Godown

1692

6.

 Contol Room

85

7.

 Lab

66

8.

 MCC, Process Rooms & AHU

267

9.

 Tool Room & Inst. Room

267

10.

 Compound wall

300 R.M

11.

 Foundation

35 Colmn.

 

C)

Related Assets

 

1

  Water Tanks (1100 KL)

2

  Tankfarm -DMT, Methanol, Glycol, Diesel, F.O & Ammonia

3

  General Foundation, Cooling towers, Chimney, Pumps  & others 

4

 Hydrant Pump House (40 KL)

5

 Structural steel  (125 MT)

6

 Utilities – Boiler House, Cooling towers, Sub station

7

 Lab eqpts, Furniture & fixture, Office epts, Vehicles, Data processing units

 

 

 

PROCESS DESCRIPTION

 

A) PTA Route:

 

PTA in solid form is charged through the screw conveyor in a slurry preparation tank.  In this tank, MEG & Catalaysts & additives are also added as required for the process.  This slurry after homogenisation is fed to the pre-reactors which is at 2 bar pressure and 260 deg.C.  It is further transferred to reactor which is at 1 bar pressure & 270 deg.C.  The water is taken out as a byproduct from the overhead vapours through distillation column and condenser.  The esterified product is then fed to the post reactor which is operated at 75 mbar pressure & 275 deg.C.  This is then transferred to PP column operating at 20 m bar pressure & 285 deg.C.  This product is again transferred to the finisher which is operated at 295 deg.C and a 1.5 m bar pressure.  The finisher is having cage drive for surface renewal.  The final product is then cooled, cut, dried, screened and conveyed to the storage area for packing.  All these process are automatic and transfer is being done through level controller of the reactors.  The reactors are heated with external jacket and coil having HTM fluid circulating at 335 deg.C in liquid or vapour phase.  The steam ejectors are used for vacuum applications.  

 

B) DMT ROUTE:

 

In this conversion, the trans-esterification section is different than that of above.  Trans-esterification section for DMT route consists of 3- esterifiers namely R1, R2 & R3.  R1 is operated at 1 bar pressure and 200 deg.C.  The raw material DMT & Glycol alongwith catalyst is fed to the  R1.  The product from the R1 is transferred to R2 & R3 by pressure and level difference.  R2 is operated under atmospheric pressure at 220 deg.C and R3 is operated under atmospheric pressure at 250 deg.C.  The product is then transferred to Monomer Hold Vessel operated under 600 mbar pressure at 265 deg.C.   The additive additions are done in these reactors as per the need of the product.  MHV onwards polycondensation takes place in the post reactor PP column & finisher similar to the PTA route.

 

 
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