Contents: 10. " 12. 18. 14 46. 16. 17 GENERAL PROCESS DESCRIPTION ‘All Sections Section 11 Section 11 Section 13 Section 13 Section 15 Section 18 Section 20 Section 20722 ‘Section22 Section24 Section 28 Section 28 Section2 Section 33 Section 37 ‘Section 38, Commonly used equipment / item number philosophy PTA Feeding, Storage and Transport PIA Unloading and Storage EG Storage, Feeding and Distribution DEG Storage and Feeding Catalyst, Stabilzer and Toner Preparation Raw Material Mixing ESPREE reactor ‘Spray System PE, PP & DC DISCAGE reactor Vacuum System Melt Distribution and Fitation Chip Production Chip Conditioning Chips Storage and Bagging ‘Spent EG Collection Flakes Depolymerisation Uhde Inventa-Fischer [EY BAG | GENERAL PROCESS DESCRIPTION ls. P| esa ease rr0-t00 [ol wes leer AC [ieee ORR ot4. Commonly used equipment! itom number philosophy This process description describes the PET production for line At and line a2. Vatious sections of the polycondensation plant are designed to serve production plant A1 as well as second production plant AZ . Such common sections are dasignated as AO. ‘The equipment in the process description is marked as follows: prefix AD equipment which will serve ine A1 and A2 (common equipment), €.9, A0-37890 y i i ul i prefix Ax equipment which will serve individual fines ~ xis considered as 1 forline At only + xis considered as 2 for line A2 only ERGY BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|s=:. | 0s.12|[ ¢-4054/ra-+1000 |o] Dies leer ice thie a/R2 PTAFeedit ‘Section 11; FFD No. ZL-11014 Basic Objective PTA is supplied in buik containers or big bags alternatively and conveyed by 1 chain transport system AO-11034 to the PTA intermediate storage slo AO- 111858, The irtermediate storage sllo AD-1 1858 serves for plant At and A2. ‘The blanketing gas is nitrogen, which is fed to the PTA intermediate storage silo as well as PTA storage silo and leaves the system via the vent iter on the PTA feeding slo. ‘Major Equipment | i f | i i AD-11833 VENT BLOWER {or aspiration of PTA receiving slo 11833 A0-11033_PTAFEEDING STATION for emptying big bags: ‘AO-11F33. VENT FILTER {or separation PTA dust AO-1F58 VENT FILTER for pneumatic transport ‘AO-1IMS8— PTASCREEN to remove coarse foreign material from PTA, AO-11F53 — PTASCREEN to remove coarse foreign material from PTA ‘A0-11032 BAG LIFTING DEVICE for big bag handling ‘A0-11034 PTACONVEYOR transport section, for conveying of PTA to the PTA silo 11858 ‘A0-11031 TILTING PLATFORM for unloading of 20 feet PTA bulk container A0-11@34 PTACONVEYOR for chain transportation of PTA to storage silos 11858 A0-11833 PTARECEIVER A0-11858 — PTASILO [SR AC [ GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|s2. 2 _[os..a||LE : I i u to receive PTA from big bags or buk container ‘A0-11V32_ INDUSTRIAL VACUUM CLEANER for cleaning of big bags [last BAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|i > _[os.12| (©4056, PB-11000 ol lesser pide | ateProcess Summary Unloading from PTA bulk container The PTA bulk container including trailer is placed on the titing platorm AO- 11031 by a tuck. After decoupling the truck from the taller and connecting the buk container’s outtet with a flexible hose, the tting platform is ited by the hydraulic system A0-110Z31. The PTA flows by gravity into the PTA receiving silo A0-11833, The PTA receiving silo A0-11833 acts as a hopper to ensure thatthe chain conveyor A0-11034 is well filed during conveying, Unloading from bia bags PTA big bags are transported from the storage area near to the PTA receiving silo A0-11D33 by forkit and lied using bag lifting device A0-11032. The 'bags must be cleaned, especially the botiom part of the bags by means of an industrial vacuum cleaner AO-11V32 In order to prevent contamination of the PTA with dt. In total, wo PTA receiving silos are provided, each of them is ‘equipped with four racks (feeding stations), on which the big bags are put down, Simultaneously four big bags can be emptied at once. ‘The PTA receiving silos receives PTA from the big bags and acts as a hopper to ensure that the chain conveyor AD-11035 / A0-11036 is well filed during conveying, PTA chain conveying (common for At and A2) ‘Tne PTA is transported to the target silos A0-11S58 by means of PTA ctiain conveyor A0-11034, Each chain conveyor consists of several sections. Each Section has a slightly higher conveying speed in order to prevent a material blockage, The PTA enters the storage silo A0-11858 via the PTA screen AO- 11M58. The PTA screens serves as a “fter’ to remove coarse foreign material such as plastic stripes etc. from the PTA before it enters into the storage silos. Nitagen is fed to the storage silos A0-11858 (as blanketing) to ‘minimise the oxygen content and leaves the system via chain conveyor AO- 11034 and vent fiter AO-11F58. “The discs of fhe chain conveyor passes through the bottom part of the PTA receiving silo AO-11S33, In this way each single "conveying compartment between the discs is filed with PTA for transportation. The recelving silo AO- 111533 is equipped with a vent fiter A0-11F33 and a vent blower A0-11B33 for aspiration he system, Periodical pulses of air are applied to the fiter bags installed in the vent fie to relieve the PTA dust sticking on the bags surface. Pneumatic transport of PTA from PTA-plant PTA is conveyed to AD-11858 by a closed nitrogen transport loop. The Conveying system must contain less than 10 Vol% oxygen to avoid any dust explosion. For this reason a closed circuit with nitrogen as conveying medium Is used. However, togetner wih the bulk PTA a certain ratio of air enters into the system, A'the outlet of the PTA intermediate so AO-11844 a certain ratio. ‘of nitrogen is lost together with PTA. An oxygen analyser is installed, which feeds fresh nirogen into the suction line of the compressor station in order to keep oxygen content below 4 Vol%. In case of excess oxygen the Rss’ AC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischeri : | i i compressor is shut down, The nitrogen circuit is controlled at a slight ‘overpressure "0 avoid air being sucked into the system. Control Description Chain conveying Emptying of PTA container and PTA big bags is done manually. The PTA chain conveyor system is controlled from a local control board. The chain ‘conveyor Is started and stopped either from the procoss control eystem or preferably in fe field from a local contol board. The RUN / STOP status is displayed on the DCS screen. The conveying speed can only be adjusted from the process control system. The maximum level inthe target silo stops the transport system automatically. Such an interuption is indicated on the local control board and is automatically reset if the level in the target silo is dropped down: ‘The PTA chain conveyors AO-1 1034 are equipped with frequency inverter to adjust its conveying speed according tothe required conveying capacity. The first conveying section has the lowest spoed. Each futher section runs with & slightly higher speed to prevent a PTA blockage in the conveying line. Pneumatic com insport gas) ‘The pneumatic conveying system is controlled from a local control board. The target silo must be selected and the transportation can be started. The ‘compressor, tary valve and the operation of the bypass valve during the Start of the ccmpressor are operated by the PLC logic from the local contro! board. ‘The pressure ofthe nitrogen circuit is controled by a pressure controller with ‘one feeding and one bleeding vaive. ‘An oxygen analyzer checks the oxygen concentration in the retuin gas. In ‘case of high oxygen content, a ball or bleeding valve is opened to biow-off a large quantty of nitrogen into the atmosphere. The system is automatically ‘efiled with fresh nitrogen by the pressure control described above. Uhde Inventa-Fischer |_| 05.12|| c-40s4/8-11000 [0] e104 [umtar GAG | GENERAL PROCESS DESCRIPTION far ge [it@ Main Operating Parameters “The following lst shows approximate values forthe operating parameters. Chain conveyor Conveying prem: Temperate: AO-11S54 PTA storage capacity ‘Pneumatic conveyor (nitrogen) Conveying capaci ‘conveying oa: Conveying pressure: ‘Conveying gos temperature Return gas temperature: ‘approx. 40°000 kg each atmospheric ambient approx. 1600 m® approx kg Hold approx gh Hold approx. 07 barg 30-50°C 50-70°C, [SER BAG [GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|2=. P| o5.12|[_c-408s /e6.11000 |] 1164 jeer fide [e/a3. PIA Feeding, Storage and Transport ‘Section 11; FFD No: ZL-11015 a. Basie Objective PIA is eupplied in big bags and conveyed by a chain transport system AO- 111064 to the PIA sio A0-11S88, The blanketing nitrogen gas fed to the PIA feeding silo leaves the system via the vent filter AO-1 1F63 on the PIA receiver ‘A0-11863, b. Major Equipment A0-1863 VENT BLOWER for aspiration of PIA receiver 11863 ‘A0-411D63_PIAFEEDING STATION for empiying big bags AOAIF63 VENT FILTER for separation PIA dust A0-41064 _PIACHAIN CONVEYOR transport section, for conveying of PIA tothe PIA silo 11868 AO-1863PIARECEIVER to receive PIA from big bags or bulk container AO-11868 PIASILO for siorage of PIA Ramet BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|2 | 05.12|{_ c-40s4/pb.11000 [o) eres leer ode. esj i i E : | : i L Process Summary Unloading from big bags A big bage are traneportad from the storage area near to the PIA receiver ‘A0-11063 by forkift and lifted using bag liftng device A0-11062. The bags ‘must be cleaned, especially the bottom part of the big bag, by means of an industrial vacium cleaner AO-11V62 in order to prevent a contamination of the PIA with dit, One PIA receiver A0-1 1883 is provided, equipped with four racks (feeding stations), on which the big bags are put down. Simultaneously four big bags san be emptied at once. ‘The PTA receiving slo A0-11863 receives the PIA from big bags and acts as ‘a hopper to ensure that the chain conveyor AO-11064 Is well filed during ‘conveying, in (common for At and AQ The PIA is transporied to the target silo A0-11S88 by means of PIA chain conveyor A0-11064, The chain conveyor consists of four sections, Each section has a slightly higher speed in order to prevent a PTA. blockage [Nitrogen is fed to the storage silo AO-11S88 (as blanketing) to minimise the ‘oxygen content and leaves the system via chain conveyor AQ-11064 and vent fter A0-11F63. ‘The discs of the chain conveyor passes through the bottom part of the PIA receiver A0-11883, In this way each single “conveying compartment” between the discs is filed with PIA for transportation. The receiving silo AO- 11863 Is equpped with a vent fier AO-11F63 and a vent blower AO-11853 for aspiration the system. Periodical pulses of iris applied to the fiter bag in ‘order to relieve the PIA dust sticking on the bag surface. Control Description Emptying of PIA container and PIA big bags is done manually. The PIA chain ‘conveyor system is controlled from a local contol board. The chain conveyor is started and stopped either from the process control system or preferably in the field from a local control board. The RUN / STOP status is displayed on the DCS screen. The conveying speed can only be adjusted from the process Control system. The maximum level in the target silo stops the transport system automatically. Such an interruption is indicated on the local contro! board and is automatically reset if the level in the target silo is dropped down, SSW AG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|s. _05.12|[ c-aosa/petsoo0 Jo] | ves eek a kr ser ec [teTemperature: Conveying pressure: Conveying casacity. PIA storage capacty: The aspiration of the PIA receiver A0-11863 is activated by deactivated b/ stop) of vent blower A0-11863 and the cleaning of the vent filter AO-1 163 is operated from the local control boar. Main Operating Parameter The PIA chain conveyor A0-11Q64 Is equipped with frequency inverter to adjust its conveying speed according tothe required conveying capacity. The first conveying section has the lowest speed. Each futher section runs with a slightly highor epeed to prevent a PIA blockage in the conveying line. fart (and ‘The following lst shows approximate values forthe operating parameters, ambient atmospheric ‘approx. 101000 ka/h ‘approx. 130m" ssi" 8AC [GENERAL PROCESSDESCRIPTION Uhde Inventa-Fischer |: | 05.12||_ c-4084/pB-11000 |o| 40/64 emer fee (RRL EG Storago, Feeding and Distribut Section 13; PFD No: ZL-11019 Basic Objective To store ethylene glycol (EG) in the storage tank and to maintain @ constant EG supply to the consumers. Major Equipment A0-13F28 EG FILTER {or fine fitration of virgin EG A0-13F27 —EGFILTER {or fine filtration of virgin EG used for additive preparation A0-19P26 EG FEED PUMP. {or feeding EG to the main consumers ‘A0-13P27 EG SUPPLY PUMP. for feeding EG to the additive preparation section A0-13822 EG STORAGE TANK for storage of EG Process Summary Ethylene glycol (EG) is transferred to AO-13821. With the EG feed pump AD 1328, the vigin EG is transferred continuously to various consumers, ‘especialy tothe demister circulation systam of the DISCAGE reactor. ‘The EG used or additive preparation section is transferred by A-19P27 into the respective additive preparation vessel fr preparing the additive batch. Uhde Inventa-Fischer|22 > 0s12][ eaoss, SSE? BAC | GENERAL PROCESS DESCRIPTION 1000 [0 ) 11064 leer fee [ike RO SkControl Description ‘The storage tank A0-13$21 Is equipped with level measurement and alarms for high and low level. The EG feed pump A0-13P26 is operated locally and equipped with an interlock, which protects the pump from dry running, if the level inthe storage tank is too low. The quantity of EG transferred to plant At ‘and A2 is measured, indicated and summarized on the DCS screen by a flow ‘meter. Each production line is equipped with ts oun flow mete. ‘The EG feed pump AO-13P27 is started / stopped from the addlive sequence. {An interlock protects the pump from dry running, ifthe level in the storage tank is to low, Main Operating Parameter “The following lst shows approximate values for the operating parameters. Allthe equipments operated at ambient temperature EG consumpton: approx. 400 day a nominal capacty (2x 6008) A0-13P28 tow rate: 22 mith pressure: 56-68 barg A0-13P27 tow rate: 22 mh pressure: 42-55 barg A0-18821 storage capacity 2000 m? Uhde Inventa-Fischer|s=2. [os 12 RS? BAC | GENERAL PROCESS DESCRIPTION ar ge5 Dk ‘Transport Section 13; PFD No: ZL-11020 Basic Objectve To store dietrylene glyco! (DEG) and to maintain a constant DEG supply to the production plant b. Major Equipment A0-13F63. DEG FILTER {or tering DEG 7 i i i A i H AO-13P65 DEG CONTAINER PUMP for feeding DEG to the storage tank ‘A0-13P68. DEG TRANSFER PUMP. {or feeding DEG to the plant 0-342:P-40 DEG BARREL PUMP for feeding DEG to the storage tank ‘A0-13861 DEG STORAGE TANK {or storage of DEG c. — Process Summary Diethylene glycol (DEG) is supplied in barrels or in containers. DEG is transferred by the existing EG pump 0-342-P-10 from barrels or by the DEG. Container punp A0-13P85 from containers to the DEG storage tank AO- 13861 The transfer rump A0-13P6 feeds the DEG through the DEG filter A0-t3F66 ino the main EG line and together with the spent EG into the paste mixing vessel Ax-18D13. A part stream is fed into the existing DEG storage tank O- 342-S-10 d. Control Description ‘The DEG storage tank A0-13S61 Is equipped with a level transmitter for high ‘and low level alarm and a level switch which stops the DEG fling pumps O- 342-P-10 and AO-13P65 to protect the tank from overfiling ‘Transfer pump A0-18P66 runs continuously and is equipped with an interlock, which protects the pump from dry running in ease of low level in the storage tank. The flow tothe paste mixing vessel is controlled by a flow control loop at the dosing pont to At and A2, The flow rate to the existing DEG storage tank “GENERAL {OCESS DESCRIPTION Uhde Inventa-Fischer “Tos:al[ eaoesresareno [ol] | sree fe gE te GndL 0-342-S-10 is controlled by a level control valve inthe line to the existing DEG storage tank for keeping the level inthe existing tank constant fe. Main Operating Parameters “The following lst shows approximate values for the operating parameters. Allthe equipment is operated at ambient temperature. ‘A0-13861 storage capacity A0-13P65 tow rate A0-13P68 owrate oressure Daily DEG corsumption: 400m? 40-12 m'h 21-26 barg 16-20 min 69-84 barg ‘approx. 3200 kal ‘at rminal capacity (2x 600 ts) Uhde Inventa-Fischer (GENERAL PROCESS DESCRIPTION leer fade ie aS cate eaae/ rove [ol6. Catalyst, Stabilizer, Toner Preparat Content: 6.4 Catalyst Preparation (CPC) 6.2 Stabiizer reparation (STS) 6.3 Toner Preparation 64 Catalyst Preparation (CPC) ‘Section 15; PFD No,: ZL-11022 a. Basie Objective ‘To prepare batches of solution of Poly Catalyst in ethylene glycol (EG) and to store them ready for use in the process, ‘Major Equipment AO-GA11 AGITATOR TO CATALYST PREPARATION VESSEL, for stirring of catalyst solution AO-ISD11_ GATALYST PREPARATION VESSEL for preparing catalyst solution in EG ‘AO-15D12_ CATALYST STORAGE VESSEL for storing the prepared catalyst solution ‘A0-15E15 HTM AIR COOLER far cooling HTM in the secondary HTM system of the additive preparation system AO-15F12. CATALYST FILTER AO-15A12. CATALYST PUMP ‘ar feeding catalyst solution to paste mixing vessel A0-15A15._HTM CIRCULATION PUMP far circulating HTM in the secondary HTM system of the adaltive preparation system AQ-15Q10 ADDITIVE SCALE forweighing additives ‘A0-18Q11 BAG OPENING /SUCTION SYSTEM ‘for manually opening and emplying of catalyst bags TAG [GENERAL PROCESS DESCRIPTION, Uhde Inventa-Fischer P_|0s.12|[_¢-40sa,ee-t1000 [0], 15164 _ a_i Se er©. Process Summary ‘The batch size Is chosen to match the production requirement and shall be basically in the range of ono day's coneumption, The eolution etorage capacity is approximately .5 days of production in the storage vessel Depending on the type of catalyst, the batch is prepared at a higher concentration, heated up to dissolve the catalyst. Afterwards EG is added to reach the final concentration, Finally the solution is cooled down ‘The selected quantity of EG at ambient temperature is filed into to the preparation vessel by AQ-15D11 by a pre-set flow meter (low counter) in the ‘main EG line. The agitator Is staried by the sequence program, the required Weight of catalyst is accurately weighed on the additive scale and added into the preparation veseel + Antimeny Trilycolate, ATG (Sb2EG3) itAntimony Tigyeolate (Sb-EG) fs used as a catalyst, the solution ie heated up to 120°C by adjusting the HTM ciculaton to approx. 160°C (20°C atthe end), When al SbsEG is completely dseoWved (sample olution colourless usual within 2 hours), the HTM heating is stopped and futher EG fs added to reach the fal concentation, Afterwards {he calalyst solution is cooled down to approx. 65°C by adjusting the HTM cteulation to approx. 75°C (85°C at the end). For catalyst cooing, {he HTH circulation fs passed tough the alr cooler 15E15. + Antimeny Triacetate, ATA (SbAc3) If Antimony Triacetate (SbAcs) is used as catalyst, the solution is dissolved. at ambient temperature. When all SbAcs is completely dissolved (sample solution colourless usually within 1 hour), further EG Is added to reach the final concentration + Antimeny THoxide, ATO (Sb203} If Antirony Troxde (S0.0,) is used os catalyst, the solution is heated Lup to 180°C to form the antimony glycolate complex by adjusting the HTM circulation to approx. 220°C (180°C at the end). When all Sb-O3 is completely dissolved (sample solution colourless usually within 2 hours), the HTM heating is stopped and further EG ts added to reach the final concentration, Afterwards the catalyst solution is cooled down {0 approx. 85°C by adjusting the HTM circulation to approx. 75°C (85°C atthe end), For catalyst cooling, the HTM circulation is passed through the air cooler 15618. ‘A sample of each batch is taken and checked in the laboratory. If the Concentrations okay, the batch is drained into the catalyst storage vessel AO- 115012 otherwise the batch has to be corrected, “The main stream of catalyst solution Is circulated continuously by the catalyst pump A0-18A12 back into the storage vessel, Only a part stream is fitered {through the CC filter AO-15F12 in order to remove fine undissolved particles [Ett __GAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer |: (> | os.12|[ c-a0sesre-i000 Jol) | r0v04 ae abefore the catalyst is dosed together with the main EG from the EG mixing tank into the paste preparation vessel. The amount of catalyst solution fed to the paste mixng vessel Ax-18D13 is controlled by a flow controller. ‘The preparation and the storage vecec (oonncoted in aoriee) are blankotod with nitrogen in order to prevent / reduce the entrance of humility and to ‘assiet the removal of by-products, The preparation vessel is connected with the process vent system to aspirate the blanketing nitrogen together with ‘vapours of water, EG and other low boiing products. Control Description ‘The CPC preparation unit is controlled and operated by a sequence program, “The catalyst Latch size is preset in the sequence program. The amount of EG necessary in the preparation vessel is calculated and fed by the sequence program, The amount of catalyst is weighed and added manually i i | uv i ‘The preparation vessel AO-15D11 is equipped with a temperature transmitter to contol the required dissolving temperature and a level transmitter to protect the preparation vessel from overfiling “The storage vessel AO-18D12 is equipped with a level transmitter. h Inthe recclation tne of the storage vessel a bc thermometer and an a Otic installed fo Koop a certain provsuro (Tow). The contamination of he b fitorie montred by dferental pressure alarm u HH Main Operating Parameters 3 q ‘The following list shows approximate values for the operating parameters. ie ‘A0-15D11 typical batch size: EG 29'400 kg fe SbEGs 600 kg a final concentration 28 wk% ‘emperatire 20° tiseoving tne mh batch tie coh pressure aim ‘A0-18012 storage capacity 1.3 day production storage volume $6 feed ate ne nF 280 ppm So 4872 ppm SdsEG. food rat eeu 5359 keh (os 25 ve) Av-Ase18aramount ~v000 kan heat exchanged 20 KW AO-15A12 flow rate 40-45 mm pressure 89-109 barg [fast GAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|i=2. > |os12 | cans sr6-100 [ol sree [asain fade |i eeAO-TSAIS owrale 20-24 mn oressure 81-88 barg Fm BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer | 7% 05.12|/_c-40s4/p5-t1000 |o) 8764 femae oe [Rasa eR} i i i i i ‘Stabilizer Preparation (STS) Section 15; PFD No. ZL-11022 Basic Objective ‘To prepare a batch of stablizer solution in ethylene glycol (EG) and to store them ready for use in the process. ‘Main Equipmont ‘AO-5A21__ AGITATOR TO STABILIZER PREPARATION VESSEL {or string of stabilizer solution ‘A0-16D21 STABILIZER PREPARATION VESSEL for preparing stabilizer solution in EG ‘A0-15D22_ STABILIZER STORAGE VESSEL for storing the prepared stabilizer solution ‘AO-15E15 HTM AIR COOLER (same as for CPC preparation) for cooling HTM in the secondary HTM system of the additive preparation system ‘A0-16F22_ STABILIZER FILTER ‘A0-18A20 STABILIZER BARREL PUMP for feeding stabilizer solution from barrel to preparation vessel ‘A0-18A22_ STABILIZER PUMP for feeding stabilizer solution to paste mixing vessel ‘A0-18A15._ HTM CIRCULATION PUMP (same as for CPC preparation) ‘ar circulating HTM in the secondary HTM system of the adaltive preparation system A0-18Q10_ ADDITIVE SCALE (same as for CPC preparation) ‘fr weighing additives Uhde Inventa-Fischer SSS BAC | GENERAL PROCESS DESCRIPTION Js | 6:12 || c-4084 /P.41000 [0 leeser ode [i omeA h i i y i ' i i i i § Process Summary ‘The batch size is chosen to match the production requirement and shall be basically. in the range of one day's conaumption. The olution etorage capacity is approximately 2 days of production in the storage vessel ‘Stabilizer solution is prepared at a higher concentration, heated up to form the Triglycol phosphate or Phosphoric acid triglycol ester (transesterfication), and then EG is added to reach the final concentration. Afterwards the slabilzer solution is cooled down and drained into the storage vessel ready for dosing, ‘The selected quantity of EG at ambient temperature is fled into the preparation vassel AQ-15D21 by a pre-set flow meter (flow counter) in the main EG line. The agitator is started by the sequence program, the required ‘weight of stabilizer is accurately weighed on the additive scale and added into the preparation vessel ‘The stabilizer solution is heat up to 160°C by adjusting the HTM circulation to ‘approx. 180°C (160°C at the end). After forming tiglycol phosphate, usually within 2 hours, the HTM heating is stopped and further EG is added to reach the final concentration. Afterwards the stabilizer solution is cooled down to ‘approx. 75°C by adjusting the HTM circulation to approx. 65°C (75°C at the fend). For cocling dawn the HTM circulation is passed through the HTM air cooler A0-15E15. ‘A sample of each batch is taken and checked in the laboratory. if the ‘concentration is okay, the batch is drained into the stabilizer storage vessel ‘A0-18022 otherwise the batch has to be corrected. ‘The main stream of the stabilizer solution is circulated continuously by the stablizer pump AD-15A22 back into the storage vessel. Only a part stream is fitered throuch the STS filer AO-15F22 in order to remove fine particles before tho stabizer is dosed together with the main EG from the EG mixing tank into the paste preparation vessel Ax-18D13. The amount of stabilizer solution fed tothe paste mixing vessel is controlled by a flow controller. ‘The preparation and the storage vessel (connected in series) are blanketed with nitrogen in order to prevent / reduce the entrance of humikity and to assist the renoval of by-products. The preparation vessels are connected with the process vent system to aspirate the bianketing nitrogen together with \vapours of water, EG and other low boiing products. Uhde Inventa-Fischer|i= >| os12| canst Pe-1000 [Est AC | GENERAL PROCESS DESCRIPTION lesser Age is Paar esaes ae4. Control Description ‘The preparation unit is controled and operated by a sequence program. The stablizer batch size is preset in the sequence program, The amount of EG necessary in the preparation vessel is calculated and fed by the sequence program. The amount of stabilizer ls weighed and added manually ‘The preparation vessel A0-18D21 is equipped with a temperature transmitter to control the required dissolving temperature and a level trensmiller to protect the proparation vessel from overtling, “The storage vessel A0-15D22 is equipped witha level transmitter. In the recirculation line of the storage vessel a local thermometer and an corfce is instaled to keep a certain pressure (flow). The contamination of the filter is monitered by differential pressure alarm, ©. Main Operating Parameters “The following list shows approximate values forthe operating parameters. ‘A0-18021 ypical batch size: EG (tt 4180 kg TEP 220 kg EG amount (for pretirg) 2000 kg ‘temperature 160 °C dissolving time 15h EG amount ((orabutlon) 2180 kg temperature (ater cooing) =70 °C batch time ~5h final concentration 5.0 wh% pressure al, ‘A0-18D22 storage capacity 2-day production storage volume 99 m feed rate (onc. in PET) 20 ppm elementary P 1476 ppm TEP food rato (ot860V8) 58.9 kgih (as 5.0 i) A0-18P22 flowrate 28-30 mim pressure 55-84 barg [Romar BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|2. | 05.12\/_c-40s4/P8-11000 [o| leer gy [i tS RE64 ‘Toner Proparation (BTS, RTS) Section 15; PFD No: ZL-11028 & ZL-21025 Basic Objective ‘To prepare a batch of blue and red toner suspension in ethylene glycol (EG) and to store them ready for use inthe process. Main Equipment Aw1SAS1 AGITATOR TONER / FAST REHEAT PREP, VESSEL for sting / mixing of solid toner with EG Ac15A53__ AGITATOR BLUE TONER J FAST REHEAT VESSEL for string of blue toner with EG. ‘Ac-15A54 AGITATOR RED TONER / FAST REHEAT VESSEL for string of red toner with EG. Ac15D51 TONER / FAST REHEAT PREPARATION VESSEL ‘ar preparing / dispersing blue or red toner and ‘aot re-heat additive in EG ‘Ac18D83._ BLUE TONER / FAST REHEAT STORAGE VESSEL ‘ar storing blue toner fast reheat suspension ‘Ac15D54 RED TONER / FAST REHEAT STORAGE VESSEL for storing red toner / fast rebeat suspension ‘Ac15P53_ BLUE TONER / FAST REHEAT DOSING PUMP ‘ar feeding blue toner /fast reheat suspension fo reactor Ac15PS4 RED TONER / FAST REHEAT DOSING PUMP ‘or feeding red toner / fat reheat suspension to reactor Process Summary “The batch size is chosen to match the production requirement and shall be basically in the range of one day’s consumption. A suspension of blue and ‘od taner is prepared in the common toner preparation vessel. EG is dosed into the toner preparation vessel Ax-15D51 by the sequence program, The ‘agtaior is stanled and the pre-weighed amount of blue or red toner Is added Into the preparation vessel. If requested, fast re-heat additive is added. Afier intensive stirrng for several minutes, the suspension is drained into the ‘respective toner storage vessel. The dosing of the toner suspension into the postesterificaton reactor Is maintained by means of the dosing pump Ax- 16P53 and Ax-15PS4 [Hast BAG [GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer| 4P~_|08.12||_¢-4084/ 8.11000 [o} zie Ae fe en ee oeControl Description ‘The toner preparation is controlled and operated by a sequence program. The toner batch size ie preset in the eequence program. The amount of EG to be {fed info the preparation vessel is pre-set and dosed by the sequence program, whereby the amount of toner powder is weighed and added manually ‘The preparation vessel Ax-16D51 is equipped with a level transmitter to protect the preparation vessel from overiling. The blue and red toner storage ‘vessel Ax-15D53)54 is equipped with a level transmitter to inform the operator for preparing the next toner batch, ‘The blue and red toner suspension is dosed into the ESPREE reactor with the toner dosing pump. Each dosing pump receives the setpoint from the respective flow controller according tothe plant capacity recipe, Main Operating Paramoters “The following lst shows approximate values forthe operating parameters. ‘Ax-18D51 —ypical batch size: EG 749.38 kg blue toner 0.64 kg fast reheat: 50.0 kg alue toner cone. 0.08 w36 ‘ast reheat conc 6.25 Wh aves sarentat) ‘emperature ambient °C sting time = 20 min batch time 10h pressure atm Ax18D51 ypical batch size: EG 799.52 kg red toner 0.48 kg ‘ed toner cone. 0.08 wi ‘emperature ambient °C sting time ~20 min bateh time ~10 pressure atm, ‘Ax-18D53 blue toner storage capacity 1 day production storage volume 1.35 m* Ax18D54 ‘ed toner storage capacity 4 day production storage volume 1.35 m" Ax19PS3. “eed rate (atwvvua) 25. ky (as 0.08 35) ‘e0d rate (bue toner one in PET): 0.8 ppm bie toner pin fast reheat {as eto substance) Ax-18P54 “eed rate (et 008) 418. kgfh (a6 005 04) ana BAC. | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer |s. | os2|| caosaipe.tt00o fo], | 23/64 emer fe [be Mae mG tT‘eed rate (red toner cone. in PET} 08 ppm red toner ii t E a i RES BAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|=2. os :2|_ casa ro-1100[o] 168 leone Ae [Rea me OERaw Material Mixing Section 18; PFD No: ZL-11030 & ZL-21030 Basic Objective To meter and to feed the raw materials such as PTA, PIA and EG in a defined fatio into the paste mixing vessel for paste preparation To prepare a homogenous paste. To feed the paste to the esterification section of the ESPREE reactor in a metered stream, Major Equipment Axt8A13 AGITATOR DRIVE (PASTE MIXING) to paste mixing vessel Axte013 PASTE MIXING VESSEL for mixing and homogenise EG, PTA, PIA and CPC Axt8sté EG MIXING TANK to collact and homogenise recycled / spent EG Axt8E16 EG COOLER t0.cool down recycled / spent EG Axt8A13 PASTE PUMP {for metering and feeding of paste to esterification reactor Axi8A16 EG MIXING PUMP for homogenisation and feeding of spent EG Axt8013 PTA FEEDER for feeding PTA from storage silo to PTA balance Axia? PTA DOSING BALANCE for exact dosing of PTA into paste mixing vessel Axtats PIAFEEDER fo feeding PIA from storage silo to PIA balance Axct8a18 PIA DOSING BALANCE for exact dosing of PIA into paste mixing vessel SRY BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|:2. > /os12|[ canes re.tto0 [o| | v0 | jamwost ge ite ag Seeemite a Ee aProcess Summary PTA is dosed from the PTA storage silo A0-11S58 into the paste mixing vessel using a speed controlled screw fecder and @ macs flow moter, PIA is dosed ‘tom the PIA storage silo AO-1168 into the paste mixing vessel Using a speec controlled loss-in-weigh screw feeder. Virgin EG is fed from the EG storage area via EG filter A0-13F26 and demister circuit to the EG seal pot Ax-20038, Spent EG from the hotwells Ax- 20038 and Ax-20D42/43 are collected in the EGS drain tank A0-37S90 and outed to the EG mixing tank Ax-18S16, in which the liquid is mixed intensively vith recycled EG from the process column Ax-20T12. The ‘temperature ih the EG mixing tank is kept at max. 70°C by circulating a part ‘of the EG stream through the EG cooler Ax-18E16. ‘The main EG stream coming from the EG mixing tank Ax-18S18 is mixed with ‘a metered quantity of catalyst solution (CPC) and stabilizer solution (STS) Using high accurate mass flow meter. A controlled part stream of recycled EG {rom the process column Ax-20712 Is dosed into the main EG line to control the temperature of the paste. This EG / CPC / STS mixture is dosed by a _mass flow meter and a contol valve into the paste mixing vessel Ax-18D13. ‘All components are well blended and intermixed in the paste mixing vessel by ‘an agitator of special design, withthe target to form a homogeneous paste, having @ mole ratio in the range of approx. 1.4 - 1.6. This paste can easily transferred tothe bottom part of the ESPREE reactor by volumetric pumps. ‘To reduce the formation of PTA / PIA dust and preventing dust entering into the process vent system, the paste mixing vessel 's equipped with a dome Containing two spray nozzles. The virgin spray EG coming from the EG tank farm is of ambient temperature. This also increase the efficiency of by- product removal. The dome of the paste mixing vessel is connected with the process vent system to suck-off low boling by-products. Blanketing nitrogen Is applied for aspiration the system. ‘The paste is continuously metered and fed into the ESPREE reactor by two speed controled paste pumps AX-18A13A/B which are normally running simultaneous, however, one pump can handle the full plant capacity ‘A high accurete mass flow meter is used to measure the paste flow rate and the pasto density continuous, The density is proportional to the molar ratio of EG and PTA. The density signal is recorded for an easier adjustment of the EG feed contoller to maintain a high accuracy ofthe feed mote ratio, which is, (of great mportant tor nigh process stabty. GAG | GENERAL PROCESS DESORPTION Uhde Inventa-Fischer 22. | os.12|_e-40s4ire-11000 |o| 20/04 jeer pac se4. Control Description ‘Throughput ‘A master control system with plant capacity as master is used for dosing all the required raw materials and additives. The PTA dosing system receives its sefpoint, calculated from the required plant capacity and corrected with the level in the paste mixing vessel Ax-18013. A mole ratio controller ‘compensates a dit ofthe PTA dosing balance within a certain range. ‘The PIA dosing system receives its setpoint calculated from the required plant capacity. ‘The flow control for EG receives a calculated setpoint corresponding with PTA and PIA quantity and the desired mole ratio. The calculation also considers the EG quantity feed, the catalyst feed, the stabilizer feed, the spray EG feed to the dome of the paste mixer and the flush EG to the seal of the paste pumps Ax-18P13. “The mole ratio is measured by the paste mass flow meter. All glyco flows anc the density centol are temperature compensated Love! ‘The level of the EG mixing tank Ax-18D16 is controlled by the feed of make- Up EG to the EG seal vessel Ax-20038 (and from there via hotvells Ax- 4 20083 / Ax-23D42/43 and EGS drain tank A0-37S80) to EG mixing tank Ax- 78516. “The level ofthe paste mixing vessel Ax-18013 is controlled by adding a small bias to the master control (plant eapacity). ‘Temperature ‘The temperature of the EG mixing tank Ax-18816 is controlled by a control valve in the VACL line from Ax-18E 16, ‘The temperature of the paste mixing vessel is controlled by a control valve in the foed lino of hot recycled EG from the process column Ax-20T12 into the ‘main EG feedng line asi" BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|= > | os12||_caasa/eeo0o fol | 27/04 sar ae@. Main Operating Parameter “The following list shows approximate values forthe operating parameter. lh Axt801 pressure ~905 mbar. am, ii {emporio es °c a level ~ 88-92 % ¥ hold-up time ~29h A a Act8S16 pressure atm a {emperature 05°70 °¢ 1 level 50 % i BE AtBAPI3- paste ow ate 32000 toh pressure 248 bey Ax-18P16 flow rate 40 mh ~e 29-84 bay fw oes (tows) PTA 21023 tah PA 20 tom eS ~ 10000 fom bec =a3 tom CPC zs ane wast ton FEES" BAC | GENERAL PROCESS DESCRIPTION i - 5 i Uhde Inventa-Fischer |: > | os 2\| cosa peso [o] ves jase ote _ |i te Baa Borat te 28, ESPREE Resctor ‘Section 20; PFD No: ZL-11083 & ZL-21033, a. Basie Objective ‘To produce dglyco! terephthalate (DGT) by a non catalysed direct esterification between terephthalic acid (PTA) and ethylene glycol (EG). ‘To separate the water produced in the process. ‘To remove and recover the excess EG (an excess is necessary to promote the reaction) for re-use. To remove some ofthe by-products from the reaction. b. Major Equiprient ‘Ax-20E10 REBOILER TO ESPREE atached to ESPREE reactor for heating ‘and maintaining thermasyphon of esterification stage ‘Ac20E12 DISTILLATE CONDENSER for condensing the reaction water ‘Ae20E13 ECONOMIZER ‘or EG preheating before entering into process column ‘Ax20E15 HTM EVAPORATOR (ES) ‘a heat the bottom of the ESPREE reactor and reboller of process column Ax-20712 ‘Ax:22E25 HTM EVAPORATOR (00) ‘io heat discage reactor, postesterfication and propolymerisation section of ESPREE reactor ‘Ax20P11. MONOMER PUMP {o transfer monomer form esterification to postesterifiation ‘Ax20P12 REBOILER PUMP. {or feeding EG from reboier of process column Ax-20712 back fo reacior Ax-20R10 and to EG mixing tank Ax-18S16 ‘Ax61P35 HTM PUMP HSE {or heating monomer pipe between estertication end postesterification section [stay BAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer |= 05.12|| 4054 /PB.41000 Jo] | 20/68 ce aa SR‘Ax20R10 ESPREE reactor multi stage reactor for ‘esterification reaction (ES) of PTA/EG paste postesterfcation (PE) prepolyeondensation (PP) Ax20712 PROCESS COLUMN for tecification / separation of EGiwater vapours ‘Ae20V10 VACUUM PIPE (PP) to lead vapours from prepoly into spray condenser ‘Ac20RZ10 EG FEEDING STATION to mix EG with monomer h i i i i ©. Process Summary ‘The esterification reaction takes place over several stages: ‘+ the fist sep is done in esterification section (bottom part of Ax20R10, ‘conversion rate 88% - 92 %) ‘+ most of the next stages are installed cascade-wise in postesterification ‘section (uoper part of Ax-20R10, conversion rate up to 98 %). During the esterification reaction, polymer chains already begin to form. Further polycondensation and the remaining esterification take place in polycondensation, The paste insluding additives is continuously supplied from paste mixing vessel Ax18D13 by the paste pumps AXIBAISAVB at a temperature of Approx. 85°C into esterification section of ESPREF reactor Ax-20R10. For process safely two parallel operated eccentric screw pumps are running leach with 50% of the capacity. In case of a failure, the other screw pump is, capable to take over the full capacity. Before the paste enters the external tube bundle heat exchanger Ax-20E10, recovered EG from process column Ax-20712 is added to increase the total (innes) mole ratio and to compensate the evaporation loss of EG in ‘esterification. The quantity of recovered EG fed into the paste flow is ‘contillad by faw contrl loap. The reboiler pump Ax-20P 12 feed the EG from the bottom of process column Ax-2072 in a part stream back to esterification inorder to maintain the inner mole tall. the level in the reboller of the [process column Ax-20712 is controlled by feeding the excess EG back into the EG mixing tank Ax-18S16, ‘The paste and the recovered EG from process column are fed into the tube side of heat exchanger Ax-20E10 of the ESPREE reactor through a spacial [GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer -4064,/P2-11000 over EE orinlet nozzle. The incoming paste is Immediately entrained with already ‘existing monomer and mixed by a static mixer below the tube bundle, The natural circulation 's generated by the boling regimes in the heat exchanger. ‘Atan oporatien concltion of approx. 255° - 260°C and a pressure of 1.3 - 1.5 boarg, he reactants boils vigorously. The conversion rate reach approx. 88% - ‘92% within 60 to 60 minutes reaction time; the degree of polycondensation (DP) increases to approx. 3 units ‘As DGT (diglcol terephthalate) is formed, reaction water is formed which, together with portions of EG enters into the process column Ax-20T12. The separated ES is paitly (measured and controlled) retumed to the esterification section for futher increase the conversion, whereas the balance EG is sent back to the EG mixing tank for re-use, ‘The required snergy to heat up the paste to reaction condition, to evaporate the formed reaction water and EG and for the reaction Itself, is supplied by HTM vapor generated in HTM evaporator Ax-20E15. Depending on the throughput the HTM vapor temperature wil vary between 280" and 296°C. “The monomer from esterification is transferred by gear pumps Ax-20P11 from bottom to top of the ESPREE reactor Ax20R10. For process safely wo parallel operaied gear pumps are running, each with 50% of the capacity. In cease of a fallre, the other gear pump is capable to take care for the full capacity Additional EG to adjust the total mole ratio is fed to the monomer line. In order to ensure a sufficient mixing of the additonal added EG with the monomer ‘and to obtain a homogenous fluid, a static mixer Ax-20RZ10 is installed The discharge pressure of monomer pumps Ax-20P11 is contioled by a pneumatic operated butterfly vaive located at the monomer inlet of the top (first) cascade of postesterification. ‘The monomer line between esteication section and postesterifcation is heated with a secondary HTM system (HSE). HTM pump Ay-81P35AB supplies the necessary pressure. For heating a temperature control loop Controls the feed of primary HPD into the secondary system, ‘Together with the reaction water also a part of the EG vapor leaves the ‘esterification, This EG/water mixture is rectified / separated in process column ‘Ax-20T12, The water vapor from the top of the process column is under pressure (saturated vapor) and is partly used as motive steam for vacuum Unit, The excess steam is condensed in distilate condenser Ax-20E12 and the condensed water collected in seal vessel Ax-24D53. The motive steam for the vacuum unit is condensed in the first / final vacuum condenser Ax- 24E51/53 and collected in seal vessel Ax-24D53 as well, Allthe process water collected in the seal vessel Ax-24D53 is fed through the stripper column A0-24T61 in order to remove low boling products such as aldehyde. A part stream ofthe stripped water is pumped back as reflux to the process column Ax-20712 by reflux pump A0-24P61A/B through reflux flow Uhde Inventa-Fischer [EE GAG | GENERAL PROCESS DESCRIPTION P| 05.12|[_€-4054 /P8.+1000 [0] 31164 + i (ee ae Eecontrol, whereas the excess water leaves the stripper column via its internal ‘overflow to the waste water treatment plant. ‘The postesterfication section is divided in total 3 cascades incorporating heating coll modules and two flash chambers. Ths installation enhances and Jmproves the evolution and removal of water as well as a uniform residence time distibutln. At a total residence time of 50 ~ 60 minutes, the conversion rate amounts to approx. 98%. The DP will increase to 6 ~ 6 units. The reaction in the postesterfcation section runs under vacuum condition. The requited evaporation and reaction heat is supplied by HTM evaporator Ax- 22625, The second cascade chamber is equipped with an injecion lance, through which additive solution (STS dissolved in EG) andlor fresh EG as alternative can be fed in. The dosing rate depends on the recipe and the plant throughput ard is done by a flow control loop. Color inhibitor such as toner dispersed in EG is fed into the third reactor cascade. The monomer flowrate between the second and the third reactor cascade is controlled by a level Control valve, which receives the setpoint from a level controller installed atin the collector chamber of the prepolycondensation. Vapor, consisting mainly of EG and reaction water, eaves postesterification reactor via the vapor lines. The vapor from postesterification reactor is lead to spray condenser Ax.20E23 where the vapor condenses directly by injected spray EG, Non condensables (eg. acetaldehyde, nitrogen) are sucked off by the vacuum unt, Tho excess of EGiwater mixture is metered and fed to process column Ax 2012 for separation, After leaving the postesterfication, the monomer flows forced by gravity into the first fasher chamber ofthe prepolycondensation section ‘The prepolyccndensation reaction takes piace in following reaction stages: = tashers ‘= falling fim evaporators Prepolycondenéation of the ESPREE reactor consists of two flasher cascades and two faling fim evaporators. In the first flasher cascade the pressure is further reduced and the product overflows through the center pipe into the ‘second flasher chamber. The product is evenly distributed and overflows into the falling fim cascades. The falling fm cascades are equipped with plenty of tubes of a spacial design. The surface area is increased and thus enhance the polymerization degree by removing of EGiwater vapor. At the end of the prepolycondensation the prepolymer is collected at the bottom, which is used as buffer for prepolymer pumps 22P21. For process safety two parallel operated prepolymer gear pumps are running, each with 550% of the capacity. In case of a failure, the other gear pump is capable to take over the tll capacty. : TEE BAC | GENERAL PROCESS DESGRIPTION = [Uhde Inventa-Fischer|:. — os2||_c-a0s4Pe-41000 [0] 32/64 ' wr Ae tt Smt om mr‘The prepolycondensation is operated at 5 to 8 mbara and 278 to 282°C. The esterification reaction is finished and the chain length of the prepolymer is increased by polycondensation of ester molecules under cleavage of EG. The ‘vapor leaving propelycondencation mainly concise of EG which te condenced In spray condenser Ax-20E38 and in demister Ax-20E36 by Injection of cold spray EG (direct condensation). 4. Control Description Throughput ‘eve! The paste feed to Ax-20R10 fs backward controlled from the level controller of the ESPREE reactor esterification section and influenced by the master control of the plant capacity. Level control of the paste mixing vessel Influences the corrected plant throughput, y i i | a ‘The level in the third cascade of postesteriication is kept constant by backward cortrol ofthe monomer pump speed Ax-20P11 “The pressure downstream of the monomer pump is kept constant by pressure control valve hr the monomer line atthe inlet to pastesterication, ‘The level in the rebolier of process column Ax-20T12 is controlled by a ‘control valve in the discharge line from the process column through the ‘economizer Ax-20E13 to the EG mixing tank Ax-18S16 (via EG cooler Ax 18516), 7 ‘Temperature: Ax20R10 - Estenication: ‘The product temperature is kept constant by means of cascade contol of the HTM evaporator temperature Ax- 2016. Postesterification ‘The product temperature is kept constant by means of control valves in the HTV ine from the HTM evaporator Ax-22E25. ‘The HTV temperature in the HTM evaporator Ax-22E25 1s controled by & temperature control loop regulating the HPD amount flowing through the HTM evaporator. = Prepolyeondensation: ‘The product temperature is kept constant by means of control valves in the HTV line from the HTM evaporator Ax-22E25, = Monomer line: ‘The temperature of the secondary system (HSE) is controled by a temperature control valve, which supplies primary HTM (HPD) into the secondary system for heating ee ee ora] san7 Re Aone Uhde Inventa-Fischer |. SoleAx20712- Process colum: ‘The head temperature is kept constant by means of cascade Control of the column reflux in order to keep EG losses al a ‘minimum level. The reboilor temperature is kept constant by ‘means of the temperature valve in the HTV line from Ax- 20615. ‘Ax20R10 Esterifcation: Pressure of the whole system incl. process column is kept Constant by @ pressure control valve in front of distilate condenser Ax-20E 12. Postesterifeation The reactor pressure (vacuum) in the last reactor cascade is controlled by a pressure contol valve in the suction line between the spray condenser Ax-20E23 and condenser Ax- 2489 i} + Prepolycondensation: be Fae cote by bale ev fed il valve othe sition side of the vacuum jt A246, Q i, nance eee ay i ‘The following st shows approximate values forthe operating parameters. th Ax20R10 — Esterification: it pressure 12-45 barg il froducttemporature 255-365 °C tesidence time 60-80 min Conversion s-02 % HTH temperature 282-200 °C ostesteriaton pressure 500-800 mbara producttemperatuwe 272.275" fesedonco tine 50-60 min conversion s75t008 % HTiemperature 200-295 °C [BAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer _|os:2|_e-40s4r6-100 [0 sree Ee sa/es mae oe7-10 mbara Zi8-20 “C ‘ellen re Bo 20min Sees of polycondensation 2040 k TM-temperature 290-295 °C H Ax-20T12 column head temperature 126.1 °C (at 1.4 barg) a Sim tomoatre 210-218 “€ It pressure 1.2-1.5 — barg g e201 capacity upto 37000 kgm 7 speed wpa 2870499) L pressure 2-4 arg } : Be ‘GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer |«: 05.12 | ¢-4054/PB-11000 rs9. Spray System PE, PP & DC ‘Section 20/22; PFD No. ZL-11037 & ZL-21037 Basic Objective ‘To separate spent EG from the reaction process and to dispatch it for direct recycing. Major Equipment ostesterificaion (PE) Ax-20023 EG HOTWELL (PE) barometric seal tank for spray EG system it u i # i ‘Ax20E23._ SPRAY CONDENSER (PE) ‘or condensation of vapours from post-ester Ax20E24 EG COOLER (PE) for cooling of spray EG to 2023 ‘Ae20P23. SPRAY EG PUMP (PE) ta circulate spray EG to spray condenser 20E23 Prepalycondensation (PP) ‘Ax20033. EG HOTWELL (PP) barometric seal tank for spray EG system ‘Ax20038 EG SEAL VESSEL barometric seal tank for fresh EG spray system ‘Ae20E33._ SPRAY CONDENSER (PP) for condensation of vapours Ax20E34 EG COOLER (PP) {or cooling of spray EG from 20833 ‘Ax-20698 DEMISTER (PP) ‘or final condensation of vapours ‘Ax-20E37 EG COOLER (DEMISTER PP) for cooling of spray EG from 2036 ‘Ax-20F33. SPRAY EG FILTER (PP) [fsiit’ GAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer |i: P| os.12||_ c-0se/re-t1000 Jo eS‘Ac20P33._ SPRAY EG PUMP (PP) ‘circulate spray EG to spray condenser 20533 ‘Ac-20P96 SPRAY EG PUMP (DEMISTER PP) ' ciculate spray EG to demister 2036 Discane (DC) ‘Ax22042 EG HOTWELL (00) 2arometric seal tank for spray EG from spray condenser 22642 Ax22043, HOTWELL (00) barometric seal tank for spray EG from spray condenser 22643 | ! ' i i ‘Ax-22E42 SPRAY CONDENSER 1 (DISCAGE) ‘or condensation of vapours. ‘Ax22643_ SPRAY CONDENSER 2 (DISCAGE) ‘or condensation of vapours Ax22644 COOLER (DC) ‘or cooling of spray EG from 22644 ‘Ax-22646 DEMISTER (OC) ‘or final condensation of vapours Ax22E47 COOLER (DEMISTER DC) ‘or cooling of spray EG from 22646 Ax22F43._ SPRAY EG FILTER (00) ‘Ax-20P43_ SPRAY EG PUMP (DC) ‘o circulate spray EG to spray condenser 22642 /43 ‘Ax20P48 SPRAY EG PUMP (DEMISTER DC) ‘p ciculate spray EG to demister 2246 [EE __BAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer |2:. = sitc. —-Process Summary ‘The vapours from Ax-20R10 postesterfcation condensed in a single spray Tenderer SOEs i The vapours ffom A¥c20R10 prepolycondensation section and DISCAGE i Toactor are eandonced in two epray condoree syste, Por separation of i mists, oligomers and low boiling components a second large size spray ' condenser lomiste) Ie. povided ih. cach ‘ystom, before. the. non V ondensable gases reach the vacuum eggregele. : E “The systems of spray condensers are described nthe foloving table: ZB 4 ‘0 Poneier | Acaunio Pot [he22Ra0 DISCAGE H stage fet | - [tt | tna | tat | ta Condenser | 20623 | - | 20es0 | aoese | azecama| zzeas ttowen | 20023 | - | 2002 | a2n0ae | 2an4oma| 20005" Pup | zones | - | 20rae | aopae | zaras | zzpao itor ~ psf mars || zara | [cco | 2oeoazs| - | aoeaa | mesr | zacas | acer etium | Sport| - | SpentEG| FreshEG| Spent EG| Fresh EG > common tankiniemaly ides for bth al pray condenser systems To enhance the eficiency of the fresh EG system (Ax-20036) the total ‘amount of virgin EG, needed for paste mixing, Is routed through the spray EG ‘system and send back to EG mixing tank. In this way the oligomers removed from the process and collected in the hotwells and the water content in the EG spray system are diluted continuously. \Viigin EG is fed to the demister EG circuits of prepoly and DISCAGE reactor in a defined tatio (approx. 40% to prepoly / 60% to DISCAGE circu). The ‘sum of both EG feeds is controlled by the level control ofthe EG mixing tank Ac18S16. Tre excess EG from EG seal vessel Ax-20D36 (DISCAGE ‘chamber) overflows to EG hotwell (OC) Ax-22043 and from there via overflow to EGS drain tank A0-37890. In the same way the excess EG from EG seal vessel Ax-20D36 (prepoly ‘chamber) overflows to EG hotwell (PP) Ax-20D33 and from there via overflow 10 EGS drain tank A0-37800 as wll [SY BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer |: P| o5.12|/_c-40s4Pe-t1000 [0 seve4 sont A | Agama‘A fixed amount of spent EG from the EG hotwell (PE) Ax-20028 is sent ‘through the economizer Ax-20E13 to the process column Ax-20T'2 in order to reduce the water content in the spent EG. The economizer heats up the spent EG to approx. 150°C. This hope to avoid a blockage of the internal column packing bed with oligomers and reduces the disturbance of the ‘column temperature profile. ‘The level of EG hotwell (PE) Ax-20D23 is kept constant by a contol vaive in the feed line fom Ax-20P33 via spray condenser Ax-20E23, Excess prooess glycol (spent EG), which overflows from EG hotwell (PP) Ax- 20033 and EG hotwell (DC) Ax-22P43 are collected in the EGS drain tank ‘A0-37S00 and sent direct to the EG mixing tank Ax-18S16 using EGS feed pump Ax-37P91 i f u i I a y 4. Control Description ‘Throughput: Feed of fresh EG to spray EG system (Ax-22P46; DISCAGE) js cascade controled by a flow controller, which receives a remote setpoint from the plant throughput capacity. Fresh EG fee to spray EG system (Ax-20026; prepoly) is cascade controlled by a flow conroller, which receive a remote setpoint from the level control of the EG mixing tank Ax-18S16, ‘Spent EG feed from EG hotwell (PP) Ax-20038 through spray condenser Ax- 2023 to EG hotwell (PE) Ax-20023 is cascade controlled by a flow contyol loop, which receives a remote setpoint from the level controller of EG hotwell (PE) Ax-20D25, Spent EG feed from EG hotwell (PE) Ax-20D23 through economizer Ax- 20513 to process column Ax-20T'12 Is controlled by a flow contrl loop. The flow rate is kept constant in order to ensure stable operating condition for the process column, ‘Temperatures: ‘Temperature control loops are provided for the spray EG system Ax-20E24, Ax-20E34, Ax 20ES7, AX22EM4, AX-22E47. (GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer os 12[_eaoerreeano ol | sovee por AY [eS RoE oTMain Operating Parameter “The following lst shows approximate values forthe operating parameters, ‘Spray EG postesterication ‘Ax-20P23-— flow rate bp cont) pressure AX 20E23 spray EG flow rate tray ana) spray EG temp. ‘Spray EG prepolycondensation: Ax20P33— flow rate toxpay ana) pressure Ax20E34 spray EG flow rate pay ea) spray EG temp, Ax20P36 flow rate wosrismy pressure Ax20E37 spray EG flow rate ona) spray EG temp, ‘Spray AX2IPAS flow rate oxy ne) pressure AX22E42 spray EG flow rate epay a spray EG temp, Ax22E43 spray EG flow rate wpey ans) spray EG temp, ‘Axe22PA6 flow rate to sonsey pressure Ae22E48 spray EG flow rate wenswo ‘spray EG temp. 94-110 ag-114 ot 45 94 78-99 3 38 10.1-25 72-92 2 4 403 4-113 49 13 49 B 75-85 63-81 m4 mh barg mh *c mh arg mh ¢ mh arg mm *c th arg mth *c tty mh arg mth c BAC | GENERAL PROCESS DESCRIPTION Lhe lie Uhde Inventa-Fischer |=. [os 2, esa Po-11000 [0] a ed 40/6410. DIScAG! Section 22; FFD No.: ZL-11042 & ZL-21042 a. Basic Objective To produce high IV polyester polymer (IV lift in DISCAGE reactor) having a degree of polycondensation (DP) of approx. 150 - 165, starting from prepolymer received from the ESPREE reactor. ‘Major Equipment ‘Ax22A20 AGITATOR DRIVE TO DISCAGE ‘80-2029 4TM DRAIN VESSEL. ‘e collect Therminal 66 ‘Ax22E25 {TM EVAPORATOR (DISCAGE) “or heating the DISCAGE reactor and postester ‘Ax22P21. 2REPOLYMER PUMP ‘transfer prepolymer from ESPREE reactor ‘o DISCAGE reactor if ae ‘Ax-22P22 POLYMER DISCHARGE PUMP t 14 ‘0 discharge melt from DISCAGE reactor it ‘AeZ2Ra0 _DISCAGEREACTOR i ‘tthe prepolymer om low to high Ax22V20 VACUUM PIPE ‘0 connect DISCAGE reactor with spray condenser Ax-22E42 | Ax-22E43 GENERAL PROCESS DESCRIPTION Unde Inventa-Fischer|. > [sa] c-aves pe-ioo femce onc [eReProcess Summary ‘The final polycondensation reaction is carried out under high vacuum. The temperature ie higher and. tho pressure is lower than in the pie polycondensation stage. To prevent variations in the fished product, the {throughput of polyeondensation is kept as steady as possible. To achieve this, the leve of the DISCAGE reactor is controlled by flow control of the product feed into DISCAGE reactor using the speed controlled prepolymer ump Ai-22A21. The speed setpoint for the prepolymer is set by the inlet level controller of the DISCAGE reactor, ‘The specificaly designed DISCAGE reactor is a horizontal reactor, which ‘combines various features in order to reat the product gently to reach a final DP of 160 to 165. The highly increasing viscosity makes it necessary to force the product in a controlled way through the reactor, avoiding dead spots, generating @ large surface of product exposed to vacuum and keeping the process conditions at the lowest possible level. The reactor is equipped with a shaft less cage type agitator Ax-22A20, with a variety of discs (blades), rings, stripper rods and baffles to full the requested features. The polymer outlet temperature is kept between 278" and 282°C. ‘The DISCAGE reactor is connected with via two separated vapour pipes with the spray condenser system, For heating the DISCAGE reactor and the vapour pipes, an HTM evaporator Ax-22E25 is porvided to supply the required heat energy. “The polymer discharge pump Ax-22A22 builds up the required pressure for the fitration and distribution ofthe melt to the melt distribution system, ‘The melt line. downstream the discharge pump, is equipped with an online Viscosimeter Ax-26MS0, which controls the viscosity by setting the corres- ponding vacuum in the DISCAGE reactor in a range of approx. 0.5 - 1.5 ‘bara, “The agitator crum atthe very end ofthe discage is heated electrically to avoid cold spots where polymer replacement might be hindered. Control Description Throw ‘The polymer throughput in the DISCAGE reactor must be kept as steady as possible to prevent product variations. The inlet level of Ax-22R20 is main- fained by speed control of the prepolymer pump Ax-22A21. A pressure ‘control loop & provided downstream A¥-22A21 to enoure auiiciont pump lubrication and to keep the feeding congitions to DISCAGE reactor constant. Polymer discharge pump Ax22A22 is operated at constant flow rate, ‘corresponding withthe preset plant throughput (master conto). Uhde Inventa-Fischer [Rei GAG [GENERAL PROCESS DESCRIPTION eal comrscme a] | arm fe Ske REE wrTemperatures: ‘The HTV temperature in the HTM evaporator Ax-22E25 is set to achieve the required product tomporature. A temperature control loop ie provided, which ‘adjust the primary HTM (HPD) amount flowing through the evaporator’s tube bundle for heating Vacuum: ‘Vacuum of CISCAGE reactor is part of the viscosity control. The vacuum ‘controller (slave) of the DISCAGE reactor receives its external setpoint as ‘output of the viscosity contvol (master). “The controls cakes place with pressure control valve by throtting the ballast ‘steam injection info the respective header ofthe vacuum unit Levels: ‘The reactor levels are measured by nucieonic measurements. The init level of DISCAGE reactor is controled by backward control of the prepolymer pump speed (feed to DISCAGE reactor), while the outlet level is only an informative measurement to optimise agitator speed, temperature and hold- up, Uhde Inventa-Fischer |=. | 05.12||_¢-4088 Ft uRay__BAC | GENERAL PROCESS DESCRIPTION 000 [0] ares lamer fac |e‘Main Operating Parameter “The following list shows approximate values forthe operating parameters. ‘Ax20R20 vacuum ~05-1 temperature 278-282 residence time = 30 oP upto 165 agitator speed 08-12 Ax22625 HTM temperature ~ 283 «287 ‘Ae22P21 capacity, normal 25200 speed upto "160 Pressure 48 ‘Axe22P22 capacity, normal 251000 speed upto 20 pressure mex. 180 Flows prepolymer (in) 25000 polymer melt (ou) 25°00 ah ara ata bara ain gin [KERN BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|:=. | os12| caoserre-ioo o] | 4/04 aaa Ee a oe mT—s Ss | 41. Vacuum system Section 24; FFD No.: 2L-11046 & ZL-21046, a. Basic Objective To generate vacuum required by the polycondensation reaction in the ESPREE reactor Ax-20R10 and DISCAGE reactor Ax-22R20 by means of a steam ejector system using process steam, generated by the esterification reaction To collect all reaction water of the process and all the process vent stream gases. To strip-out the mejorty of the low boiling hydrocarbons (HC's) from the waste water, fr iis elimination together withthe process vent stream gases, by combustion inthe HTM plant b. Major Equipment A0-24861 SLOWER (STRIPPER) 1 supply ambient air and process vents to te stripper column ‘Ax24D53. SEAL VESSEL (VACUUM UNIT) ‘0 coliect all condensed process reaction water and fer barometric sealing ofthe vacuum system Ax24E51 FIRST CONDENSER 1 stage condenser to condense process vapor ‘and mative steam from initial vacuum stages AX 2485215 INAL CONDENSER ‘mull stage condenser to condense process vapor and motive steam from vent group AO-24E61 OFF GAS HEATER fo reheat gas from the stripper to avoid condensation ‘Ax24J50 VACUUM AGGREGATE consisting of vacuum group 2438 for prepoly vacuum group 2446/47/48 for Discage and vent group 2451/52/53, ‘mult stage vacuum unit to generate the required vacuum lup to 30 mbara) for postesteriication, 'up to 3 meara) for propoly and (up to 0.3 mbara) for DISCAGE. [ GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer os.2[ cose pono fol | seven se m/e‘A0-24P53. STRIPPER FEED PUMP ‘0 feed process water to the stripper column ‘Ax24P54 DRAIN WATER PUMP ‘0 drain out water from the underground pit | ‘A0-24P61 REFLUX PUMP 0 feed the process water as reflux'to the process column A0-24761 STRIPPER COLUMN ‘o eliminate low boilers from process water by a counter current process flow ©. Process Summary “The vacuum eggregate consists of tuo groups. Group one is the compression group and consists of 1 heated booster ejec- tors (Ax-24J38) for prepolycondensation and 3 heated booster ejectors (Ax- 24J46/47/48) for the DISCAGE reactor and a common surface condenser (Ax-24651), “The jackets of the booster ejectors are heated with steam to prevent icing, because at a suction pressure below 6 mbara, the corresponding saturated steam temperature drops below O°C. Ice is then form inside the suction ‘chamber affecting the operation. Group two ie the vent group and consists of three ejector stages (AX 24351152158) combined with a three stage surface condenser (Ax-24E52/53), “The vacuum in postesterification section is tied inthe condenser Ax- 24652 Reaction varours from the postesterifcation cascades, which are not ‘condensed in spray condenser Ax-20E23 (non condensables) are entrained ‘and condensed in the surface condenser Ax-24E62 from the vacuum system as far as possible. ‘The vacuum in prepoly reactor is generated by a one-stage-booster ejector system (Ax24J36), whereas the vacuum in the DISCAGE reactor is ‘enerated by a three-stage-booster vacuum elector system (Ax-2446/47/48), The mative s'eam is emitted by the motive nozzle at higher velocities and thus entraining and accelerating the surrounding vapours resulting in vacuum generation. Cue to a limited compression rallo of a single stage steam ejector, two oF more steam ejectors are arranged in series for reaching high vacuum levels such as 0.3 mbara. The process vapour and motive steam from all booster ejectors are condensed in the common surface condenser Ax24E51 AG GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|=. > os 12), casa ro-100 (a e i i 5 fear Ae i einNon condensable vapour proportions from the first condenser (Ax-24E51) are condensed together with the motive steam from the vent group ejectors (Ax 24J5152/53) in the final condensers Ax-24E52/63, This final condenser is ‘vided internally in three ectione. In tho fet eection, the vapours are ‘compressed by vent ejector Ax-24J51 from 100 mbara (in Ax-24E51) to about 260 mbara. In the second section, the gases are further compressed by vent tjector Ax-24J52 from 280 mbara to 630 mbara and the vent ejector Ax 24153 compresses the gases from 630 mbara to atmospheric condition (1000 ‘mbara). Cooling water runs through both surface condensers in series. The condensed vapour and motive steam together with the remaining process reaction waler are collected inthe seal vessel Ax-24D53, ‘The stripper feed pump Ax-24P5S feeds the process water to the stip column A0-24T61 where itis sprayed on a packing bed. Process vents are ‘collected from various off.gas points in the plant and blown together with fresh air from the bottom ofthe stripper column A0-24TE1 to top in a counter Current stream through this packing bed by means of blower A0-24B61. A considerably ber COD value in the process water is obtained. The airfoff- {gas mixture Is then sent through the off-gas heater A0-24E61 to the HTM Burner for combustion In case of low load or purging of one HTM burner with fresh alr, the of gas is sent to open atmosphere (usually only for a very short time) via a control butterfly vaive. “The reflux pump A0-24P61 feeds the stripped process water to the process ‘column Ax-20712, where itis used as column reflux to control the column head temperature. The stripped excess process water leaves the stripper sump to the waste water treatment plant, where itis neutralised in the collection basin 4. Control Description ‘The vacuum aggregate itself is running at its minimum suction pressure, The pressure (vacuum) in the postestefication section is controlled by a pressure Control valve in the suction ine. The vacuum in the 2”: flasher chamber of postesterficaton is controled by a control valve in the suction line to Ax- 2436, ‘The pressure (vacuum) in the prepoly and DISCAGE reactors are controlled by throtting tie ballast steam pressure valve. The ballast steam is directly ‘added into the ejector heads of the vacuum unit ‘The level of seal vessel Ax-24053 is maintained by a level control valve in the ‘eed line to the stipper column, “The gas flow rate to the stripper column A0-24TB1 Is adjusted by a pressure Control loop ata fxed flow rate [aca BAC | GENERAL PROCESS DESCRE Uhde Inventa-Fischer|:. | o5.12||_¢-4054/Pp-11000 fear ae ee Ba‘The off-gas leaving he stripper column is heated by providing process steam {othe off-gas heater A0-24E61. A temperature control loop keeps the off-gas ‘temperature at its setpoint, thus to avoid condensation inside the pipe. Main Operating Parameter “The following lst shows approximate values forthe operating parameters. e245 motive steam pressure; 1-15. barg postester suction pressure: 30-60 mbara propoly| suction pressure: 3-20 mbara DISCAGE reactor suction pressure: 0.3-20 mbara A0-24861 blower gasfiow: —~ 16000 mm ‘AG-24E61 off-gas heater gas temp. aterheater: ~90-100 °C ‘A¢24P53 stripper feed pump flow: 24-28 mm pressure: 50-60 barg ‘AG-24P61wofux pump fiow: 102-150 mh pressure: 75-83. barg ‘AG-24T61 stripper column —_—_gas feed temp, ~68 °C Romer BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|=# | os.2|| c-aossre-11000 [0] | aavo4 roar gee [ie ARR42. Melt Distribution and Transfe Section 26; PFD No: ZL-11080//ZL-21050 a. Basic Objectve To filter polymer melt and to distribute the melt o the pelletizer units 1 i Major Equipment Ax 2650 MELT FILTER SYSTEM toffilter the polymer mett ‘Ax26M50—-_-VISCOSIMETER {or continuous online measurement of viscosity Ax-26P55 HTM SECONDARY PUMP to circulate HSE to melt filer system and pellotizer die head for heating ‘AXAVBIC-26P51 MELT BOOSTER PUMP tometer the polymer melt tothe chipping system A/B/C ‘Ax26YP50 MELT TRANSFER PIPE to transfer the melt from discharge pump to polltizer units ©. Process Summary The polymer melt is discharged from the DISCAGE reactor by a specially designed gear pump, the polymer discharge pump Ax-22A22, which supplies ‘sulficient pressure to feed the melt through the melt fiter Ax-26FS0. The melt fiter is execuied as piston screen changer with four cavities and one curved filer screen in each cavity. When the differential pressure increases above a certain limit, the piston is moved out from the housing and the curved fier ‘sereen is removed from the cavity and replaced with @ new one. All curved fiter screens are exchanged durina the changing procedure. ‘The melt filers heated and the temperature is kept constant by a secondary HTM system (HSE). Downstream the melt fiter an online viscosimeter AX26M50 is installed, which controls the viscosity by selting the corresponding vacuum in the DISCAGE reactor. “The polymer fows through a special melt valve, which diverts the melt tothe thiee booster pumps AxAIBIC-26P51. Each of the booster pumps feed the melt to one of the chipping units AxAV/BIC-28M11 § cuisceunstne: _ureninenecnn : sl enc] cere Procaes Dee Ton | |Uhde Inventa-Fischer #2 > e512 | caossireoo Jo] | 40704 i bs erControl Description Thvoughput/ tow control ‘The melt booster pumps receives a setpoint forthe throughput from a master flow controle. This master flow controler considers the throughput of the polymer disctarge pump (plant capacity), the level in the DISCAGE reactor {and the number of chipping units in operation Pressure contol ‘The pressure at the suction side of the melt booster pumps is kept constant by adjusting the pump speed. ‘Temperature contro! The temperature of the melt line is heated and kept constant by a secondary HTM system (HSB) circuit. A temperature control loop controls the feed of primary HTM iHPD) into the secondary HSB system. “The met fiers heated and the temperature is kept constant by a secondary HTM system (HSE). HTM secondary pump Ax.26P55 supplies the necessary pressure. For heating a temperature contol loop controls the feed of primary HTM (HPD) Into the secondary HSE system, Main Operating Parameter The following ist shows approximate values for the operating parameters. ‘Melt conditions pressure 100-240 barg fomperature 278-282 °C HSB heating temperature (nat ine) ~285 °C HSE heating temperature (melt fiter system) =282 °C Uhde Inventa-Fischer |: | os.:2|/_ c-40sa/pe-tt000 |o [RIES BAG | GENERAL PROCESS DESCRIPTION cece Ae fice eave13. Chip Production ‘Section 28; FFD No: ZL-11054 & ZL-21054 a. Basie Objective ‘To convert motten polymer into pelts (chip) To crystallize the pelets (iatent heat crystallisation). b. Major Equipment AWNVBIC-28822 VENT BLOWER {or aspiration the air from the pre-dryer drum ‘AWAIBIC-28E15 HTM HEATER (DIE PLATE) {or heating of the de plate Ac 28616 HTM COOLER (DIE PLATE) for cooling HTM fiowing through die plate A28622 RECOVERY CONDENSER {or condensing vapors from chips dryer Ae 28628 SPRAY WATER COOLER for cooling the spray water of water circuit Ax 28F24 ROTARY FILTER for removing chipping dust Ax28024 PROCESS WATER TANK to receive process water from the rotary filters AWAIBIC-28H11 START-UP VALVE {or start-up (feed) to pelletizer or crain mett to buggy AXNIBIC-28M11. CHIPPING UNIT to conver the polymer met to sold pellets in an under water outing process AWAIBIC-20M12 PREDRYER to separate water from pellets (dewatering) AWVBIC-28M13_ CHIP SCREEN to separate oversized chip AxAV/BIC-28P15 HTM SECONDARY PUMP fo circulate HTM through die plate ‘AvNVBIC-28P24 PROCESS WATER PUMP BAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer 3 i ieee{o provide process water tothe under water pelltizer unit A 28°25, [SPRAY WATER PUMP. {o provide process water to the recovery condenser Ax-28E22 Process Summary 3 chipping systems (A, B and C) are provided. Each system consists of a Start-up valve, under water pelletizer unit, agglomerate catcher drum, chip ‘screen and process water system, The rotary dryer Ax-28F24, the Recovery Condenser Ai-28E22 and the Spray Water Cooler, Ax-28E26 are common forthe sublines A til C. ‘The polymer booster pump AxAVBIC-26P51 supplies the melt to the start-up valve AxA/BIC-28H1 1, The polymer melt is forced through the holes in the die plate of the pelletizer unit AXAIB/C-28M11 forming strands which enter the water filed cutting chamber. In the cutting chamber the strands leaving the die holes are cut almost instantaneously into pellets. Because of the high temperature cifference between the melt and the process water temperature the ut polymer drops solfies immediately at their surface and forms the ‘characteristic spherical shape of under water cut pellets. 4 ‘The pelletiwaier mixture flows through the agglomerate catcher, which is a par of the chips dryer AxA/BIC-28M12. This agglomerate catcher avoids that pellet clusters (agglomerates) enter the rotor area of the centrifugal pellet dryer. In the centrifugal pellet dryer AxA/BIC-28M12 the pellots are separated from the process water. Due to the fast rotation of the angled rotor blades the pellets aro forced helically upwards, The process waler is separated by the ‘centrifugal force from the pellets trough the perforated diyer screen and {lows back into the collectingiwater tank ‘The pellets are retained within the dryer drum by the stationary dryer screens. tnt they reach the top and leave the dryer through the pellet outlet. The ‘moisture content of the pellets is reduced significantly. Water vapours are ‘sucked off by Blower AXAIBIC-28B22 into the recovery condenser A¥AIBIC- 28E22, in which the vapours are condensed. ‘The process water Is provided by a closed recirculation system, containing emineralsed water. Ine system consisis of a rotary water Titer AKAVBIC~ 28F24, a spray water pump Ax-28P25 with is spray water cooler Ax-28E26 ‘and the process water pump AxA/BIC-28P24. A common water tank AX 28024 is equpped with a steam jet preheater for heating the process water ‘during startup, [stay _ BAC | GENERAL PROCESS DESCRIPTION "| os.12||_e-4084mB-11000 ee Agave Uhde Inventa-Fischer“The separated process water from the drying screen containing cutting dusts combined together with the spray water from the recovery condenser and flows through a slowly rotary filer screen drum (process water sieve) Ax 28F24 into the water tank. The process water pump AXAJBIC-28P24 feeds the fitered process water back to the cutting chamber of the under water pelletizer unt. ‘A patt stream of the fitered process water is used as spray water for the recovery condenser. The spray water pump Ax-28P26 feeds the process ‘water through the plate heat exchanger Ax-28E26 (to removing the heat energy transfer from the melt droplets) to spray nozzles in the recovery Condenser. Enlrained water vapour from the centrifugal dryer are condensed by the spray water and retuned together with the separated process water back through the slowly rotating screen drum (fotary fier) into. the collecting/water tank, Ax-28024 Oversized chips or agglomerates, wihich have passed the agglomerate catcher and leaving the centitugal pellet dryer AxAVBIC-26M 12 are separated by the chip vibrating soreen AxA'BIC-28M13, The regular size chip is passed into the chip intermediate slo Ax-29S11. Pneumatic operated pellet diverter valves allows sampling during production or separation of off-spec pellets during start-up. 4. Controt Description Under water reletizing unit ‘The speed of the rotating knife is controled from the local control board or from the process control system. The speed adapts to variations of the 4 polymer low rate from booster pump AXA/BIC-26P51 to ensure that pellets of f constant size are produced, Agglomerata catcher ‘A pholo-lectical eye activates an alarm, f agglomerate clusters or lumps ae being produced Centrifugal drver ‘The rotation cf the dryer rotor is monitored by means of an inductive sensor which is interconnected with the local contro! system, Process water circulation ‘control loop is provided to control the flow rate of the process water supply to the under water pelltizer unit by means of a flow controller, which gives. the Setpoint tc the frequency inverter of process water pump AxA/BIC-28P24. ‘The process water fed to the pelletizer unit as well as the spray water is temperature controlled, ©, Main Operating Parameter “The folowing st shows approximate values forthe operating parameters . Melt conditions pressure 100-150 barg : TEE GAD [GENERAL PROCESS DESCRIPTION, = | unde Inventa-Fischer Postal caase/eeanono [ol] eaves i ie leat anatemperature Pallets ‘weight per 100 chips Process water circulation temperature spray water spray water temperature 278-282 °C 14-18 g(oval) 70-120. mth 80-90 °C ~135 mn ~38 °C sci __ BAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|# > | os.12|| c.aosa/P-11000 |o| 54164 jase OA |i eR a4 Chips Conditioning ‘Section 29; PFD No: ZL-11058 & ZL-21058 Basic Objective ‘To transpor the pellets from intermediate silo to conditioning sito, To reduce the acetaldehyde content (A) formed during production, To transport the pellets from the conditioning silo to the chip silos. Major Equipment Ax29813 CONDITIONING AIR BLOWER {or feeding air to the chip conditioning silo ‘Ac29816 AIR BLOWER for feeding air tothe intermediate chip silo ‘Ax29017 EXPANSION VESSEL (WHH) to ensure enough cooling water for circulation ‘Ax29611 AIR HEATER (TRANSPORT) ‘heat up air for hot chip transport Ax29E12 CHIPS COOLER (part o'29812) to cool down conditioned chip ‘Ax29E13 CONDITIONING AIR COOLER {o remove heat energy of blower 29813 from dry air before entering into the conditioning silo ‘Ax20616 AIR HEATER TO INTERMEDIATE SILO {heat up the air fed to the chip intermediate silo Ax29617 WATER COOLER {or cooling the circulation water flowing through 2012 ‘Ax29F11 AIR FILTER (TRANSPORT) for fitering the ar before used as conveying medium for hot chip transport ‘Ax29F14 AIR FILTER (TRANSPORT) ‘or fitering the at before used as conveying medium for cold chip transport Ax29H13_ AIR DRYER fo remove moisture from air to be fed tothe chip conditioning silo stay BAC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|==. | os12/ 2 5108 lar Ae | OME Gt‘Ax29A17 COOLING WATER PUMP {o maintain the cooling water circulation ‘through the chip cooler 29612 ‘Ax29011 HOT CHIP CONVEYOR ‘o transport pellets from Ax-29S11 to Ax-29812 ‘Ax29014 SHIP CONVEYOR ‘2 transport pellets from conditioning silo to chp storage silos ‘Ax20015 CHIP FEEDER (BLENDING) ‘0 feed off spec chip to intermediate sto 20811 ‘Ax20016 BAG LIFTING DEVICE ‘or iting big bags y L i i H Ax29S11 SHIP INTERMEDIATE SILO :0 buffer and to feed chip to hot transport system Ax29812 SHIP CONDITIONING SILO ‘o remove AA from chip during the hold-up time ‘Ax20S15 4JOPPER OFF SPEC CHIPS ~ buffer chips before feeding to intermediate silo 29811 Process Summary ‘The intermediate silo Ax-20811 receives the chip from the chipping systems. Alternatively off spec chips are filed into the off spec hopper and dosed by chip feeder Ax-20015 in a controlled manner into the intermediate silo Ax- 29811 for blendingimixing the off spec chips with on spec chips. ‘The tempered chips in the intermediate silo Ax-29S11 are conveyed into the Chip conditioning silo Ax-29812 by the pneumatic hot chip conveying system ‘Ax-20Q11 using compressed air. The aii fitered through air fiter Ax-29F 11 and heated ty air heater Ax-29E11 to almost chip temperature (~ 170°C) before used as transport medium. The chip conditioning silo Ax-29812 consists of two main parts; the upper part or the concitioning section and the lower part or the chip cooling section ‘The main target of the conditoning process is to remove the undesired side product aceteldehyde (AA) from the pellets. In the conditioning section the ‘acetaldehyde (AA) is released from the crystalized pelets by gas diffusion force due to the long hold-up time in combination with the temperature (tempering). In the lower section the hot crystallized pellets are cooled down by passing the built-in heat exchanger Ax-28E12. The cooled chips leave the silo and are conveyed to the storage and/or packing area by a cold chip ‘conveying system. te BAG | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|:=*. | 00.12) c-oss iP ee Ae fe Sse GS mr oak SB 1000 [0 6/04Ambient air is passed through the dehumidifier AX-29H13. The dew point is reduced signficantly to approx. 40°C. The dy air is fed to the conditioning silo Ax-29S12 by means of conditioning air lower Ax-29813. Conditioning air ‘cooler Ae 20613 removes the heat energy from the alr blower. Thie cold and dry ar Is blown to the bottom ofthe chip conditioning sto Ax-29S12, where it ‘assists coaling of the chip and therefore reaches its process temperature at the cooler oullat. The air now passes in counter flow to the chip flow through the conditioning silo and absorbs the released acetaldehyde from the chips. ‘This air together with acetaldehyde (process air) leaves the conditioning slo and is partly fed to the process off-gas system (Ax-24861) and partly sucked con by ar blower Ax-29816. The air blower AX-29B16 blows the process alr through the air heater Ax 29616 into the intermediate silo Ax-29511, The heater increases the air {temperature tothe required process condition for tempering the chip. A pait of the process air leaving the intermediate silo Ax-20811 is fod in a direct way via an adjustable butterfly valve to the chips dryer Ax-28N12, Whereas the main part of the process air leaving the intermediate silo Ax: 229811 is directed through the incoming chip pipe creating a counter flow. Control Description ‘Throughput level Chip intermediate slo Ax-20S11 acts as a buffer silo. Its level is forward controlled by the speed of the rotary valve, which is part of the hot chips ‘conveying system Ax-2901 1. ‘The level in chip conditioning silo Ax-29812 is fonvard controlled by the speed of the rotary valve, which is part of the conditioned cold chips ‘conveying system Ax-29014, ‘Temperature: Dew point of the air to be fed into the chip conditioning silo Ax-29812 is Controlled by he independent control system ofthe air dryer Ax-29H113. Conveying air forthe hot conveying system is heated by HSB feeding through the conveying air heater Ax-29E11. A temperature control loop keeps the conveying air temperature at its setpoint. Aicflow rate: ‘The ait flow to the chip conditioning slo Ax-20812 is adjusted manually at an appropriate fow rate GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer os. ea0eeee-1ee [ol sree re Ane Geesfe, Main Operating Parameter ‘The following list shows approximate values forthe operating parameters. ‘Ax29813 conditioning air blower flow ~ 31000 ‘Ax29E13 conditioning air cooler after cooler: ~40 Ax20816 air blower flow: ~ 1500 -1"700, AX29E16 airheater afterheater: — ~ 170-175 ‘Ax20812 conditioning silo conditioning part ~170 cooling part ~60 gh °c ah °c tc c [Eis AC | GENERAL PROCESS DESCRIPTION Uhde Inventa-Fischer|e=. >. os12|| canst iPe-s000 0] ayes leona ode [ine astra es18. Chips Storage and Transport Section 33; FFD No: ZL-11069 & ZL-21069, Basic Objectve To store the chips for bagging ‘Major Equipment Ax39043. SHIP PACKING UNIT “or bagging the chip into big bags ‘Ax38044 OHIP PACKING UNIT ‘or bagging the chip into big bags, ‘Ax33045 SONTAINER FILLING UNIT “er conveying the chip to container Ax39831 HIP STORAGE SILO ‘Ax-33832_ CHIP STORAGE SILO ‘Ax33833 CHIP STORAGE SILO ‘Ax-33839 CHIP OFF SPEC SILO Process Summary “The pneumatic chip conveying system transfer the chip from condoning silo Into the chip storage slo Ax-3383132/33 or if required into the off spec silo ‘Ax¢-33838, The target silo can be selected from the process contol system, Chip bagging units Ax-38041 / Ax-33049 are provided for bagging the chip into big bags. ‘A pnoumatc conveyed chip transport system (container filing unit), Ax- 33045, is installed to feed the chip from the storage silo directly into containers. Control Description Start and stop of the container filing unit is controlled from the local contro! board next to “he container [iSii? BAC] GENERAL PROCESS DESCRIPTION Unde Inventa-Fischer| 2 os.2| canes e-too [ol sore [sce AC i ae BoP16. ‘Spent EG Collection ‘Section 37; FFD No: ZL-11078 Basic Objective ‘To callect spent EG from the hotwell overflow resp. from various drain points, ‘Major Equipment ‘A0-37P90 EGS TRANSFER PUMP ‘o transfer spent EG to mixing tank or process column ‘Ae37P01_ EGS FEED PUMP ‘0 transfer spent EG to mixing tank Ax-18S16 ‘A0-37890 EGS DRAIN TANK \o collect EG from hotwells and drain points Process Summary The major part of the virgin EG is fed to the demister circuit of DISCAGE reactor and collected in EG seal vessel Ax-20038 (discage chamber). The ‘excess EG overflows from EG seal vessel Ax-20D36 to EG hotwell (DC) Ax- 22042143 in order to dilute the oligomers, by-products and the water content formed during the final polycondensation reacton. This spent EG overflows {rom the hotwell (OC) Ax-22042/43 to the colecting chamber of the EGS ‘drain tank A0.37880. ‘The rest ofthe vigin EG is fed in a similar way to the demister cuit of the prepolymer reactor and collected in EG seal vessel Ax-20036 (prepoly ‘chamber). The excess EG overtiows from EG seal vessel to EG hotwell (PP) ‘Ax-20038 for dilting the oligomers, by-product and water content formed ‘during prepolymerisation reaction. A part stream of this spent EG is routed to the postesterifcation hotwell, ‘whereas the excess spent EG overflows from the hotwell Ax-20D33 together with the epen: EG from hotwell (DC) Ax-22042/48 to the collecting chamber of the EGS drain tank AD-37S90 as well ‘The EGS drain tank A0-37890 is divided in three chambers, Each ine has its own colleting chamber. This allows a line independent recipe and process ‘uideline, whereas the drain chamber serves as @ common collecting Compartment for both lines, EGS feed pump Ax-37P91 transfers the spent EG from the collecting chamber to EG mixing tank Ax-18S16, Uhde Inventa-Fischer [isia?__6AG_ | GENERAL PROCESS DESCRIPTION 5.12 | €-40s¢/ 6.11000 [o fees eaveUsed / spent EG from various drain points, (e.g. cleaning of plate heat exchangers, raining of pipes for equipment maintenance etc) are routed to the EGS drain tank A0-37800 and collected in the drain compartment. EGS transfer pump A0-37P90 transfers the drained spent EG to the process column Ax-20712 for recovering, to the EG mixing tank AX18S16. for reeycing orto the existing spent EG collecting tank 0-345-S.02. 4. Control Description ‘The spent EG flow from the collecting chamber to EG mixing tank Ax-18S16 is controlled by a level control loop. The spent EG flow from the camman drain compartment to process column, EG mixing tak or altematively to the existing spent EG collecting tank Is: Controlled by a flow control loop. Main Operating Parameters “The following lst shows approximate values for the operating parameters bh A0-37P90 tow rate: 125-16 mith 4 oe eeu nes ff , ! Reet ena nee E pressure 45-56 borg 4 | 7 ‘A0-37800 collecting chamber: =16.5 m iH Aran compartment: 13m i A TES GAO | GENERAL PROCESS ESCRIPTON Unde Inventa-Fischer|2. | 12 c-aose/ps-100 [o| feemer ay [ees Bee417. Flakes Depolymerisation Section 38 PED No. ZL-11048. a. Basle Objectve Feeding depalymerised post-consumer PET-flakes into prepolymer line b. Major Equipment At-38F38 VENT FILTER ‘A‘-30M38_ METAL SEPARATOR A1-38838 FLAKES SHIFT SILO ‘A-38042 EG FEED VESSEL DEPOLY ‘44-38052 HOTWELL DEPOLY ‘A1-38E51_ SPRAY CONDENSER DEPOLY ‘A1-38E52 SPRAY WATER COOLER ‘A1-38F60 PREDEPOLYMER FILTER A1-38F81 DEPOLYMER ‘A1-38F52_ FILTER SPRAY WATER FILTER ‘A1-38M41_ DEPOLY EXTRUDER ‘A1-38MB1_VISCOSIMETER A1-38P42_ EG DOSING PUMP |A1-38P61_ DEPOLYMER BOOSTER PUMP f A1-38P52__ SPRAY WATER PUMP f ‘A1-39P64 VACUUM PUMP ‘A138C41 FLAKES DOSING DEVICE : TSSS7__BAG [GENERAL PROCESS DESCRIPTION, _ |Uhde Inventa-Fischer|: | 05.12\/_cosa/pe.11000 [o| eres i leer ie ReamProcess Summary The PET tlakes are exclusively supplied by silo truck. From the silo tuck the flakes are blown by means of pressurized air which Is generated on the silo truck (OSBL) to the Storage Silo, A1-38836. From the Storage Silo the flakes ‘are further fed into the Flakes Shift Silo A1-38838, located over the Flakes Dosing Device, A1-38M41, whichis built asa twin screw extruder. Inthe Depoly Extruder the flakes are molten, degassed and depolymerized. The depolymerization is made by addition of EG, metered by the EG Dosing Pump ‘A1-98P3642, at a controlled ratio into the Depoly Extruder. The ‘depolymerization is controlled by a capillary type inline Viscosimeter, At1- 38M6t ‘Tho depolymer is discharged from the Depoly Extruder into the coarse Predepolymer Fiter, A1-38F60. From there the melt is fed to. the Depolymer Booster Pump, A1-38P61, and is fitered by the finer, backflushable Depolymer Filter, A1-38F61, before itis metered by the Depolymer Dosing Pumps, At- '38P61, into the prepolymer lines to the existing finishers, ‘The degassing is made in a vacuum zone in the Depoly Extruder. Degassing is, mainly necessary to lower the water content ofthe fakes, in order to keep the viscosity on a high enough level. The vapors from the Depoly Extruder are ‘condensed ina Spray Condenser, A1-38E51, which is operated by process water cooled by chiled water. The required vacuum is generated by a water ring Vacuum Pump, A1-38PS4, The process water to the Spray Condenser flows to the berometric Hotwell, A1-38062, ‘The Spray Water Pump, A1-38P52, pumps the process water via the Spray Water Filter, A1-38SF82, to the Spray Water Cooler, At-38SE52, where it is ‘cooled down tothe necessary temperature needed in the Spray Condenser. ‘GENERAL PROGESS DESCRIPTION | Uhde Inventa-Fischer 0s.12| c4088/pB.41000 [0] | esves seston See, Sea| i : a: i ©. Control Description “The flakes are dosed by the flakes dosing device, A1-38041, into the extruder. ‘The melt pressure attr the extruder is controlled by the speed ef the depolymer booster pump, A1-38P91, ‘The viscosity is measured by the viscosimeter, A1-38M61, which controls the amount of EG fed by the EG-pump, A1-38P42, into the extruder. d. Main Operating Parameters, A1-38M41 flow rate Melt temperature A1-38P54 vacuum pressure ‘AN-38P52 owrate A1-38P42 ‘ow rate 150 tay 290 °C 50 mbara 5000 kg/h 25 kal Uhde Inventa-Fischer (GENERAL PROCESS DESCRIPTION 06:2] eaose 7-0 [ol ee Ae Bae,