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