Polymer Plant Eqpt 1

POLYMER PLANT EQUIPMENT

Equipment handled by PED in a typical Polymer Plant

CentrifugeRotary dryerPneumatic Conveying SystemMetering PackageMixers (Homogeniser)Extruder & PelletiserDelumper Dewatering ScreenPellet DryerClassifier ScreenBagging & Palletising Systems

POLYMER PLANT EQUIPMENTREACTOR CENTRIFUG

EROTARY DRYER

POLYMER POWDER STORAGE

METERING PACKAGE

HOMOGENISER MIXER

EXTRUSION & PELLETISING

PELLET STORAGE

BAGGING & PALLETISING

ETHYLENEH2

SOLVENTCATALYST

SOLVENT (LIQ.)

POLYMER CAKE

POLYMER SLURRY

SOLVENT (VAP.)

ADDITIVESSTABILIZERS

DEWATERING

SPIN DRYING

CLASSIFICATION

BLENDING

ELUTRIATION / SCREENING

BAGGING STORAGE

WAREHOUSING

CENTRIFUGEPurpose:To separate polymer solids from polymer slurry

Working PrincipleThe basic centrifuge idea is based on what happens in a settling tank, in which particles, sediment and solids gradually fall to the bottom, and the liquid phases of different density separate due to the force of gravity. However, such clarification is an extremely slow process and is unable to meet industry's needs for rapid, controllable results. The general idea behind centrifuges is therefore to ensure that the mechanical separation of different liquid phases and solids can be carried out on a rapid, continuous basis in order to meet the demands associated with modern industrial processes.

In essence, a centrifuge is a settling tank whose base is wrapped around a centerline.Rotating this entire unit rapidly means that the effect of gravity is replaced by a controllable centrifugal force that can have an effect upto 10,000 times greater.This force is then used to separate liquids from other liquids or solids.

SETTLING TANK SETTLING TANK WITH DISCS

DISC STACK CENTRIFUGE

CENTRIFUGETypes:

• Horizontal • Vertical• Atmospheric • Pressurised• Solid Bowl • Screen Bowl

CENTRIFUGE Decanter centrifuges are generally used for

greater solids concentrations with larger particle sizes.

Disc stack centrifuges, on the other hand, are ideal for a wide range of separation tasks that involve lower solids concentrations and smaller particle and droplet sizes. This applies to both liquid liquid and liquid solid separation.

CENTRIFUGE

Filters

Disc Stack Centrifuges

Decanter Centrifuges

Particle Size(µm)

Amount of Solids

40%

30%

20%

10%

0.1 1 10 100 1000

Disc Stack Vertical Centrifuge

Inserting special plates (the "disc stack") provides additional surface settling area, which contributes tospeeding up the separation process dramatically. It is the particular configuration, shape and design ofthese plates that make it possible for a disc stack centrifuge to undertake the continuous separation of a wide range of different solids from either one ortwo liquids.

The concentrated solids phase formed by the particles can be removed continuously, intermittently or manually, depending on centrifuge type and the amount of solids involved in the specific application.The clarified liquid phase (or phases) overflow close to the rotating axis, in the outlet area on top of the bowl. The liquids then flow into separate chambers. Each separated liquid phase then leaves the bowl due to the force of gravity or by means of a paring disc, which is a special pumping device. The chambers can be sealed off from each other to prevent any riskof cross-contamination.

How a disc stack centrifuge works ?

A disc stack centrifuge separates solids and one or two liquid phases from each other in one single continuous process, using extremely high centrifugal forces. When the denser solids are subjected to such forces, they are forced outwards against the rotating bowl wall, while the less dense liquid phases form concentric inner layers.The area where these two different liquid phases meet is called the interface position. This can be easily varied in order to ensure that the separation takes place with maximum efficiency.

CENTRIFUGE

Solid Retention Intermittent Solid Discharge

Continuous Solid Discharge

CENTRIFUGE (BOWL TYPE)The separated solids are conveyed by the helical screw conveyor along the bowl cylinder and over the conical section of the decanter to the solids discharge. As they pass over the cone, the solids dewater by a combination of drainage and compression, the degree of which is dependent on the nature of the solids, the adjustment of the centrifuge, and the required degree of dewatering.

CENTRIFUGE(SOLID BOWL)

CENTRIFUGE(SCREEN BOWL)

 Actually two machines in one combines the clarifying benefits of the solid bowl centrifuge and adds a final dewatering screen section to produce maximum dryness. Best suited for crystalline or granular solids  with free-draining characteristics. Unit capacities up to 100 tons/hr dry solids.

CENTRIFUGE(SCREEN BOWL)

CENTRIFUGE(VERTICAL)

POLYMER DRYERSThe wet slurry out of Centrifuge still has about 30% solvent / water. This needs to be dried in Dryer.

Types of Dryers:

Rotary Dryers Fluidised Bed Dryers

ROTARY DRYERType Of Rotary Dryers

Direct Fired TypeSteam Tube Type

ROTARY DRYER (DIRECT FIRED TYPE)

Operating Principle

In direct fired dryers, hot air generated by firing of fuel is made to pass through rotating drum with lifters. Hot air when comes in contact with the wet slurry, dries the polymer powder which is conveyed either pneumatically or through rotating scroll

•

ROTARY DRYER(STEAM TUBE TYPE)

This unit gives continuous heating or cooling of solids in an inert atmosphere, or in a medium vacuum state or under pressure. Indirect heat transfer is effected by conduction and convection, and constant temperature can be set by steam pressure. Unit operation is closed. Complete recovery is possible. Low sweeping gas required.

ROTARY DRYER(STEAM TUBE TYPE)

The wet feed which has free flowing granular form is made to work over the rotating bundle of heated tubes.

Due to radiation and conduction effects, the moisture is evaporated and the product becomes

progressively dry as it travels across the dryer and reaches final

moisture level at the discharge point.

Due to effective turbulence the solids are dried uniformly.

ROTARY DRYER

ROTARY DRYER

ROTARY DRYER (TYPICAL P&ID)

FLUIDISED BED DRYERSMaterials are treated in fluidized, agitated and suspended conditions by various gases. Heat is provided directly by burning fuel or injecting fuel to the fluid bed.

Heating elements for indirect heating by steam can also be installed.

Spent off-gas can be recycled for preheating air to save fuel Spent off-gas can be recycled for preheating air to save fuel costs. This is a relatively maintenance-free equipment.costs. This is a relatively maintenance-free equipment.

METERING SYSTEMSMetering Systems are required for feeding of controlled and metered quantities of virgin Polymer Powder and other additives to impart the required properties to the end product.

Types of Metering Feeders:

Volumetric Feeders Gravimetric Feeders Mass Flow Meters Belt Feeders

Typical Compounding in Polymer Plant

Loss in Weight Feeders

Loss in Weight Feeder

Loss in Weight FeedersMass Flow Feeder

How Loss in Weight Feeders work?

The Feeder and the supply bin are weighed with material supply.From the Loss in Weight per unit time of the bin, the actual flow rate is compared with the set point and the feeder is controlled in such a way that the actual flow rate corresponds accurately and consistently with the set point.During the refilling the feeder operates volumetrically by the control magnitude stored during the gravimetric period of operation.

Types of Loss-in-Weight Feeders

Vibro Feeder For Granular Material

Single Screws For Powdery Non-Sticky Material

Self Cleaning Double Screws For Powdery Sticky

MaterialSpirals or Double Spiral For Mixture of Pellets

& Powder

Why Loss in weight as compared to Volumetric Feeding?

SINGLE SCREW LOSS IN WEIGHT FEEDER

Types of Feeding Devices

Installation

Some more Installations

Belt Weigh Feeder

Working Principle of Belt Weigh Feeder

Belt load and belt speed signals are routed to the microprocessor-controlled measurement, control and regulation system, where they are processed and the actual feed rate is continuously compared with the set feed rate (set point) to assure that belt speed is controlled such that feed rate is maintained at a constant level.

Types of Feed Hoppers

Types of Feed Hoppers

Coriolis type Mass Flow MetersMeasuring principle

The Coriolis force is a force, which acts upon a moving mass on a rotation wheel. This physical law is the basis of Coriolis measuring systems. Feed material is fed to a measuring wheel running at a constant speed.

The Coriolis force acting upon the feed material is measuredwith high precision by integrated load cell and it is exactly proportional to the mass flow, even at varying bulk density and grain size.

Coriolis type Mass Flow Meters

P = feed rate [t/h]

MP =

• R 2

FZ = centrifugal force

FC

FR

FZ

M= torque = FC · R

= angular velocity [1/s]R = radius of measuring wheel [m]

FR = friction force

FC = CORIOLIS force

No impact to Fc

EXTRUDER & PELLETISERSystem Components:• Extruder (Barrel & Screw)• Diverter Valve• Gear Pump• Screen Changer• Die Plate• Underwater Pelletiser• Hydraulic Oil Unit• Hot Oil Unit / Barrel Cooling Water Unit• Lube Oil Units•Pellet Cutting Water (PCW) Unit

EXTRUDER & PELLETISER

• Largest Power Consumer In A Polymer Plant

• High Operating/design Pressure (~350 Kg/cm2g)

EXTRUDER & PELLETISERParameters For System Design

• Capacity (Kg/h)• Melt Flow Index (MFI) Range• Feed Inlet Temperature• Feed Volatile Content• Max Allowable Processing Temperature• Density• Product Pellet Size. Finishing requirements

TYPES OF EXTRUDERSBASED ON NUMBER OF SCREWS:Single Screw TypeTwin Screw Type

BASED ON DIRECTION OF ROTATIONCo-rotating TypeCounter Rotating Type

EXTRUDER & PELLETISER

EXTRUDER & PELLETISER

EXTRUDER & PELLETISER

EXTRUDER & PELLETISER(MAIN DRIVE SYSTEM)

Main Drive

Process Side

Reduction Gear

Distribution Gear

EXTRUDER & PELLETISER(MAIN DRIVE SYSTEM)

EXTRUDER & PELLETISER(SPECIFIC ENERGY INPUT)

Specific Energy Input Vs Throughput

0.8 MFI20 MFI

Rate t / h

SEIkWh/kg

EXTRUDER & PELLETISER(BARREL HEATING / COOLING)

Steam ~ 40 bar

Water Water

Electrical Heaters

EXTRUDER & PELLETISEREXTRUDER & PELLETISER(BARREL HEATING / COOLING)(BARREL HEATING / COOLING)

Barrel cooling circuit for water cooling

Barrel heating circuit for steam heating

EXTRUDER & PELLETISEREXTRUDER & PELLETISER(BARREL HEATING / COOLING)(BARREL HEATING / COOLING)

Barrel Heating / Cooling Manifold

Barrel Heating / Cooling Manifold

Barrel Heating / Cooling Manifold

Barrel Junction Boxes

Barrel Junction Boxes

Junction boxes

Heater shells (wired up to junction boxes)

Cooling manifold (mounted)

EXTRUDER & PELLETISER

EXTRUDER & PELLETISER(SCREW SHAFTS)

EXTRUDER & PELLETISER(SCREW SHAFTS)

2 Flight & 3 Flight Screws

3-flighted profile (Do/Di= 1.22) 2-flighted profile (Do/Di= 1.44 – 1.8)

SLOT CONTROL

EXTRUDER & PELLETISER

EXTRUDER & PELLETISER

EXTRUDER & PELLETISER

EXTRUDER & PELLETISER

EXTRUDER & PELLETISER

EXTRUDER & PELLETISER(GEAR PUMP)

Gear Pump Cross section

Dual Pack Screen Changer

Filter Elements

Dual Cylindrical Slide Bars

Product Inlet

Hydraulic Actuators

EXTRUDER & PELLETISER(SCREEN CHANGER)

EXTRUDER & PELLETISER(SCREEN PACK)

EXTRUDER & PELLETISER(SCREEN CHANGER & DIE PLATE)

EXTRUDER & PELLETISER(DIE PLATE & CUTTER)

Typical Die Plate Cross Section

Multiple Row Design Twin Row Design Single Row Design

More Heat Transfer Area

EXTRUDER & PELLETISER(UNDERWATER PELLETISER)

PELLETISER CROSS SECTION

PELLETISER CUTTER SETTING

SPIN DRYER

SPIN DRYERProcess Water is removed prior to the Product reaching the rotating impact stage resulting in less power consumption. The two level design prevents the Rotor from agitating constantly in water, reducing component stress and eliminating the need for expensive and maintenance intensive shaft seals.

Once the majority of Process water is removed, the product enters the rotor where it is picked up and conveyed upward through the dryer

Air flow counter current to product flow is introduced in the upper portion of the dryer. This prevents the moisture from escaping with the product and further reduces the surface moisture level. Surface moisture removal can be achieved upto 500 ppm level.

SPIN DRYER

SPIN DRYER

BLENDERS

During production, variation in properties of product takes place due to various reasons. The customers demand a homogeneous product. Hence the need for Homogenising Blenders.

Types of Blenders:

Fluidised Silo Blenders (for Powders) Static Multi Tube Blenders (for Pellets)

BAGGING & PALLETISING Granular, Powder or Pellets Bagging &

Palletisation for Polymers

Types:Fully AutomaticSemi Automatic25 Kg. or 50 Kg. Bag1000 Kg. Big Bag ( FIBC)20000kg F IBC Bag inside containers

BAGGING & PALLETISING

Parameters For System DesignDesign Basis Production RateNo. of Days Per Year OperationNo. of Shifts Per Day Effective Hours Per ShiftWeight Of Each BagType Of SystemWeighing AccuracyFuture Expansion Provision

BAGGING & PALLETISING

System Specifications

Capacity , Bph / TphWeight of BagBag Specification / Type of Bag – Gussetted or

Pillow BagWeighing AccuracyMaterial CharacteristicsType Of Bag Closing - Sealing or StitchingPalletiser CapacityWrapping Requirement

BAGGING & PALLETISING

Machine System ComponentsWeighing Cum Tipping M/c (Net Weigher)Auto Bag PlacerStitching / Sealing M/cCheck Weigher / Metal DetectorInk Jet PrinterBelt ConveyorsPalletising M/cRoller ConveyorFork Lift TrucksShrink / Stretch Wrapping

BAGGING & PALLETISINGBAGGING & PALLETISING

BAGGING & PALLETISINGBAGGING & PALLETISING

BAGGING & PALLETISINGBAGGING & PALLETISING(NET WEIGHER)(NET WEIGHER)

Type of Bag Closures

Bag Feed In Device

MOVIE CLIP

BAGGING & PALLETISINGBAGGING & PALLETISING(STICHING MACHINE)(STICHING MACHINE)

Hand Stitching Machine

BAGGING & PALLETISINGBAGGING & PALLETISING(CHECK WEIGHER)(CHECK WEIGHER)

Check weighers check packed goods as they run through for compliance with the stated weight. Incorrectly weighing packs trigger a signal for removal.

BAGGING & PALLETISINGBAGGING & PALLETISING(METAL DETECTOR)(METAL DETECTOR)

Metal detectors are used for palletizing bags. They check the bags approaching the Palletizer for metallic foreign matter and if found positive, direct them to a bag removal station.

BAGGING & PALLETISINGBAGGING & PALLETISING(BAG REJECTION / REMOVAL)(BAG REJECTION / REMOVAL)

Packages which are recognised as faulty are separated from the conveyed stream of packages via removal stations. They can be executed as swivel-mounted belt sidings, as a baffle or reject push-plate

BAGGING & PALLETISINGBAGGING & PALLETISING(Bag Flattening)(Bag Flattening)

Sack flattening stations are positioned upstream of the Palletizers in order to produce the most evenly flat cuboid shape. They are composed of a belt conveyor as bottom belt and a height-adjustable, swivel-agitated pressure plate positioned above it, "irons" smooth the passing sacks. Depending on the bag fillings a model with vibratory bottom belt and a weighted pressure plate can be used.

Labelling and Coding UnitsLabelling and coding units apply details of

contents, loads or regulations on to packed goods or on to side surfaces of pallet-loads, mostly after stretching or shrinking. Computer controlled labelers print the labels and apply them as goods run past. Ink-jet coders inscribe the packages passing by with texts and markings using the ink-jet process. The imprints can be changed on-line by appropriately equipped devices, also automatically from package to package, e.g. for continuous numbering.

Labelling and Coding Units

BAGGING & PALLETISINGBAGGING & PALLETISING(PALLETISER)(PALLETISER)

PALLETISERPALLETISER

PALLETISER

PALLETISER

PALLETISER

PALLETISER

BAGGING & PALLETISINGBAGGING & PALLETISING(PALLETISER)(PALLETISER)

Airated Slide PlateAerated slide-plates and preceding intermediate balcony are used for palletizing of bags with a high sliding friction coefficient such as film sacks.

The air ( from regulated pressure fan) emanating from the perforated slide-plate surface forms a slide-air film which relieves the positioning and depositing of the bags.

Robotic Palletiser

Pallet Security through Stretching and Shrinking

Pallet loads are often exposed to considerable accelerative forces during transport and handling and must be protected from deformation, scuffing with adjacent loads and falling from the stacked load.

Stretching and shrinking of the pallets in plastic film are proven safety processes, with which the shipping goods are simultaneously protected against soiling and dampness

BAGGING & PALLETISINGBAGGING & PALLETISING(SHRINK WRAPPING)(SHRINK WRAPPING)

The film cover, which becomes very stiff after shrinking, especially in the case of greater film-thicknesses, withstands considerable stress caused by accelerative forces.

Glueing UnitsGlueing units serve to stabilise pallet loads. By means of roll, brush or spray gun they apply a strip of glue on the packages as they run through. The anti-slip glue strengthens the palletized-goods layers , but permits depalletizing without damage to packages.

Palletless shipping units using the contour-hood shrink-wrapping system

The palletless shrink-wrap packaging replaces the pallet with the packaged goods themselves which becomes a self-supporting unit thanks to the shrink-wrapped cover. As a result not only is the significant expense for pallet use spared, but storage and transport space is also gained. Such packages are shipping units with integrated transport security.

They have great stability even under harsh transport conditions, can be easily handled with the usual harnessing equipment and protect their contents hermetically tight against moisture and dirt.

Slip Sheet Applicator

Papersheet applicator Film applicator

Film applicators are used either for feeding of stacking films as slip sheets or, in another version, for laying plastic films on empty pallets to protect the first stack layer from ground dirt and moisture. Another application is placing film or cardboard between the layers to stabilise the stack.

BAGGING & PALLETISINGBAGGING & PALLETISING(FIBC BAG)(FIBC BAG)

FLEXIBLE INTERMEDIATE BULK CONTAINER

BAGGING & PALLETISINGBAGGING & PALLETISING(FIBC LAYOUT)(FIBC LAYOUT)

Bag LoadersWhere bagged goods are to be loaded in the form of individual containers, bag loading machines may be used in order to attain economy and to control the physical demands put on personnel. Bag-loading can be almost completely automated with Autoloaders which stack the bagged goods directly onto truck loading surfaces or onto pallets placed on them.

BAGGING & PALLETISINGBAGGING & PALLETISING(AUTO LOADERS)(AUTO LOADERS)

Autoloader forms vehicle-wide layers of bags which are transferred by a stacking conveyor and forwarded to the loading head located over the vehicle loading surface. The loading head deposits the layers of bags on the vehicle and each time is lifted by one layer. After reaching the desired number of layers the Autoloader reverses by one stack length and positions the next stack.

Moveable Truck-loading Machines

Moveable truck-loading machines, for loading of vehicles with fixed body and of containers, can drive their long booms via the rear deep into the vehicle. The swivelling and inclineable telescopic loading belt at the boom end conveys the bags over the width of the vehicle to the depositing points.

Off-the-floor Truck-loading Machines

To load trucks in covered vehicle zones, moveable off-the-floor bag loading machines are installed on the building's roof located over the thoroughfare. The lowerable loading belt is moved down through a slit in the ceiling onto the open vehicle..

Covered vehicles are loaded with a machine onto which a linked conveyor is lowered through the ceiling slit, the conveyor loading the horizontally moveable loading belt in a height-adjustable belt-seat

Single and double jointed Wagon-loading Machines

For loading of covered railway wagons of the normal type, single jointed loading machines are used. Double jointed large volume loading-machines have a swivelling intermediate belt boom