INDUSTRIAL TRAINING

IN

Petrochem Limited.
INTERNSHIP REPORT & PROJECT WORK

SUBMITTED TO: SUBMITTED BY:

PLASTIC DEPARTMENT Himanshu Agnihotri
HBTU KANPUR III B.Tech, Plastic Technology
Harcourt Butler Technical University, Kanpur

ACKNOWLEDGEMENT
1
This Internship was supported by IVL Dhunseri. We thank the
personnel of IVL Dhunseri, who all provided insight and expertise
that greatly assisted the internship.

We thank Mr. T.K Giri, Sr. Manager (HR & Admin) and Mrs.
Anandita Paul (HR) for making possible for us to get involved in the
internship. We are especially thankful to Mr O.R.K. Reddy (SGM,
Process) for their valuable guidance and cooperation.

We would also like to show our gratitude to Mr. P. P. Dey (AGM,

Process) and Mr. Swaroop Paul (Process head, Plant-2) for sharing
their pearls of wisdom with us during the course of this internship.

With grateful heart, we would like to all the personnel who all helped
us to commence a successful training. We would also like to thank
entire DPL family for their co-operation, valuable guidance and
support.

Mr. O.R.K Reddy Mr. T.K Giri

(SGM, Process) Sr Manager (HR & Admin)

PREFACE

2
In-plant training plays a vital role to connect the theoretical
knowledge to the practical insights and this is our first practical
knowledge with the theoretical concepts acquired during the years in
technical University. We are fortunate that we got the opportunity of
undergoing summer training in most sophisticated and modern PET
plant, IVL Dhunseri, Haldia.

The experience gained during this short stay was fascinating to say
the least. It was a tremendous feeling to see the practical operation of
different equipment and processes, which until now existed for us
only in the books of college library. What still fascinates us, how the
plant is being monitored and operated with such a high precision and
accuracy to get the desired result. In this short period, it was not
possible for us to wholly decipher the detailed functioning of the
plant; but still we are fortunate enough to get a sound overview of it.

Thanks for the guidance extended by the people in the different

sections of the plant. We also undertook a project on Design of a
plate type heat exchanger in Cutter demineralised water system.

Finally, after this small tenure we feel that nothing is more practical
than a good theory. So we realized that to be successful as a process
engineer or for that matter any engineer one needs to possess a sound
theoretical base along with the acumen for effective practical
application of the theory.

3
 Table of contents
Company Profile

Products

Environment & Safety Department

Quality Control (QC) & Quality

Assurance

Utility

Heater

4
 Company Profile

Overview

Dhunseri tea Company (DTCL) was incorporated in 1961. The S L Dhanuka group took
over the management of the company in 1955 from James Finlay & Company. In 1970, the
company was renamed Dhunseri Tea & Industries. In 1980, the company acquired the
Namsang and Dilli Gardens in Assam. It took over Bahadur Tea Company and amalgamated
it with DTCL on 1 Apr.'91. In 1994, it acquired three more tea estates Santi tea estate,
Khetojan tea estate and Khagorijan tea estate. Santi tea estate was amalgamated with DTCL
on 1 Apr.'93. The company has 1248 hectares of plantation area in Assam.

It came out with a public issue in Dec.'92 and a rights issue of NCDs with
detachable warrants in Jul.'94. The funds from the rights issue were utilised to acquire the
three tea estates mentioned above and to expand manufacturing facilities. DTCL cultivates
and sells tea in packed form. DTCL also has a pharmaceutical division called Iveon
Laboratories (ILL). It produces IV fluids with the latest FFS technology. In 1993, the
company expanded the production capacity from 35 lac bottles pa (LBA) to 167 LBA. The
company has set up packaging plants near its gardens, and markets them under the
LalGhora and Kala Ghora brands.
5
 During 1998-99, the Company raised a sum of Rs. 8 Crores by issue of 15%
Secured Non-Convertible Debentures on private placement basis with financial institutions
to augment long-term resources of the Company for working capital requirements. The
company has promoted South Asian Petrochem Ltd., a 100% E.O.U. petrochemical project
at Haldia, West Bengal, for manufacture of PET Resins under technical and financial
collaboration with Lurgi Zimmer AG of Germany, during the 1999-2000. The 100% EOU
petrochemical project viz South Asian Petrochem Ltd was completed ahead of schedule. The
Technical and Financial collaboration was done by Zimmer AG, Germany.

Plant Overview
The plant at Haldia spreads over some 35 acres, also has a 12 MW captive power plant.
Erstwhile South Asian Petrochem Limited (since merged with Dhunseri Petrochem & Tea
Ltd.) (DPTL or the Company) which started operations in 2003 is the second largest
producer of food grade polyethylene terephthalate (PET) in India. This unit consists of two
plant for manufacturing PET.
There are 2 technologies that are employed:
1. ZIMMER
2. ORLICON BERMACK
Theplant-1 uses world class German technology known as ZIMMER. Dhunseri Petrochem
& Tea Ltd (DPTL) commissioned a Rs.4 billion for this plant to manufacture
polyethylene terephthalate (PET) at Haldia, West Bengal. This unit is the company's
second plant at Haldia. DPTL already had a 2,10,000 tonnes per annum PET
manufacturing facility there. With commissioning of this new plant (Plant-2), which is
based on the technology knowns as ORLICON BERMACK, total PET capacity of the
company has increased to 4,10,000 tonnes per annum. Presently the plant1 and plant 2
produces 605 and 800 Tons/day respectively.
DPTL is a part of Kolkata (Calcutta) based Dhunseri Group (Dhunseri or the Group),
promoted by Mr. C.K. Dhanuka and Family (the Sponsors In the year 2009-10, appx.
40% of the total sales of the petrochemical division of DPTL are accounted for by exports to
over 29 countries of which 78% comes from exports to the U.S. and European Union
countries.

Company Info
Full Company Name:
IVL Dhunseri
Head Office: Dhunseri House, JL-126, mouza-Basudevpur, Pvt Ltd; PS Durgachak& JL-
145,
Works: 4A Woodburn Park, mouza- paranchak, PS; Kolkata, Bhabhanipur, haldia,
West Bengal-700020midnapor
Phone: 91-33-22801950 (5 lines) district 721602
Fax: 91-33-22878350west Bengal India
E-mail : dhunseri@vsnl.com
Web : http://www.dhunseritea.com

6
 MARKETING NETWORK

IVL Dhunseri enjoys a marketing presence covering around 500 PET consuming customers
in around 50 countries. Its products are available in the ASPET brand in North America, the
European Union, the Middle East, Eastern Europe and Africa. To help deal with its
international operations better, DPL established a branch office in Dubai Multi
Commodities Centre Authority under the name of Dhunseri Petrochem & Tea Ltd.

ASPET PRODUCT RECOGNITION

Product of the company is approved by international & national regulatory bodies:

American FDA regulations covering Federal Food, Drug & Cosmetics Act
European EC
Pepsi Worldwide
Bureau of Indian Standard Regulations
Japan Polyolefin Association
Canadian Health Authorities
Coke-India

CUSTOMERS
DPL enjoys a marketing presence covering around 500 PET consuming customers in
around 50 countries. Some of the leading customers around the world are:

7
 Pepsi
Hindustan Coca Cola
Umrao polymers
Bisleri
Aquafina
Vishal polypack

OTHER PET PRODUCING COMPANIES

There are multiple leading companies in the field of PET production.

Some of the leading esteemed organization:
RELIANCE
PEARLPET
FUTURA POLYMERS
JBF INDUSTRIES

PRODUCTS
DPL Haldia plant produces PET resin. It manufactures the finest bottle grade PET resin
ASPET (brand name) for following applications:
Packaging of drinking water
Carbonated soft drinks
Edible oil
Pharmaceuticals etc.

About PET resin

IUPAC NAME-Polyethylene terephthalate
CHEMICAL STRUCTURE-

PHYSICAL PROPERTIES
PET in its natural state is a colourless, semi-crystalline resin. Based on how it is processed,
PET can be semi-rigid to rigid, and it is very lightweight. It makes a good gas and fair
moisture barrier, as well as a good barrier to alcohol (requires additional "barrier"
treatment) and solvents. It is strong and impact-resistant.

YOUNGS MODULUS(E) - 28003100 MPa

TENSILE STRENTH(t) - 55-75 MPa
ELASTIC LIMIT- 50-150%
8
GLASS TRANSITION TEMPRETURE (Tg) - 67-81C
VICAT SOFTENING TEMPERETURE - 82 C
WATER ABSORPTION (ASTM) 0.16

USES OF PET

Because PET is an excellent water and moisture barrier material, plastic bottles made from
PET are widely used for soft drinks (see carbonation). For certain specialty bottles, such as
those designated for beer containment, PET sandwiches an additional polyvinyl
alcohol (PVOH) layer to further reduce its oxygen permeability.
Biaxially oriented PET film (often known by one of its trade names, "Mylar") can be
aluminized by evaporating a thin film of metal onto it to reduce its permeability, and to
make it reflective and opaque (MPET). These properties are useful in many applications,
including flexible food packaging and thermal insulation. See: "space blankets". Because of
its high mechanical strength, PET film is often used in tape applications, such as the carrier
for magnetic tape or backing for pressure-sensitive adhesive tapes.
Non-oriented PET sheet can be thermoformed to make packaging trays and blister packs. If
crystallisable PET is used, the trays can be used for frozen dinners, since they withstand
both freezing and oven baking temperatures. As opposed to amorphous PET, which is
transparent, crystallisable PET or CPET tends to be black in colour.
When filled with glass particles or fibres, it becomes significantly stiffer and more durable.
PET is also used as a substrate in thin film solar cells.
Terylene (a trademark formed by inversion of (polyeth)ylene ter(ephthalate)) is also spliced
into bell rope tops to help prevent wear on the ropes as they pass through the ceiling.
PET is used since late 2014 as liner material in type IV composite high pressure gas
cylinders. PET works as a much better barrier to oxygen than earlier used (LD)PE.

9
 MANUFACTURING TECHNIQUE
.

PET in its natural state is a colourless, semi-crystalline resin. Based on how it is processed,
PET can be semi-rigid to rigid, and it is very lightweight. It makes a good gas and fair
moisture barrier, as well as a good barrier to alcohol (requires additional "barrier"
treatment) and solvents. It is strong and impact-resistant. PET becomes white when exposed
to chloroform and also certain other chemicals such as toluene.

The raw materials to make PET are monoethylene glycol (MEG) and purified terephthalic
acid (PTA) or dimethyl terephthalate (DMT). PTA is the preferred feedstock for process
economic reasons although DMT may be favoured in polyester film applications due its
adhesion addition quality. The main process steps are raw material preparation,
esterification/transesterification, pre-polycondensation and polycondensation.

The PTA is mixed with the MEG and catalyst solution in a paste and fed into the
esterification system. The esterification takes place under atmospheric pressure by splitting
off the water.

Monomer (bis hydroxyterephthalate) can be synthesized by the esterification reaction between

terepthalic acid and ethylene glycol with water as a by-product, or by transesterification reaction
between ethylene glycol and dimethyl terephthalate with methanol by product. Polymerization is
through a polycondensation reaction of the monomers (done immediately after esterification/
transesterification) with water as by product.

Polyethylene terephthalate may exist both as

10
 Amorphous (transparent)
semi-crystalline polymer.

The semi crystalline material might appear transparent (particle size < 500 nm) or opaque
and white (particle size up to a few microns) depending on its crystal structure and particle
size

RAW MATERIALS
Purified Terephthalic Acid (PTA)
IUPAC Name: Purified Terapthalic Acid
Formula: C6H4(COOH)2
Chemical structure:

Molar mass: 166.13 g/mol

Appearance: white crystalline powder

Density: 1.522 g/cm

Melting point: 300 C

Boiling point: 350 C (de composes)

Solubility in water: 0.0017 g/100 mL at 25C

Solubility: polar organic solvents aqueous base

Suppliers Mitsubishi Chemical Private Industries Limited (MCPI), Haldia

Indian Oil Corporation Limited (IOCL), Panipat
Mitsubishi Chemical Indonesia, Indonesia NPC, Japan
Sahid Tondgooian Petrochemical Co., Turkey

Mono ethylene glycol (MEG)

IUPAC Name: Ethane-1,2-diol

Formula: C2H6O2

Chemical structure:

11
Molar mass: 62.07 g mol1
Appearance: clear, colourless liquid
Density: 1.1132 g/cm
Viscosity: 1.61 102 N*s / m2
Melting point: 12.9 C (8.8 F; 260.2 K)
Boiling point: 197.3 C
Solubility in water: Miscible
Solubility: soluble in most organic solvents

Suppliers Saudi Arabian Basic Chemical Industries (SABIC)

Indian Glycol Limited (IGL) , RIL, IOCL.

Purified isophthalic acid (IPA)

IUPAC Name: Isophthalic acid

Formula: C6H4(COOH)2
Chemical structure:

Molar mass :166.14 g/mol

Appearance: White crystalline solid
Density :1.526 g/cm3, Solid
Solubility in water: Insoluble in water
Acidity (pKa ): 3.46, 4.46

Suppliers Interquisa (Spain)

K.P. Chemicals Corporation (Korea)
A.G. International Chemical Company (Japan)
LOTTE(Korea)

Di ethyle glycol (DEG)

IUPAC Name: 2-(2-Hydroxyethoxy) ethane-1-ol
Formula: C4H10O3

Chemical structure:

Molar mass :106.12 g/mol

Appearance: Colourless liquid
12
Density :1.118 g/mL
Viscosity:
Melting point: 10.45 C
Boiling point: 244245 C
Solubility in water: miscible
Suppliers China Man Made Fibre Corporation (Taiwan)
Petrochem Middle East (Dubai)
Saudi Arabian Basic Chemical Industries (SABIC)

Catalyst

Antimony trioxide
IUPAC Name: Antimony(III) trioxide
Formula: Sb2O3
Chemical structure:

Melting point : 656 C (1,213 F; 929 K)

Molar mass: 291.52 g mol1
Appearance: white solid
Density: 5.2 g/cm3, -form: 5.67 g/cm3 -form
Suppliers Guangzhou chemical corp.

Colouring agent

Blue toner
Suppliers Color Matrix Europ Ltd.

Furnace oil (FO)

Suppliers- IOCL (Indian Oil Corporation Ltd)
BPCL (Bharat Petroleum Corporation Ltd)

Therminol 66
Therminol 66 is a high performance highly stable synthetic heat transfer fluid offering
extended life and very low top-up rates resulting in reduced running costs and minimal
downtime for operations at temperatures up to 345C. Therminol 66 derives its
outstanding performance from the unique stability of the polyphenyl structure.
13
 Intended for use in systems operating at or near atmospheric pressure, Therminol
66 offers potential savings in both capital and operating costs. Therminol 66 is in use
world-wide for many process heating and waste heat recovery applications: resin
manufacture, phthalic anhydride distillation, polyester film and fibre production, phenol
production, polyamide polymerisation and extrusion, preheating combustion air in the steel
and petrochemical furnaces.

Typical Physical, Chemical and Thermal Properties of Therminol 66

Composition - Hydrogenated terephenyl
Average molecular weight - 252
Appearance - Clear pale yellow liquid
Max. bulk temperature - 345C
Max. film temperature - 375C
Kinematic viscosity (40C) - 29.64 mm2/s
Density (15C) - 1011 kg/m3
Flash point (Closed cup) - 170C
Pour point (ISO 3016) - -32C
Boiling point (1013 mbar) - 359C
Coefficient of thermal expansion - 0.0009/C
Suppliers Solutia Chemicals India Pvt.

DETAILED DESCRIPTION OF THE PROCESS

The polymerisation reaction takes place into several steps divided into 2 different processes. The
entire process is divided into two main processes are

1. Continuous Polycondensation (CP)

2. Solid State Polycondensation (SSP)

Below present flow diagram shows a brief description of the process:

14
 The Mechanism of Condensation Polymerization
Condensation polymerization, a form of step-growth polymerization, is a process by which
two molecules join together, resulting loss of small molecules which is often water. The
type of end product resulting from a condensation polymerization is dependent on the
number of functional end groups of the monomer which can react.

The monomers that are involved in condensation polymerization are not the same as those
in addition polymerization. The monomers for condensation polymerization have two main

Characteristics
The monomers that are involved in condensation polymerization are not the same as those
in addition polymerization. The monomers for condensation polymerization have two main
characteristics:.
Instead of double bonds, these monomers have functional groups (like alcohol, amine, or
carboxylic acid groups).
Each monomer has at least two reactive sites, which usually means two functional
groups. Instead of double bonds, these monomers have functional groups (like alcohol,
amine, or carboxylic acid groups).
Each monomer has at least two reactive sites, which usually means two functional
groups.

15
 Advantages
Since step-growth polymerization reactions are reversible.
It is more straightforward to recycle many step-growth polymers back to monomers
or oligomers.

Raw materials Preparation

PTA
The basic raw materials for the production of PET are Purified Terephthalic Acid (PTA). PTA
is in powder form and received in container or in jumbo bags of capacity 1150 kg each.
PTA powder is conveyed with nitrogen by means of TCC or tube chin conveyer and stored
in silo (150 m3). For unloading of PTA from jumbo bags, five charging stations are
available. Unloading of EPTA have two methods to unload in hopper. One is directly by
fully loaded truck to hopper and other is opening of jumbo bag on hopper. Which is show
below in figure.

16
Each jumbo bag is manually lifted by means of hoist and charged through charging
stations. For conveying of PTA, tube chain conveyer (TCC) and Pneumatic conveying system
area used. Nitrogen is used in pneumatic conveying. The nitrogen is being compressed, the
temperature is raised and hence it is cooled using a discharge cooler, which is nothing but
a shell and tube heat exchanger. Nitrogen passes on to the tube while the coolant (water)
flows within the shell. Nitrogen at high pressure is cooled around 60 0C to 70 0C. There is a
water separator which separates the water from the Nitrogen. There is a similar discharge
filter which filters any impurity present in Nitrogen and passes onto two lines- one goes to
big bag conveying and another goes to bulk unloading i.e., 20 tons. The hopper consists of
two lock feedersone at the top and other at the bottom. They are nothing but rotating
blades arranged in circular manner. The first lock feeder carries PTA to the bottom of
hopper, while the 2nd one carries it to the inlet of the pipeline wherefrom compressed N2
conveys it to the PTA storage silo. PTA from here goes to feed silo wherefrom it is being used
to run the process plant.

From feed silo PTA is fed for processing into first vessel that is Paste preparation tank by
means of screw feeder.

17
 MEG
MEG is a colourless, transparent liquid and received in storage tanks of capacities 3000 KL
(4 tank) and 4000KL (2 tank) pumped into the main process building.

Purified Isophthalic Acid (IPA)

IPA is in solid powder form and is used for reducing the melting point and to enhance
clarity. It is received in jumbo bags of 1100 kg capacity. Each bag is manually lifted by
means of hoist & charged into IPA feed silo. From feed silo it is fed into the paste
preparation tank for processing by means of screw feeders.

Antimony trioxide (Catalyst)

It is in powder form & is received in 15 kg buckets. It is used for enhancing
polycondensation rate of reaction. Catalyst batch system comprises of preparation vessel &
feed vessel. Depending on plant capacity a catalyst batch is prepared in preparation vessel.
Catalyst batch is prepared with MEG, antimony trioxide & blue toner in preparation vessel.
After agitation & on clearance of sample for concentration from quality control (QC) lab
one batch is ready in preparation vessel. Depending on the requirement the batch is
manually dropped to the catalyst feed vessel by opening manual valve. The catalyst solution
in glycol from catalyst vessel is fed to the paste preparation tank by means of pump.

Blue Toner (colouring agent)

It is in powder form and is received in 5 buckets. It is a colouring agent and makes the
polymer shiny. Its batch system also consists of a preparation vessel and a feed vessel.
Depending on plant capacity its batch is prepared in MEG in the preparation vessel. After
agitation and on clearance from QC the batch is ready. From where it is manually dropped
to the feed vessel. This solution in glycol is transferred to the paste preparation tank by
means of pump.

Phosphoric Acid
It is in liquid form and is received in 25 litres cans. It is used for thermal stability of the
polymer. Its batch system also consists of preparation vessel and feed vessel. Depending on
plant capacity phosphoric acid batch is prepared in preparation vessel. The phosphoric acid
batch is prepared by taking MEG in preparation vessel and phosphoric acid is added in this
tank. After agitation and on clearance of sample for concentration from QC one batch is
ready in preparation vessel. Depending on requirements the batch is manually dropped
from preparation vessel to feed vessel.

18
 Steps of process
Paste Preparation
The raw materials PTA & MEG are metered quantified and mixed in the paste preparation
vessel to make thick paste. PTA & MEG are normally mixed in a mole ratio of 1:1.15. For
bottle grade PET resin production, the co- polymer IPA & DEG are metered and added into
paste preparation vessel. DEG addition is around 0.5% -0.6% and IPA addition is around
1.9% by weight of PET. As a concentration of 0.9% of DEG evolves during the
manufacturing process, the PET thus produced shall have around 1.7% of DEG and 1.8% of
IPA respectively by weight of PET. Antimony triacetate is added as a catalyst into paste
preparation vessel. Cobalt acetate and Blue Toner are added to paste to improve the colour
of PET.

Esterification-1(ES-1)
The paste from the paste preparation vessel is fed into ES-1. Here the product temperature
is maintained at 265 0C- 270 0C. The MEG vapour pressure can be increased above the
atmospheric pressure so that the reaction rate is improved. Thus, owing to a residence time,
operating temperature of reactance and the vapour pressure, the esterification reaction
proceeds liberating waste water as the by product. In this unit conversion of reaction
occurs from 90% to 92%. As esterification reaction occurs at high temp so we used HTM in
coil and Dow vapour in the jacket of the reactor as a heating medium. Dow vapour comes
from HTM evaporator where Dowtherm is evaporated by using HTM.

Esterification-2(ES-2)
The product BHET (Bis hydroxyl ethylene terephthalate) from ES-1 is then fed into ES-2
through product transfer pump, where the conversion is further increased from 92% to
97%. Phosphoric acid is added here from a separate tank and it acts as a heat stabilizer, as it
is ES-2 where the transition from BHET to PET begins, moreover if added before it can
deactivate the catalytic properties of Antimony triacetate and hence added only when the
BHET to PET transformation is complete. In ES-2 the temperature is maintained at 266 0C.
Here also temperature is maintained by supplying HTM in coil and Dow vapour in the
jacket of the reactor as a heating medium. Dow vapour comes from HTM evaporator where
Dowtherm is evaporated by using HTM.

Prepolymerisation-1 (PP-1)
The product from ES-2 is transferred to PP-1 by gravity. The reactants are at a temperature
of 270 0C. A vacuum level of 100 mbar (abs) is maintained with the help of vacuum pump.
Under the catalytic action of Antimony trioxide, the prepolycondensation reaction starts
from here at higher product temperatures and under vacuum. Here degree polymerization
is near about 30. Here is no sampling point as to maintain the vacuum pressure. Here also

19
temperature is maintained by supplying HTM in coil and Dow vapour in the jacket of the
reactor as a heating medium. Dow vapour comes from HTM evaporator where Dowtherm
is evaporated by using HTM.

Prepolymerisation-2 (PP-2)
The product from PP-1 is transferred by gravity to PP-2. Here the product temperature is
further increased to around 275 0C and a vacuum level of around 10 mbar (abs) is
maintained. Temperature is maintained by passing HTM in the jacket of the reactor and the
vacuum pressure maintained by jet ejector and vacuum pump. Here degree polymerization
is near about 60-65. An agitator is attached to the reactor that keeps on revolving in
clockwise direction that stirs up and mixes up the content of the reactor.

The reactor is kept in horizontal supine so as to provide a larger surface area for MEG to
get liberated from the surface of the polymer.

Finisher

The product from PP-2 is then transferred to Finisher with the help of prepolymer feed
pumps. The product temperature at the exit of Finisher is 280 0C. The vacuum level in
Finisher is fine and is around 1.22-1.5 mbar (abs). In Finisher, the vacuum is achieved with
the help of EG vapour jet ejector and the vacuum pumps (Rotajector). Here degree
polymerization is near about 99.9%. During the process of polycondensation the excess EG
keeps getting liberated which in turn keeps increasing the viscosity of the polymer.

In PP-2 and Finisher the EG liberation is enhanced by the polymer film formation due to the
agitation of the contents. Thus at PP-1, PP-2 and Finisher outlets the Intrinsic Viscosity (IV)
are around 0.18, 0.27 and 0.61-.63 dl /g respectively. The EG that liberates in the
polycondensation steps is condensed in the scrapper-condenser of each polycondensation
loop and recycled to paste preparation vessel, ES-1 and ES-2 reactor.

Process Column (PC)

The MEG vapours in plant 2 go along with water vapours from both ES-1 and ES-2
go into the process column where the water is distilled and taken out as distillate. A portion
from the reflux vessel where the distillate gets collected is recycled to the process column
20
and the rest is sent to the effluent treatment plant. The EG obtained, one part is transferred
into the paste preparation tank and another part goes to the EG tank. Here the average temp
of the process column is to maintained 1300C to 1450C. In this process column number of
trays is 16 and we used bubble cap trays.

Cutter and Chips production:

From the Finisher the polymer under pressure comes to gear pump with the help of gear
pump It goes via 4-way valve to the respective filter to Cutter.

Each filter has 79 candles or filter elements with 40-micron mesh size, these filters filter
contaminants coming with raw materials and in process generated.

Then the filtered polymer goes to a section known as Cutter where there are 112 holes,
here the polymer comes in contact with demineralize water (if DM water is not used the
polymer would get oxidized resulting in yellow coloration of chips).

DM water to each cutter is supplied in three ways 1st the overflow water which comes
from the back side at a flow rate of 7 m3 /h, 2nd sprayed from the nozzle at a rate of 15
m3 /h. Here the polymeric strands get solidified coming in contact with water fed to cutters
where thus chips are produced.

Thereafter chips conveyed using conveyor water at a rate of 22 m3 /h to dryer where chips
get dried and screened in classifier accordingly so that the large size crystal can be
separated in a separate bag. This product is amorphous PET (APET) having crystallinity 5%
to 10% and IV is around 0.61-.63 dl /g. The molecular weight of APET is around 18000-
20000. This product is then sent to another section Solid State Polycondensation (SSP) for
further IV build up. Sometimes APET may also be sold. Before being sent to the SSP unit the
chips are stored in Amorphous pet silos.

SOLID STATE POLYCONDENSATION (SSP)

According to the post-SSP method, after polycondensation in the melt phase, the
molecular weight of the resultant polymer is further increased in the solid-state
polycondensation.
SSP is also an efficient recycling technique through which the molecular weight of
the postconsumer polymer such as PET is increased, and the resulting material can
be processed without mechanical properties deterioration.

21
The flow diagram of the process:

Used in the final stages of some polymer production processes (e.g., nylon, polyester and
polycarbonate production) to produce very high molecular weight polymers.
Molten low molecular-weight polymer is cooled and formed into solid particles (by
extrusion or by spray drying).
In the solid-state reactor, the pellets are held at temperatures above the glass transition
temperature (but <TM) so that functional end groups are sufficiently mobile to react.
The by-product is removed by applying high vacuum or with an inert gas stream (e.g.,
nitrogen).
The low temperatures make it advantageous for production of polymers that are prone to
thermal degradation.
The polymerization rate is very low residence times in solid-state polymerization reactors
are long.
. This process is affected by the following parameters: the rate of the reversible chemical
reaction, the diffusion rate of the reaction by-products through the polymer matrix to
the particles surface, the diffusion rate of the reaction by-products from the particle
surface to the gas.

Precrystallizer
The precystallizer is a non- vibrated fluidized solid bed cross flow type where air is blown
from bottom to top and granules are held by a special perforated sheet and forwarded from
side to side.

The amorphous PET with IV 0.61-.63 dl/gm is processed in SSP to get an IV lift up to 0.880
dl/gm or mores per market demand. We have two SSP lines A&B each of 240 tons/day. The
amorphous PET chips are conveyed into chip dosing vessel depending upon the
requirement.

The chips flow by gravity via a rotary lock feeder into the precrystallizer. Here the chips are
fluidized by hot N2 increasing the chips temperature to 180 0C. Owing to high turbulence
of chips in the fluidized bed and due to the residence time (around 15 minutes) the chip
gets crystallized to a crystallinity level of 40%-42%. Here one Precrystallizer cyclone is
present to remove the dust particle. The crystallization process is highly exothermic and
may result in the lump formation of chips in the precrystallizer inlet. The operation of the
22
precrystallizer is carried out by optimizing the N2 gas temperature and flow. In the first
and second zone the temperature and flow rates are around 150 0C, 26000m3/hr and 180
0C, 12000m3/hr respectively. The circulating N2 gas is heated up in a finned tube heat

exchanger with liquid HTM flowing through the tubes.

First Crystallizer
The precrystallizer product (chips) then comes into First crystallizer by gravity. In the First
crystallizer. We have, two paddles rotating in opposite direction and with liquid HTM
flowing through the paddles from inside. A negative slope to facilitate better chips
movement towards the outlets. Jacket of the crystallizer heated up with liquid HTM. Sweep
N2 to carry away the chips dust caused by the rotation of the paddles. The chips at the inlet
are at around 189-190oC and the outlet at around 191-192oC maximum.

Second Crystallizer:
The First crystallizer product then comes into another crystallizer called as Second
crystallizer. In second crystallizer N2 flows in a direction that is opposite to the falling
chips from First crystallizer. The chips at the inlet of second crystallizer are at around 205-
207oC and the outlet at around 208-210oC.

23
SSP Reactor:
The final crystallizer product (chips) then comes into SSP reactor. In the crystallizer the
chips fall from the top to bottom and heating material (hot Nitrogen) goes from bottom to
top. As the temp of the chips changes, viscosity changes. The average temp of the reactor is
205 0C -210 0C and the residence time in the reactor 14~18 hours (depending upon the IV
of the products) and the Nitrogen gas flow rate is 3200-3500 Nm3/hr. The IV of the chips
is increased here in the SSP reactor up to 0.75 dl/gm or more.

24
The rise in IV in SSP reactor is influenced by-

(1) Initial IV of the base chips

(2) Catalyst concentration

(3) Carboxylic end group

(4) Chip size

(5) Residence time

(6) N2 gas flow to the reactor

(7) Dew point of circulating N2 gas

(8) Temperature

In all these 4 units i.e. precrystallizer, first crystallizer, second crystalliser, SSP reactor the
surface EG is removed from the crystalline substances at high temp (400 oC) is as follows:

25
 Nitrogen Purification Unit (NPU)
The Nitrogen in plant 2 at (low temp) which comes from precrystallizer, final crystallizer,
two units is passed through an economizer (1) and is heated by the Nitrogen coming from
the oxidation unit. It is then passed through an electrical heater (as per reaction temp
requirement) and goes to oxidation reaction unit which contain Pt catalyst by means of a
pump.

N2 carries out surface EG from chips and following reaction takes place;

CH2OH-CH2OH CH3CHO H2O + CO2

(Pt catalyst and high temperature) (350~375degree Celsius)

BAGGING OF PET

There are 8 PET storage silo 4 for amorphous chips and 4 for crystalline. The bagging
section consist of total 6 filling sections four for the crystalline chips and two for
amorphous chips. The volume of amorphous silos are 1000m3 (2 silos) and 300m3 (2silos)
and the volume of the crystalline Pet chips silo are 500(2silos and 250 m3 (2 Silos). The
grades are according to the I.V. of the chips which is set according to the market demand.
For crystalline there are five grades 18C, 19C, 20C, 21C and 21CF having label colour
blue, green, white, red and white with red stripes respectively and for amorphous it has
only one grade i.e. 16C. bagging is done in different weights depending upon the demand
it consists of mainly 25kg, 1tone,1.05 tone, 1.1 tone and 1.15 tone bags.

The jumbo bags are hooked on 4 sides with pneumatic air cylinders and filling rate
is 50 kg per dump and total is 23 dumps for ASPET bagging and 20 dumps for APET
bagging and bagged. Each bag has a barcode describing its filling section, date, month, year
and bag number for example consider the bar code given below

26
It can be decoded as-

Q Describes the bagging section

17 It gives the year that is 2017

U- Month (June)

27- Date

0080- Gives the bag number

There are four filling sections for crystalline having a specific latter assign namely T, R, Q
and S and for amorphous filling section letter O is assign. For months the letter which is
written in front of the corresponding name of the month is used, the list is given bellow-

January-Z

February-Y

March- X

April- W

May- V

June - U

July - T

August S

September R

October Q

November- P

December O

In case of 25 kg bags they are kept in lots each lot consist of 440 bags and the total weight
of single lot is 11 tons. Each ton has 40 bags and a barcode. On the bag numbers along

27
with the letter describing lot number and PET grade are written on it, the letter describing
the grade are

Y-21C X-20C

Z-22CJ W- 19C

For example, consider Y0481 here Y tells the grade and 0481 tells the lot number.

After filling the bags are sealed and kept at specific location in the bagging area. The whole
bagging area is divided into 4 columns A, B, C, and D ranging from right to left respectively
and in 13 rows from 1 to 13. Each bag is kept at specific location to avoid mixing of a bag
with a particular grade with other bags having different grade and easy loading and
unloading of bags into the trucks

Parameter, Units, Specifications and Tolerance

Different specifications of the bags in plant 2:

28
 PRODUCT SPECIFICATION

Parameters Unit 16C 19C 20C 21C 21CF

Intrinsic dl/gm 0.625 0.76 0.80+/- 0.84+/- 0.84+/-
Viscosity +/-0.01 +/-0.02 0.02 0.02 0.02
Carboxylic meq/kg 35 max 30 max 30 max 30max 30max
end group
Acetaldehyde ppm -- 1 1 1 1

Crystallinity % -- >50 >50 >50 >50

Dust content ppm 25 100 100 100 100

max max max max
Moisture ppm 2500 2500 2500 2500 2500
Content max max max max max
Chips gm 3.13 1.7 1.7 1.7 1.7
Weight per +/-
100
Melting Point oc 254+/-2 248+/- 248+/- 248+/- 248+/-
2 2 2 2
L Color % >75 >90 >90 >90 +/-90

B Color % -3 to -2 -0.5 to - -3 to -2 -3 to -2 -3 to -2
1.2

APPLICATIONS:

Grade Application

16WO1 PET films (BOPET) PET calendared sheet, Crisp

packaging, Audio-Video tapes, X-ray films, Adhesive
tapes, Antistatic packaging

AS19C Mineral water bottle, Small jars

29
AS20C Alcoholic beverage, pharmaceutical product bottle, wide
mouth jars
AS21C Coca-Cola, PepsiCo bottle, APET sheets

AS21CF CSD, Still/sparkling water bottle

AS22CJ 20 liter/5 gallon mineral water jar, thick wall performs

AS25H Fiber preparation

AS20HF Preparation of hot-fill bottle

SAFETY DEPARTMENT
Safety is the one of most important thing in the industrial plant. Safety should be on the
priority for any work we do. Ignoring the safety is increasing the chances of accidents. In
IVL Dhunseri, there is a department for safety named as Fire & Safety Department. Total
ten persons are in the department.

It is intended to help an organization to control occupational health and safety risks. It was
developed in response to widespread demand for a recognized standard against which to be
certified and assessed, reduce the potential for accidents, aid legislative compliance and
improve overall performance.

As per the plant operations, any accident should be reported immediately to fire and safety
department. Training is given by safety department to the persons working in the plant at
different intervals. Safety shoes and helmet is necessary in the plant. Pictorial diagram are
30
placed at various places in the plant regarding safety. Pictorial diagram are easy to
understand.

The main aim of safety department is ZERO ACCIDENTS. It includes man, material and
money protection.
Personal protective equipment, also known as PPEs are used by the workers. Different types
of PPEs are

Safety shoes
Helmet
Heat resistance hand gloves
Cut proof hand gloves
Electric proof hand gloves
Leather hand gloves
Multipurpose gas cartridge
Gas full face mask
Gas half face mask
Dust mask
Protective glasses for eye protection
Self-cleaning breathing apparatus
Ear plug

There are various others protective equipment. Using PPE is the best option for prevention
from accidents.

There are two types of work done in plant: routine work and non-routine work. Routine
work is done daily such as loading and unloading of oil, loading of finished product etc.
Required safety is enough and doesnt need inspection from safety department.

QUALITY CONTROL (QC) & QUALITY ASSURANCE

Quality Assurance (QA) is a way of preventing mistakes or defects in manufactured
products and avoiding problems when delivering solutions or services to customers. QA is
applied to physical products in pre-production to verify what will be made meets
specifications and requirements, and during manufacturing production runs by validating
lot samples meet specified quality controls. QA is also applied to software to verify that
features and functionality meet business objectives, and that code is relatively bug free prior
to shipping or releasing new software products and versions.

31
32
 Quality Policy of DPL
At DPL, It committed to customer satisfaction. It shall meet customer needs and
expectations by timely delivery of quality products through continual improvement of
technology, infrastructure and work environment with innovation and total participation.

Quality Assurance Dept. Works

QC & QA department is one of the most important department of any organization or
industry. QC & QA helps to check the properties of running product and maintain the
required standard. This dept. also checks and tests the effect of new substitute of chemicals
in our product. In IVL Dhunseri we follow the SQC (Six sigma quality control) for the best
and accurate result of our finished product for our customer, which is the priority of the
IVL Dhunseri. By following six sigma quality control we improve the quality of our product
upto 99.99%.
QAD tests the different properties of every batch of finished PET to maintain the standard. It
follows the ASTM (American Standard for Testing and Material) testing standard. Following
tests are performed by QC & QA.

33
 Acid Number of PTA & IPA Sample
Determination of Moisture Content in Incoming and In process Sample
Determination of particle size of incoming PTA & IPA sample
Determination of colour values of incoming material (PTA, IPA, ATA etc.)
determination of ash content of incoming sample (raw material and finish PDTS.)
Determination of Iron content of Incoming sample like PTA, TPA, MEG, DEG,
H3PO4, water sample by UV Spectrometer
Determination of percentage UV Transmittance of MEG for all MEG samples
received through tankers, ship, in process sample
Determination of Acid Number of MEG & DEG
Determination of Aldehyde content in MEG tanker/process
Determination of DEG in MEG (MEG in process MEG sample)
Determination of IV (intrinsic viscosity) of polymer
Determination of crystallinity of PET resin of all process samples (precrystallizer,
final crystallizer, cooler deduster, reactor, finished product )
Determination of pH in water sample
Determination of Carboxyl end group in polymer & base/SSP resin
Determination n conductivity & TDS in water sample
Determination of free glycol in process column and reflux water

Acid Number of PTA & IPA Sample

The known quantity of PTA /IPA sample is dissolved in di-methyl formaldehyde and titrated
against NaOH
Indicator = phenolphthalein
Low pH = colourless,
. pH- 8 =pink,
. pH- 10 =red

Acid No = ((A-B)N56.01)/N

Where, A = NaOH spent for sample

B = NaOH spent for blank
N = Normality of NaOH

Determination of Acid Number of MEG & DEG

The known quantity of MEG/DEG is dissolved in demineralised water and titrated against
aqueous NaOH solution.

R-COOH + KOH R-COOK + H2O

Acid No. = (V-v)N56.11/W

Where,
V = volume of 0.02 (N) NaOH spent for sample
v = volume of 0.02 (N) NaOH spent for blank
N = normality of 0.02 (N) NaOH
W= weight of sample in gm
Acid no is determined to know the extent of reaction in ES1 & ES2.

34
 Determination of IV (intrinsic viscosity) of polymer
For process sample and finished product (ES-1, ES-2, PP-1, PP-2, Amorphous, SSP resin and
finished product)

Equipment: Ubbelhode viscometer (capillary tube type)

The polymer is dissolved in a mixture of phenol and 1,2-dichlorobenzene solvent where

upon time of flow is determined in a Ubbelhode viscometer. The relative viscosity is
obtained from quotient of the time of flow of the polymer solution (t) and that of pure
solvent (t0). As,

rel =s / o = t / to

The relative viscosity is linked with intrinsic viscosity via Bill Meyers equation-

intr = 1/4 (rel -1) / C + ln (rel) /C

The intrinsic viscosity is defined as the limiting value of the ratio of logarithm of the relative
solution viscosity to the concentration, C of the polymer in the solution for C against 0

Lt intr = Lt (ln(rel) /C)

C0

It depends on the solvent, the temperature at which the relative viscosity is determined and
on the concentration C which is to be shown in gm/lit.
In this method of analysis the relative solution viscosity is determined at concentration C is
equal to 0.5 up to 0.65 gm/lit.

Calculation
Determination of relative viscosity-

Irel = t1 / to
Where,
t1 = mean time of flow of polymer, sec
to = mean time of flow of solvent, sec

Intrinsic viscosity = F / (weight of polymer in kg)

Factor F is available from standard table

Determination of crystallinity of PET resin of all

process samples
Density of polymer chips is measured with a floating method by comparison in a density
gradient column with an inert and wetting liquid. From the resulting density crystallinity
can be calculated using density values for totally crystalline PTA & for totally amorphous
PTA from literature.

% of crystallinity = (1.455Density-1.938) / (Density0.143) 100

35
 PLANT UTILITY

A reliable and efficient performance of utility plants is of high importance in order to

save costs in the industrial production processes. IVL Dhunseri ensures that the
utility plant is optimally adapted to match their process steam and water
consumption profile. It encompasses following components;

1. Water treatment plant

2. Air compressor

3. Cooling tower

4. Effluent Treatment Plant

5. Nitrogen storage

6. Chilled water

In the following discussion we have describe the water treatment plant, effluent treatment
plant and cooling tower in details.

WATER TREATMENT PLANT:

The water that is treated over here is supplied by Haldia Development Authority (HDA).
This water is stored in two sumps where sodium hypochlorite (NaOCl) is dosed to remove
the algae & bacteria present in the water. Then the water is pumped and it enters a
multicapacity sand bed filter. Before entering the filter bed, FeSO4 is dosed into it which
acts as a coagulant and flocculation takes place. It also helps in precipitation of calcium
bicarbonate salts. All the precipitated calcium salts and the flocs formed are then filtered in
the filter bed. The outlet of the filter bed contains reduced calcium and less TSS (Total

36
suspended solids). Then the filtrate enters the activated carbon filter where the excess
chlorine which was unutilized is removed. This filter bed also removes any colour or odour
if present in water. Thereafter the filtrate goes through a pipeline where Sodium
hexametaphosphate (SHMP) AND Sodium metabisulphite (SMBS) are added. SHMP acts as
an antiscalant whereas SMBS removes the chlorine, if any, present in the system which is
not removed by activated carbon filter. Here the chlorine should be maintained at 0 ppm
level or else the membrane (which is used in Reversed Osmosis) may get oxidize
completely. From here the activated filter the goes to a micro filter for further purification.
From here the line gets divided into two sections-

1. One of which goes to the drinking water supply after chlorine dosing.

2. another goes to the reverse osmosis(R.O.) columns for its softening

R.O. columns contain layers of semi permeable membranes usually made of cellulose
acetate or polyamides. The hard water after passing through the membranes is separated
into two parts, one part which has greater flow rate and lower conc. is the desired soft
water and is called the permeate, the other part called the rejecters has lower flow rates but
higher conc. of salts. One part of the soft water is stored in soft water storage tank used as
make up water in cooling tower. And another part goes to the demineralization plant (D.M
plant). Here the soft water having lesser TDS & TSS is then passed through a degasser tower
which is nothing but a packed tower where the carbonate load is reduced and then the
water is send to a mixed bed (containing both cation and anion exchange resins) .
Dematerialized water used in cutting section as mentioned earlier.

The D.M. water produced meets the following criteria:

1. pH=6.5~7.0

2. Conductivity<0.2 microsemens/cm

3. Silica<0.02 ppm 4. Hardness=0.0

This water is stored in the D.M. water storage tank.

37
 FLOW DIAGRAM OF WATER TREATMENT PLANT

COOLING TOWERS
The heated water from the plant returning to the top of the cooling tower (hot water deck)
through a header. From this the water is distributed to individual cells through the
distributor valves. The valve is throttled accordingly to get constant flow in each cell. The
cooling tower is an Induced draft cross flow one where the water from individual cells are
divided into fine droplets use in distributor nozzles and GRP made V supports and the air
is sucked from the sides of the tower using four fans located at the top of the tower. Here
both heat and mass transfer takes place simultaneously, the temperature of the water is
cooled down from 380C to 330C.

Four types of losses generally occur here

1. Evaporation loss

2. Windage loss

3. Drift loss

4. Blow down

38
 Two entrainment catchers are there in each cell to reduce drift loss and mainly the blow
down loss is taken care of by adding soft water as and when required.

EFFLUENT TREATMENT PLANT (ETP)

ETP (Effluent Treatment Plant) is a process design for treating the industrial waste water for
its reuse or safe disposal to the environment.

Need of ETP
To clean industry effluent and recycle it for further use.
To reduce the usage of fresh/potable water in Industries.
To cut expenditure on water procurement.
To meet the Standards for emission or discharge of environmental pollutants from
various Industries set by the Government and avoid hefty penalties.
To safeguard environment against pollution and contribute in sustainable
development.

Treatment mechanisms:

Physical Chemical Biological

39
Different parts in ETP:

(1) SCREEN CHAMBER

Screen chamber is inlet for the ETP which is used as a storage tank for the effluent water
coming out from the plant. The pH at ETP inlet is between 6.5-8.0. The temperature of the
effluent water at inlet is about 60c.

(2) OIL AND GREASE TRAP:

40
The mixed effluent from screen chamber is pumped with the help of FRP Pumps to oil and
grease trap. Main function of this chamber is to remove the oil and grease from effluent
water.

To trap the oil and grease, we use a conveying system with 2 motors and a leather belt.
When motors start rotating grease and oil from water gets trap with the belt and water
moves forward towards the equalization tank.

(3) EQALIZATION TANK:

The water streams coming continuously shall be collected in the equalization tank. An air
grid is provided in this tank to blow air with the help of air blower. This is to keep the solids
in suspension and avoid settling in this tank. The inlet pH of the effluent is expected to be in
the range of 7.5~8.0. The effluent flows to a equalisation tank where the pH is indicated by
a pH indicator and liquid (base) is dosed to maintain pH which is mainly NaOH. Purpose of
this tank is to maintain certain alkalinity level in the effluent. The mixed effluent from
equalization tank is pumped with the help of FRP pumps to conventional aeration tank.
Depending on the raw effluent characteristics nutrient dosing will be done for best
microbial development.

(4) CONVENTIONAL AERATION TANK:

The effluent is pumped from the equalization tank into conventional aeration tank (CAT).
The effluent is then pumped to a CAT for degradation of organic matter by anaerobic
bacteria where major portion of BOD& COD is reduced. The CAT works on the principle of
degradation of organic matter within sludge bed situated at the bottom of the reactor. The
anaerobic bacteria present in sludge bed come in the bottom of the tank. The Anaerobic
bacteria present in the sludge bed come in intimate contact with the organics, which are
reduced to low molecular fatty acids. These fatty acids are then converted to simpler end
products such as CO2, CH4 gas, H2O molecules and more bacteria. Urea and DSP are
added to effluent as a food to anaerobic bacteria.

The CAT consists of3 agitators for mixing up the effluent. The pH of sludge in CAT is about
7.8-8.8. The sludge and water from the CAT is then pumped to clarifier A.

(5) CLARIFIER A:
The sludge and water from the CAT is pumped to the clarifier A. Clarifier A consists of a
single agitators which helps in slowly agitating the effluent. In the clarifier A, sludge being
heavy gets settle down in the bottom and water stores on the upper portion of clarifier A.
Here the sludge which is in the suspended form settled down &recirculated to aeration
tank. If the MLSS of the aeration tank increases beyond limits, then the settled sludge is
thrown out of the system with the help of PUMP. The sludge from clarifier A is recycled by
pumping it to the CAT. The excess amount of sludge is pumped to sludge thickener for
further treatment. The water from clarifier A is pumped to Extended aeration tank. The pH
on the outlet of clarifier A is between 7.0-8.0.

41
(6) EXTENDED AERATION TANK (EAT):
. The effluent treated, then is pumped to EAT wherein further degradation of COD/BOD
takes place anaerobically in a similar fashion as that of CAT. The EAT consists of 2 agitators
for mixing. The Ph of sludge in EAT is about 7.8-8.8. The sludge and water from the EAT is
then pumped to clarifier B.

(7) CLARIFIER B:
The sludge and water from the EAT is pumped to the clarifier B. Clarifier B consists of a
single agitator which helps in slowly agitating the effluent. In the clarifier B, sludge being
heavy gets settle down in the bottom and water stores on the upper portion of clarifier B.
Here the sludge which is in the suspended form settled down &recirculated to aeration
tank. If the MLSS of the aeration tank increases beyond limits, then the settled sludge is
thrown out of the system with the help of PUMP. The sludge from clarifier B is recycled by
pumping it to the EAT. The excess amount of sludge is pumped to sludge thickener for
further treatment. The water from clarifier B is pumped to FLASH MIXER. The pH on the
outlet of clarifier A is between 7.0-8.0.

(8) FLASH MIXER:

Flash mixer is temporary storage type tank which is used for storing water coming out from
Clarifier B. The water from the Flash mixer is pumped to flocculator.

(9) FLOCCULATOR:
. In the Flocculator., sludge being heavy gets settle down in the bottom and water stores on
the upper portion of Flocculator. Here the sludge which is in the suspended form settled
down & pumped to sludge thickener. The water from Flocculator. is pumped to PSF FEED
SUMP. The pH on the outlet of Flocculator is between 7.0-8.0.

(10) PSF FEED SUMP:

This is outlet for the ETP from where we get purified water. It consists of filter with a
membrane which separates the water from sludge Purified water can be used further in
processing.

(11) SLUDGE THICKNER:

SLUDGE THICKNER is a storage tank for the sludge generated from Clarifier A, Clarifier B
&Flocculator. Sludge is transferred to the FILTER PRESS with the help of pump.

(12) FILTER PRESS:

The sludge generated from Clarifier A, Clarifier B & Flocculator would be taken to
FILTERPRESS. The objective of filter press is remove moisture from sludge. Water/moisture
is removed from the sludge and converted into cake form.

42
COAL HEATER
In Coal Heater the heat created and the ash discharge line is shown in the following flowsheet

Combustion Chamber Furnace(Bed)

In this coal heater as a media Therminol 66 is used. Here first present a fluidized bed of sand. At
first Flue gas is supplied from the Forced Draft fan to the bed and from the upper portion of the bed
coal grinds has been sprayed and by the help of matches first time fire is flow through the bed. By
the help of coal, the fire is continuously flow. Here sand is used for equal distribution of the
temperature and it also contains the heat. In bed temperature remains 306.7 oC. The temperature of
Therminol 66 maintained 330C. The flow of the oil is maintained at 850-900m3/hr and the
pressure is 45kg/m2. In the bed there is four section, this is because to maintain the fire and the
heat. This four section have total 1500 nozzles each have 375 nozzles and each nozzle have 12
holes for the flue gas pass. Here level is maintained from 420 -460 mm wc. The inlet pressure is
11.5kg/cm2 and the outlet pressure is 8.5kg/cm2 approximately.

43
 Heat Exchanger
From the bed the Therminol oil go to the Heat Exchanger and here present coils inside the heat
exchanger and 8 coils are present those coils are made up of copper. When the oil come out from
the furnace it has low temperature and in the heat exchanger its temperature increases near about
20oC i.e. 320oC.In the bottom of the heat exchanger present a fly ash settling chamber and here fly
ash is collected and from here by Slot Chain Conveyer which have some plate type setting and by
this ash is send to the Silo where water is sprayed to the ash so that it will not fly

in the atmosphere. Here two motors are also used. In Heat Exchanger inlet pressure is 8.5kg/cm2
and the outlet pressure is 6.9kg/cm2 approximately.

Membrane Panel
From the Heat Exchanger, the heated oil then goes to the membrane panel which is situated at the
top of the furnace and this membrane is heated by the Furnace, Coils, Heat Exchanger and here
temperature becomes 324oC and from here heat went to the plant and stored to the expansion
tanks.

Boiler
The main function of the boiler is to heat water and produce steam. Here the shell and tube type
boiler is used. From the shell side water is passed and from the tube side flue gas is passed. Here
water became steam continuously and for this water is supplied from the water tank. Here
temperature remain 120^oC.

Air Pre-Heater
From the Boiler the flue gas goes to the air pre heater and there the flue gas temperature became
33^oC. The main purpose of the APH is to recover the heat from the boiler flue gas which increase
the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas.

Bag Filter/ Cyclo Max

From the APH the flue gas now went to the Bag Filter or if the Bag Filter does not work then went to
the Cyclo Max. In bag Filter coal dust is collected from flue gas and before bag Filter there is a Inlet
cum bypass dumper valve is used. After that there is an ID (Induced Draft fan) which consume air.

Heater
Chimney
After the Bag Filter the ash is send to the chimney, and from that the extra ash is send to the
atmosphere.

44
FUEL OIL HEATER

Normally the heating is done by the help of coal heater but FO heaters are kept in standby.
There are two heaters and there are 3 FO pumps working 2 at a time and 1 is kept in
standby. Each FO heater has a burner assembly mounted on it, the burner assembly consist
of the following things-
Camp
A cylindrical gun
FO supply line
FO return line
Two bypass line
Oil regulator
Flame sensor
Servo motor
Each HTM heater has five coils and each coil has two turns through which the HTM which has
lost some of its heat in the process (temp around 280-degree C, pressures around 2.5 bars) is
circulated. FO coming from FO yard at3.5bar pressure through pipelines enters a separator and
pumped to the top of the heater using screw pumps at around 20 bar pressure and by means FO
guns atomization takes place. Otherwise if the droplet of FO is large, soon deposition and

45
incomplete combustion might occur. The flow is concerned by means of FO supply line. When not
in operation these twos.

valves are closed while another ring is opened which allows a bypass., the FO to circulate in a
closed loop. The supply of air is maintained by the help of camp. Once the LPG is sprayed by
means of separate gun and due to high voltage (11000 volts) applied across the electrode adjacent
to the FO gun and the spark is produced called pilot flame, the FO supply line is opened and FO is
allowed in. The fuel is burned by the help of this flame. The temp of the heater is controlled by
controlling the servo motor which control flow of both air and oil at minimum opining (12%) the
rate is 350 kg/hr. and with the help of diffuser plate which is used for the movement of the gun
and situated just below the burner which is situated below gun. In this process HTM gets heated
up and is recirculate to the plant. A flame sensor is used to sense the flame of the heater. The HTM
after heating attains a temp of around 330 C and pressure of 6 bars and sent to the process section
and also the heated gasses are sent to the air preheater where it gets mixed with the atmospheric
air coming from the blower and heat it and the heated air is again sent to the heater and the
remaining is sent to the chimney to dispose to the atmosphere.

FO heater parameter
Model- TP-80HT

Output-80, 00,000kcal/hr. or 4.3 MW

Fuel- FO (furnace oil)

Max temperature- 330 0c

46
 FUTURE OF DHUNSERI PETROCHEM LTD.
With IVL Dhunseris achievement of a high degree of self-reliance in polymer
technology, IVL Dhunseri is poised for a bright future. All out action have been
taken for capacity augmentation, increase in polymeric production, value
addition, cost reduction for obtaining higher margins and improving
productivity. All environment friendly projects with latest technology are
being incorporated to meet the challenge posed by other technologies. IVL
Dhunseri will continue to play a significant role in meeting the vital needs of
polymeric products in the country and abroad.

(CUTTER-DEMINERALISED WATER SYSTEM)

In cutter section, we know that De mineral water (DM WATER) is
used to withdraw heat from the polymer formed, so that it may
crystallize and we can get crystallized product but in the way of
cooling the polymer, the DM water gets heated and we have to
withdraw this extra heat by plate type heat exchanger in order to
maintain the cycle. For this reason, we use cooling water. We must
determine number of plates and outlet target temperature of DM water
less than 34 c.

GIVEN DATA-
POLYMER:

flow rate(m)=33541.56 kg/hour

Specific heat capacity=2.299kj/kgc

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Polymer inlet temperature in cutter: 286.3c

Polymer outlet temperature in cutter: 40c

Chilled water flow rate(m)=1000 m3/hr

Chilled water inlet temperature=11.5c

Cooling water outlet temperature=15.8c

DM water flow rate(m)=169 m3/hr

DM water inlet temperature=42c

DM water outlet temperature=34c

(take co-current process)

OBJECTIVES:

1.NUMBER OF PLATES USED-to be determined.

Data taken:

Density of water at 42c=989.1kg/m3

Density of water at 34c=995kg/m3

Heat capacity of water at 42c=4.18kj/kg k

Heat capacity of water at 34c=4.178kj/kg k

Thermal conductivity of water=0.58w/m k

Calculation

Polymer heat load=m*Cp*T

=9.3171x2.299x246.23
=5274.249kW

There is a heat loss of 10% to the surrounding,

Therefore, heat load to the heat exchanger=4746.824kw

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Heat liberated by polymer shall be accepted by DM water employed.

Therefore, Q=MCp(dT)

4746.824 = 188 x 989.1 x 4.179xdT

dT= 21.9044c

DM water Outlet temperature from cutter = 56.1c

This is the temperature of DM water inlet flow in heat exchanger 1.

Let the intermediate temperature between the heat exchangers be 42c.

Now, LMTD= (42-11.5) (34-15.8)/ ln ((42-11.5)/(34-15.8)) = 23.82c

The heat taken up by the second exchanger = heat taken up by the polymer- heat
taken up by the second exchanger

Heat taken up by the second exchanger = 4746.824 3022 =1724.824 kW

Assume overall heat transfer coefficient=5000 w/m2c (for water-water system

& no phase change)

Q=U*A*LMTD

Area available,

172.824x1000=5000xAx23.823

A=14.480 m2

Area of a single plate=(0.4344)m2

Number of plate= 34

So, no of channel=(34-1)/2=17 (approx)

For DM water :
Let total flow rate loss in the first heat exchanger be 10% of the total flow.

Therefore,

Channel flow rate=169 m^3/hr

Hence channel velocity,

=Q/A

= (169/3600x3x0.48x17)x1000 m/sec
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=1.9176 m/s

Re=989.1*1.9176*3*10^(-3)/0.5102*10^(-3)

=11152.72

Pr=0.5102*10^(-3)*4.179*1000/0.58

=3.6787

Nu=0.023*(11152.72)0.8*(3.6787).3

=58.79

Therefore, hdm= 11366.0W w/m2c

For COOLING WATER :

Flow rate=1000 m3/hr

Velocity= 1000/0.001*3*3600*0.48*17

=11.347 m/sec

Re= 998.2*11.347*3*10^(-3)/0.7438*10^(-3)

=15227.985

Pr=0.7488*10^(-3)*4.178*1000/0.58

=5.61

Nu=0.023*(15227.985)0.8*(5.61)0.4

=101.722

Therefore, hc=19666.25 w/mc

Thickness of plate=3mm & thermal conductivity of Stainless Steel=15.2 w/mc

CALCULATION OF HEAT TRANSFER COFFICIENT: -

(1/U) = (1/19666.25) + (3*10^(-3)/15.2)+ 1/11366.06)

U=2974.5094 w/m2c

(This value of overall heat transfer coefficient is a bit lower than the assumption
made)

Area available = (1724.824*1000)/ (23.823 * 2974.5094)

=24.34 m2
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Area of a single plate= 0.4344 m2

Number of plates= 24.34/0.4344= 55.32=56 (approx)

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