DOC. NO.

: 09035-00-GIN-PR002
JOB NO. : 2009035

DESCRIPTION OF PROCESS SECTION

PROJECT :

DINH VU POLYESTER PLANT PROJECT

LOCATION :

DVIZ, HAI PHONG CITY, VIETNAM

OWNER

PVTEX., JSC

Document Class: X

B1

Feb. 22, 2010

Issued For Design

Y. N. Kim

J. S. Kim

B. I. Cho

01

Nov. 20, 2009

Issued For Approval

Y. N. Kim

J. S. Kim

B. I. Cho

REV.

DATE

DESCRIPTION

PREPARED

CHECKED

APPROVED

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REVISION LOG
REV. NO.

REV. DATE

REVISED PAGE

REVISION DESCRIPTION

01

Nov. 20, 2009

Issued for Approval

B1

Feb. 22, 2010

1~24 of 31

Revised Equipment Tag. and Description

1, 24 of 31

Added PFD and UFD drawing No.

2, 3 of 31

Revised Process summary

22 of 31

Added 2.14 Product Drain

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TABLE OF CONTENTS
1.

GENERAL.......................................................................................................................

2.

POLYCONDENSATION UNIT........................................................................................

3.

STAPLE FIBER PRODUCTION UNIT..........................................................................26

FILAMENT PRODUCTION UNIT.................................................................................30

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1. GENERAL
Polyester Plant will be constructed for Petrovietnam Petrochemical and Textile Fiber
Joint Stock Company (PVTEX., JSC) at Dinh Vu Industrial Zone. This Polyester
Plant consists of three sections:
- Polycondensation Unit
- Staple Fiber Production Unit
- Filament Production Unit
The primary purpose of the polycondensation unit is to produce a high molecular
polymer melt with specific viscosity, i.e. the length of the molecular chain of approx.
100 elements. The polymer melt is distributed to staple fiber production unit, filament
production unit and the chipping unit.
Polyethylene terephthalate (PET) is produced from purified terephthalic acid (PTA)
and ethylene glycol (EG) as main raw materials in a series of subsequent chemical
reactions.

2. POLYCONDENSATION UNIT
For an overview of the unit, reference is made to the following Process Flow
Diagrams:
- 09035-11-PFD-PR001

PFD for PTA feeding, storage and transport

PFD for PTA Conveying & Storage

09035-11-PFD-PR101

- 09035-15-PFD-PR001

PFD for Catalyst preparation

- 09035-15-PFD-PR002

PFD for Dulling agent preparation

- 09035-18-PFD-PR001

PFD for Raw material mixing

- 09035-20-PFD-PR001

PFD for ESPREE Reactor

- 09035-20-PFD-PR002

PFD for Spray system Postesterification (PE),

Prepolycondensation (PP) & DISCAGE (DC)

- 09035-22-PFD-PR001

PFD for DISCAGE Reactor

- 09035-24-PFD-PR001

PFD for Vacuum System Poly

- 09035-26-PFD-PR001

PFD for Melt Distribution

- 09035-30-PFD-PR001

PFD for Chips Production

PFD for PET Chip Conveying & Storage

09035-33-PFD-PR101

- 09035-37-PFD-PR001

PFD for Spent EG Collection

- 09035-39-PFD-PR001

PFD for Product Drain / TEG Handling

B1

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09035-61-UFD-PR001

UFD for HTM Storage, Filling, Vent and Drain

09035-61-UFD-PR002

UFD for HTM System : HTM Distribution Plant

09035-61-UFD-PR003

UFD for HTM System : HTM Heating Plant Part A

09035-61-UFD-PR004

UFD for HTM System : HTM Heating Plant Part B

09035-80-PFD-PR001

PFD for MEG Storage

- 09035-93-PFD-PR001
2.1

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PFD for Filter Cleaning

PTA FEEDING, STORAGE AND TRANSPORT

Refer to PFD Document No.: 09035-11-PFD-PR001 / 09035-11-PFD-PR101

2.1.1

B1

B1

Basic Objective
PTA is supplied in big bags and conveyed by a pneumatic conveying system to the
PTA storage silo 11S58. Closed circulation loop is applied using nitrogen as
conveying media.

2.1.2

Major Equipment
11U01

PTA PNEUMATIC CONVEYOR

transport section, for conveying of PTA to the PTA storage silo

11UB11A/B PTA TRANSFER BLOWERS

11UB12A/C VENT BLOWER
11UD11

NITROGEN RECEIVE DRUM

11UE11

PTA TRANSFER BLOWERS DISCHARGE COOLER

11UF11A/C VENT FILTERS

for feeding station
11UF12

DUST FILTER

11UF13A/B NITROGEN LINE FILTER

11UV11A/C PTA TRANSFER HOISTS
for big bag handling
11US11A/C PTA FEEDING HOPPERS
to receive PTA from big bags
INDUSTRIAL VACUUM CLEANER
for cleaning of big bags
11UQ11A/C PTA ROTARY FEEDERS

11S58

PTA STORAGE SILO

for storage of PTA

B1

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2.1.3

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Process Summary
Unloading from big bags
PTA big bags are transported from the storage area near to the feeding stations by
forklift and lifted by bag lifting device. Three PTA feeding hopper are provided
equipped with two nozzles for simultaneous emptying of PTA big bags.

B1

PTA conveying
The PTA is conveyed to the storage silo 11S58 by means of PTA pneumatic
conveyor.
Closed circulation loop is applied and nitrogen is used as conveying media to
prevent dust explosion by minimizing oxygen in the storage silo and conveying
pipes.
A dust filter is provided at the storage silo to remove PTA dust before the nitrogen
returns to the nitrogen circuit.
Nitrogen makeup and venting system is provided to maintain the circuit pressure
constant, and nitrogen pulsator is provided to remove PTA dust from the dust filter.
2.2

EG STORAGE AND TRANSPORT

Refer to PFD Document No.: 09035-80-PFD-PR001

2.2.1

B1

B1

Basic Objective
To store Ethylene Glycol (EG) and to maintain a supply of EG to the polyester plant.

2.2.2

Major Equipment
80P01A/B EG TRANSFER PUMPS
for feeding EG to the polyester plant
80S01

B1

EG STORAGE TANK
for storage of EG

2.2.3

Process Summary
Ethylene glycol (EG) is imported by ship and is transferred through the import
pipeline into the EG storage tank. EG import line is about 2km from liquid jetty to
polyester plant battery limit. From there the glycol is transferred by EG transfer pump
to various consumers in the production building.

2.3

CATALYST PREPARATION
Refer to PFD No.: 09035-15-PFD-PR001

2.3.1

Basic Objective
To prepare batches of catalyst solution in ethylene glycol (EG) and to store them
ready for use in the process.

B1

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2.3.2

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Major Equipment
15A11

AGITATOR CPC
for stirring / dissolving of catalyst powder

15D11

CPC PREPARATION VESSEL

for preparing catalyst solution in EG

15D12

CPC STORAGE VESSEL

for storing the prepared catalyst solution

15E14

HTM COOLER

15F12A/B

CPC FILTERS

15P12A/B CPC PUMPS

15P14

SECONDARY HTM PUMP

15Q10

ADDITIVE SCALE

B1

for weighing additives

15Q11

BAG OPENING / SUCTION SYSTEM

for manual opening and emptying of catalyst bags

* CPC

2.3.3

Catalyst Solution

B1

Process Summary
The batch size is chosen to match the production requirement and shall be basically
in the range of one days consumption. The solution storage capacity is a minimum
of 2 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, then EG is added to reach the final concentration.
Afterwards the solution is cooled down.
The selected quantity of EG at ambient temperature is filled into the CPC preparation
vessel 15D11 by a preset flow counter in the main EG line. The required amount of
Antimony Trioxide (Sb2O3) powder, Antimony Triacetate (SbAc3, Sb(CH 3COO)3) or
Antimony Triglycolate (Sb2EG3, Sb2(C2H4O2)3) is accurately weighed on the additive
scale and added into the preparation vessel.
- If Antimony Trioxide (Sb2O3) powder is used as a catalyst, the agitator is started
after EG dosing and the solution is heated up to 180C in order to form antimony
glycolate by adjusting the HTM circulation to approx. 200C (180C at the end).
When all Sb2O3 is completely dissolved (sample solution colourless usually within
2 hours), the HTM heating is stopped and further EG is added to reach the final
concentration. Afterwards the catalyst solution is cooled down to approx. 85 C
by adjusting the HTM circulation to approx. 75C (85C at the end). For cooling
down, the HTM circulation is passed through the air cooler 15E14.
- If Antimony Triglycolate (Sb2EG3, Sb2(C2H4O2)3) is used as catalyst, the agitator is
started and the solution is heated up to 120C by adjusting the HTM circulation to
approx. 150C (120C at the end). When all Sb2EG3 is completely dissolved
(sample solution colorless usually within 1 hour), the HTM heating is stopped and

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further EG is added to reach the final concentration. Afterwards the catalyst

solution is cooled down to approx. 85C by adjusting the HTM circulation to
approx. 75C (85C at the end). For cooling down, the HTM circulation is passed
through the air cooler 15E14.
-

If Antimony Triacetate (SbAc3, Sb(CH 3COO)3) is used as catalyst, the agitator is

started and the solution is dissolved at ambient temperature. When all SbAc3 is
completely dissolved (sample solution colorless usually within 1 hour), further EG
is added to reach the final concentration.

A sample of each batch is taken for concentration analysis. When the test result is
okay, the batch is drained into the CPC storage vessel 15D12.
The main stream of the CPC solution is circulated continuously by the CPC pump
15P12. Only a part stream is filtered through the CPC filter 15F12 in order to remove
fine undissolved particles before the catalyst is dosed together with the main EG
from the EG mixing tank into the paste mixing vessel. The amount of catalyst
solution fed to the process is controlled by a flow controller.
The preparation and the storage vessel (connected in series) are blanketed with
nitrogen in order to prevent entering of humidity and to assist the removal of
byproducts. The preparation vessel is connected with the process vent system to
aspirate the blanketing nitrogen together with vapor of water, EG and other low
boiling products.
2.4

DULLING AGENT PREPARATION

Refer to PFD Document No.: 09035-15-PFD-PR002

2.4.1

Basic Objective
TiO2 is suspended in EG at ambient temperature. After dilution and separation of
oversized particles, the suspension is diluted with EG to the final dosing
concentration and transferred into the TiO2 storage vessel ready for use in the
process.

2.4.2

Major Equipment
15A71

AGITATOR FOR TIO PREPARATION VESSEL 15D71

for stirring / dispersing of TiO2 slurry

15A72A/B AGITATOR FOR TIO DILUTION VESSELS 15D72A/B

for stirring / dilution of TiO2 slurry
15A75

AGITATOR FOR TIO ADJUSTING VESSEL 15D75

for stirring / adjusting of TiO2 slurry

15A77

AGITATOR FOR TIO STORAGE VESSEL 15D77

for stirring / keeping TiO2 slurry in motion

15A81

B1

AGITATOR FOR TIO SEDIMENT VESSEL 1 15D81

for stirring TiO2 slurry

B1

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15A83

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AGITATOR FOR TIO SEDIMENT VESSEL 2 15D83

for stirring TiO2 slurry

15D71

TIO PREPARATION VESSEL

for mixing TiO2 and EG

15D72A/B TIO DILUTION VESSELS

for dilution / resting of TiO2 slurry
15D75

TIO ADJUSTING VESSEL

for adjusting of the final slurry concentration

15D77

TIO STORAGE VESSEL

for final TiO2 slurry buffering

15D81

TIO SEDIMENT VESSEL 1

for collecting coarse TiO2 particles peeled from centrifuge

15D83

TIO SEDIMENT VESSEL 2

for collecting TiO2 slurry from dispersion device

15F77A/B TIO FILTERS

for final filtration of TiO2 suspension
15M74

TIO CENTRIFUGE
for separation of coarse TiO2 particles (agglomerates)

15M82

DISPERSION DEVICE
for dispersing TiO2 particles (agglomerates)

15P74

CENTRIFUGE FEED PUMP

for feeding TiO2 slurry into the centrifuge

15P77A/B TIO DOSING PUMPS

for feeding TiO2 slurry to the esterification reactor
15P82

SEDIMENT FEED PUMP

for feeding TiO2 slurry through the dispersion device

15Q70

BAG LIFTING DEVICE

for lifting and handling of TiO2 big bags

15Q71

TIO FEEDER
for feeding TiO2 powder into the preparation vessel

15V71

BAG OPENING SYSTEM

for emptying TiO2 big bags

2.4.3

Process Summary
The batch size is chosen to match the 1 day production requirements. The

B1

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suspension storage capacity is approximately 2 days of production in the storage

vessel. In this way it can be assured that in case of a disturbance the production is
not influenced.
The premix of approx. 50 wt-% EG and 50 wt-% TiO2 is prepared in the TIO
preparation vessel 15D71. The selected quantity of EG is measured and filled into
the preparation vessel 15D71. Afterwards the correct amount of TiO 2 is feed from the
bag opening system 15V71 through the TIO feeder 15Q71 into the preparation
vessel. A homogenous suspension is achieved by intensive mixing with the agitator
15A71.
The 50 wt-% TiO2 suspension is then drained from the preparation vessel 15D71 into
the TIO dilution vessels 15D72A/B where more EG is added to obtain a suspension
of approx. 18 wt-%. To increase the capacity flexibility and to keep a minimum
retention time, two dilution vessels 15D72 are installed.
After a retention time of at least 10 - 12 hours, the suspension is transferred by the
centrifuge feed pump 15P74 through the TIO centrifuge 15M74 where oversized
particles, agglomerates, are separated from the slurry. The slurry itself is collected in
the TIO adjusting vessel 15D75. When the whole TiO 2 batch has passed the
centrifuge 15M74 a sample is taken to determine the actual TiO2 concentration.
EG is added into the adjusting vessel 15D75 to obtain the final TiO 2 concentration of
15 wt-%. Afterwards a sample is taken again and analyzed in the chemical laboratory
before the batch is drained into the storage vessel 15D77. In order to check the
centrifuge efficiency the 1 m filter test has to be carried out.
The oversized particles (sediment) which are separated from the slurry in the
centrifuge (approx. 3 5% of the TiO 2 will be separated) are collected in the
sediment vessel 1 (15D81). This vessel is equipped with an agitator to prevent
sedimentation of the agglomerates.
The collected sediment from the centrifuge has to pass another dispersion step.
Therefore it is pumped by the sediment feed pump 15P82 through the dispersion
device 15M82 where the TiO2 agglomerates are crushed and dispersed before being
collected in the TIO intermediate vessel 2 (15D83), ready for reuse in the next TiO 2
preparation batch. To prevent sedimentation the sediment vessel 2 is equipped with
an agitator 15A83.
In order to minimize the electrostatic charge, the crushed suspension must rest in
the sediment vessel 2 (15D83) for at least 4 hours before it is transferred into 15D71
to prepare the next TiO2 batch. The slow-moving agitator 15A83 prevents
sedimentation.
Before the content of the sediment vessel 2 (15D83) is drained into the preparation
vessel 15D71, its concentration has to be determined in the chemical laboratory in
order to re-adjust the EG concentration in the next premix batch properly.
2.5

RAW MATERIAL MIXING

Refer to PFD Document No.: 09035-18-PFD-PR001

2.5.1

Basic Objective
-

To meter and to feed PTA and EG in a defined ratio into the paste mixing vessel

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for paste preparation.

- To prepare a homogenous paste.
- To feed the paste to the lower part of the ESPREE reactor (Esterification) in a
metered stream.
2.5.2

Major Equipment
13F26

EG FILTER
for fine filtration of virgin EG

18A13

AGITATOR DRIVE (PASTE MIX.)

to paste mixing vessel

18D13

PASTE MIXING VESSEL

to prepare and homogenise the paste

18S16

EG MIXING TANK
for homogenisation of virgin and recycled EG

18E16

EG COOLER
to cool down recycled EG

18P13A/B

PASTE PUMPS
for metering and feeding paste to esterification

18P16A/B

EG MIXING PUMPS
for homogenisation and feeding of EG

18Q13

PTA FEEDER
screw feeder for feeding PTA from storage silo

18Q17

PTA DOSING BALANCE

for exact dosing of PTA into paste mixer

2.5.3

Process Summary
PTA is dosed from the PTA storage silo 11S58 into the paste mixing vessel using a
speed controlled screw feeder and a mass flow meter.
Virgin EG is pumped from the EG storage area via EG filter 13F26 to the plant. EG
from hotwells 20D33 and 22D43 are collected in the EGS drain tank 37S90 and
routed into the EG mixing tank 18S16, in which the liquid is intensively mixed with
recycled EG from the process column 20T12. The temperature in the EG mixing tank
18S16 is kept at max. 70C.
The main EG stream, coming from the EG mixing tank 18S16 is mixed with the
metered catalyst solution using high accurate mass flow meter control and with a
controlled partial stream of the recycled EG from process column 20T12. The stream
is metered and controlled by a mass flow meter and fed into the paste mixing vessel
18D13.

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The partial stream of recycled EG from the process column 20T12 is used to control
the temperature of the paste.
All components are well blended and intermixed in the paste mixer by an agitator of
special design with the target to form a homogeneous paste, having a molar ratio of
approx. 1.5, which easily can be transferred to the bottom part of the ESPREE
reactor by volumetric pumps.
To prevent the formation of PTA dust and thus entering into the process vent system,
the paste mixer is equipped with a dome containing two EG spray nozzles one on
top of the other. The spray EG coming from the EG tank farm is of ambient
temperature. This will increase the efficiency of acetaldehyde removal.
The connection to the process vent system on top of the dome generates a slight
vacuum to aspirate the system.
The paste is continuously metered and fed into the ESPREE reactor by two speed
controlled paste pumps 18P13A/B which are normally running simultaneously,
however one pump can handle the full plant capacity.
A mass flow meter is used to measure continuously the paste flow rate and the paste
density. The density is proportional to the molar ratio of EG and PTA. The density
signal is recorded for easier adjustment of the EG feed controller to maintain a high
accuracy of the feed mole ratio, which is important for high process stability.
2.6

ESPREE REACTOR
Refer to PFD Document No.: 09035-20-PFD-PR001

2.6.1

Basic Objective
- To produce diglycolterephthalate (DGT) by a non-catalysed direct esterification
between terephthalic acid (PTA) and ethylene glycol (EG).
- To separate the water produced in the esterification process.

2.6.2

To remove and recover the excess EG (an excess is necessary to promote the
reaction) for reuse.

To remove some of the byproducts from the reaction.

Major Equipment
20E10

REBOILER TO ESPREE
external heat exchanger for esterification

20E12

DISTILLATE CONDENSER
for condensing the reaction water

20E13

ECONOMIZER
for preheating EG before entering into process column

20E15

HTM EVAPORATOR (ES)

to heat the bottom of the ESPREE reactor and reboiler of process
column 20T12

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20P11A/B MONOMER PUMPS

to transfer monomer from esterification to postesterification
20P12A/B REBOILER PUMPS
for feeding EG from process column reboiler back to reactor 20R10 and
to EG mixing tank 18S16
20R10

ESPREE REACTOR
multi stage reactor for
- esterification reaction (ES) of PTA/EG paste
- postesterification (PE)
- prepolycondensation (PP)

20T12

PROCESS COLUMN
for rectification / separation of EG/water vapor

20V10

VACUUM PIPE (PP)

to lead vapor into spray condenser

20RZ10

EG / CPC FEEDING STATION

to mix EG and/or CPC with monomer

2.6.3

Process Summary
The esterification reaction takes place in several stages:
-

the first step is done in esterification (bottom part of 20R10, conversion rate of
88% - 92%)

the next three stages are installed cascade-wise in postesterification (top part of
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 including additives is continuously supplied from paste mixing vessel
18D13 by the paste pumps 18P13A/B at a temperature of approx. 65C into
esterification section of the tower reactor 20R10.
Before the paste enters the external tube bundle heat exchanger 20E10, recovered
EG from column 20T12 and dulling agent slurry (TiO2) is added to increase the total
(inner) mole ratio to 1.75 - 1.80 and to compensate the evaporation loss of EG in
esterification. The quantity of recovered EG fed into the paste flow is controlled by a
flow control loop. Reboiler pump 20P12 feeds the EG from the bottom of column
20T12 in a part stream back to esterification in order to maintain the inner mole ratio.
The level in the process column reboiler 20T12 is controlled by feeding the excess
EG back into the EG mixing tank 18S16.
TiO2 slurry enters together with the recovered EG from the column into the paste line
below the external heat exchanger. In this way a homogeneous distribution of TiO2 in
the monomer is ensured. The TiO2 slurry metering is done by mass flow meter
controls, which in turn adjust the speed of the eccentric screw pump.

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The paste, the recovered EG and the TiO 2 slurry are fed into the tube side of the
heat exchanger 20E10 of the ESPREE reactor through a special inlet nozzle. The
paste is immediately mixed with already existing monomer by a static mixer
underneath the tube bundle. The natural circulation is generated by the boiling
regimes in the heat exchanger. At a operating condition of approx. 255 - 260C and
a pressure of 1.2 - 1.5 barg, the reactants boil vigorously. The conversion rate
amounts to approx. 88 - 92% within 60 to 80 minutes reaction time; the degree of
polycondensation (DP) increases to approx. 3 units.
As DGT is formed, reaction water is formed which together with portions of EG
enters into the process column 20T12. The separated EG is partly (measured and
controlled) returned to the esterification to further increase the conversion, whereas
the balance EG is sent back to the EG mixing tank for reuse.
The required energy 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 20E15. Depending on the throughput the HTM vapor
temperature will vary between 282C and 290C.
The monomer from esterification is transferred by gear pumps 20P11A/B from
bottom to the top of the tower reactor. For process safety two parallel operated gear
pumps are running, each with 50% of the load. In case of a failure, the other gear
pump is capable to take care for the full load.
Additional EG to adjust the total mole ratio or alternatively to add catalyst solution is
fed into the monomer line. In order to ensure a sufficient mixing of the additional
added EG or catalyst solution with the monomer and to obtain a homogeneous fluid,
a static mixer 20RZ10 is provided.
The discharge pressure of monomer pumps 20P11A/B is controlled by a pneumatic
butterfly valve located at the monomer inlet of the top (first) cascade of
postesterification.
Together with reaction water also a part of the EG vapor leaves the esterification.
The EG/water mixture is rectified in column 20T12. The water vapor from the top of
the column is under pressure (saturated vapor) and is partly used as motive steam
for vacuum unit. The excess steam is condensed in distillate condenser 20E12 and
the condensed water collected in seal vessel (vacuum) 24D53. The motive steam for
the vacuum unit is condensed in the first / final vacuum condensers 24E51/53A/B
and collected in seal vessel (vacuum) 24D53 as well.
The water collected in the seal vessel (vacuum) 24D53 is fed through the stripper
column 24T61 in order to remove low boiling products such as aldehyde. A part
stream is pumped back as reflux to the process column 20T12 by reflux pumps
24P61A/B through reflux flow control, whereas the excess water leaves the stripper
column via its overflow.
The postesterification section is divided in 3 cascades incorporating heating coil
modules. This installation enhances the evolution and removal of water as well as a
uniform residence time distribution. At a total residence time of 50 - 60 minutes, the
conversion rate amounts to approx. 98%. The DP will increase to 5 - 6 units. The
reaction in postesterification runs under vacuum conditions. The required
evaporation and reaction heat is supplied by HTM evaporator 22E25. Depending on
the product throughput, the HTM vapor temperature will vary between 290C and
295C.

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The second and the third cascade chamber is equipped with injection lances,
through which additive solution as an alternative can be fed in.
Vapor, consisting mainly of EG and reaction water, leaves postesterification via the
vapor line. It is lead to the spray condenser 20E23 where the vapor is condensed
directly by injected spray EG. Non condensables such as acetaldehyde or nitrogen
are sucked off by the vacuum system. The spray EG is circulated by spray EG
pumps 20P23A/B via the EG coolers 20E24A/B to the spray condenser 20E23. The
excess of the EG/water mixture is metered and fed to process column 20T12 for
separation.
After leaving postesterification, the monomer is transferred by gravity into the flasher
of prepolycondensation. The monomer flow rate is controlled by a level control valve,
which receives its setpoint from a level controller at the collector of the
prepolycondensation. The prepolycondensation reaction takes place in the following
reaction stages:
- flasher
- falling film evaporators
Prepolycondensation of the ESPREE reactor consists of two flasher cascades and
two falling film evaporators. In the first flasher cascade the pressure is further
reduced and the product overflows through the center pipe into the second flasher
camber. The product is evenly distributed and overflows into the falling film
cascades. The falling film cascades are equipped with plenty of tubes of a special
design. The surface area is increased and thus enhances the polymerization degree
by removing of EG/water vapor.
At the end of the prepolycondensation the prepolymer is collected in the bottom,
which is used as buffer for prepolymer pumps 22P21A/B.
The prepolycondensation is operated at 5 to 8 mbara and 278 to 282C. 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
prepolycondensation mainly consists of EG which is condensed in spray condenser
20E33 and in mist eliminator 20E36 by injection of cold spray EG (direct
condensation).
2.7

DISCAGE REACTOR
Refer to PFD Document No.: 09035-22-PFD-PR001

2.7.1

Basic Objective
To produce polyester polymer having a degree of polycondensation (DP) of approx.
95 - 108, starting from prepolymer received from the ESPREE tower reactor.

2.7.2

Major Equipment
22P21A/B PREPOLYMER PUMPS
to transfer product from ESPREE reactor to DISCAGE reactor
22A20

AGITATOR DRIVE (DC)

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HTM EVAPORATOR (DC)

22P22A/B POLYMER DISCHARGE PUMPS

B1

to discharge melt from DISCAGE reactor

22R20

DISCAGE REACTOR
for polycondensation of product up to DP 108

22V20

VACUUM PIPE (DC)

to lead vapor into spray condenser

2.7.3

Process Summary
The final polycondensation reaction is carried out under fine vacuum. The
temperature is higher and the pressure is lower than in the prepoly-condensation
stage. To prevent variations in the finished product, the throughput of
polycondensation is kept as steady as possible. To achieve this, the level of the
DISCAGE reactor is controlled by flow control of the product feed into DISCAGE
using the speed controlled prepolymer pumps 22P21A/B. The speed setpoint for the
prepolymer pump is set by the inlet level controller of the DISCAGE reactor.
Normally, two pumps are running simultaneously, however one pump can handle the
full capacity.
The specifically designed DISCAGE reactor is a horizontal reactor, which combines
various features in order to treat the product gently to finally reach a DP of 95 to 108.
The highly increasing viscosity makes it necessary to force the product in a
controlled way through the reactor, avoiding dead spots, generating a large surface
of product exposed to vacuum and keeping the process conditions at the lowest
possible level. The reactor is equipped with a shaftless cage type agitator 22A20,
with a variety of discs (blades), rings, stripper rods and baffles to fulfill the requested
features. The process temperature (outlet) is kept between 282C and 285C.
The DISCAGE reactor is connected to the HTM evaporator 22E25 to provide the
required heat energy.
The polymer discharge pumps 22P22A/B builds up the required pressure for the
filtration and distribution of the melt to the melt distribution system.
The melt line, downstream of the discharge pump, is equipped with an online
viscosimeter 26M50, which controls the viscosity by setting the corresponding
vacuum in the DISCAGE reactor in a range of approx. 1 - 2 mbar.

2.8

SPRAY SYSTEM PE, PP & DC

Refer to PFD Document No.: 09035-20-PFD-PR002

2.8.1

Basic Objective
To separate spent EG from the reaction process and to dispatch it for direct
recycling.

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Major Equipment
Postesterification (PE)
20D23

EG HOTWELL (PE)
barometric tank for spray EG system

20E23

SPRAY CONDENSER (PE)

for condensation of vapor

20E24A/B EG COOLERS (PE)

for cooling of spray EG from 20E23
20P23A/B SPRAY EG PUMPS (PE)
to circulate spray EG to spray condenser 20E23
Prepolycondensation (PP)
20D33

EG HOTWELL (PP)
barometric tank for spray EG system

20D36

EG SEAL VESSEL
barometric tank for fresh EG spray system

20E33

SPRAY CONDENSER (PP)

for condensation of vapor

20E34A/B EG COOLERS (PP)

for cooling of spray EG from 20E33
20E36

DEMISTER (PP)
for final condensation of vapor

20E37

EG COOLER (DEMISTER PP)

for cooling of spray EG from 20E36

20F33A/B SPRAY EG FILTERS (PP)

20P33A/B SPRAY EG PUMPS (PP)
to circulate spray EG to spray condenser 20E33
20P36A/B SPRAY EG PUMPS (DEMISTER PP)
to circulate spray EG to demister 20E36
DISCAGE (DC)
22D43

EG HOTWELL (DC)
barometric tank for spray glycol system

22E43

SPRAY CONDENSER (DC)

for condensation of vapor

22E44A/B EG COOLERS (DC)

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for cooling of spray EG from 20E43
22E46

DEMISTER (DC)
for final condensation of vapor

22E47

EG COOLER (DEMISTER DC)

for cooling of spray EG from 22E46

22F43A/B SPRAY EG FILTERS (DC)

22P43A/B SPRAY EG PUMPS (DC)
to circulate spray EG to spray condenser 22E43

B1

22P46A/B SPRAY EG PUMPS (DEMISTER DC)

to circulate spray EG to demister 22E46
2.8.3

Process Summary
The volatile vapor from 20R10 postesterification section is condensed in a single
spray condenser.
The volatile vapor from 20R10 prepolycondensation section and DISCAGE reactor
are condensed in two spray condenser systems. For separation of mists, oligomers
and low boiling components a second large size spray condenser (demister) is
provided in each system, before the gases reach the vacuum aggregate.
The systems of spray condensers are described in the following table:
20R10 Postester
Stage

first

20R10 Prepoly

22R20 DISCAGE

first

final

first

final

Condenser

20E23 -

20E33

20E36

22E43

22E46

Hotwell

20D23 -

20D33

20D36*

22D43

20D36 *

Pump

20P23A/B -

20P33A/B 20P36A/B 22P43A/B 22P46A/B

Filter

20F33A/B

22F43A/B

Cooler

20E24A/B -

20E34A/B

20E37

22E44A/B

22E47

Medium

Spent EG -

Spent EG

Fresh EG

Spent EG

Fresh EG

* common tank (internally divided) for both final spray condenser (demister) systems
To enhance the efficiency of the fresh EG system (20D36) the total amount of virgin
EG, needed for paste mixing, is routed through the spray EG system and sent back
to EG mixing tank. In this way the oligomers removed from the process and collected
in the hotwells are diluted continuously.
Virgin EG is fed to the demisters EG circuits of prepoly and DISCAGE reactor in a
defined ratio (approx. 40% / 60%). The sum of both EG feeds is controlled by the

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level control of the EG mixing tank. The excess EG overflows from EG seal vessel
20D36 (prepoly chamber) to EG hotwell (PP) 20D33 and from there via overflow to
EGS drain tank 37S90. The excess EG from EG seal vessel 20D36 (DISCAGE
chamber) overflows to EG hotwell (DC) 22D43 and from there to EGS drain tank
37S90 as well.
A fixed amount of spent EG from the EG hotwell (PE) 20D23 is sent through the
economizer 20E13 to the process column 20T12 in order to reduce the water content
in the EG. The economizer heats up the spent EG to approx. 150C. This helps to
avoid a blockage of the internal column packing bed with oligomers.
The level of EG hotwell (PE) 20D23 is kept constant by a control valve in the feed
line from 20P33A/B.
Spent EG from the process, which overflows from both EG hotwells (PP and DC) are
collected in the drain tank 37S90 and sent direct to the EG mixing tank 18S16 using
pump 37P91.
2.9

SPENT EG COLLECTION
Refer to PFD Document No.: 09035-37-PFD-PR001

2.9.1

Basic Objective
To collect spent EG in the drain tank for further treatment or to transfer the spent EG
in a storage tank.

2.9.2

Major Equipment
37P90

EGS TRANSFER PUMP

to transfer spent EG to process column or collecting tank

37P91

EGS FEED PUMP

to transfer spent EG to the EG mixing tank

37P92

EGS RETURN PUMP

to transfer the spent EG from the storage back to the drain tank

37S90

EGS DRAIN TANK

for collecting overflow EG from the hotwells (PP + DC)
for collecting EG from various drain points such as plate heat
exchangers, pumps, EG samples etc.

37S92

EGS COLLECTING TANK

for collecting spent EG during abnormal situations

2.9.3

Process Summary
The EGS drain tank 37D90 is divided in 2 chambers. One chamber serves as a
collecting compartment for the overflow EG from the hotwells. The other chamber is
a common drain compartment for the whole plant.

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Virgin EG and spent EG from the prepoly reaction are combined in the EG hotwell
(PP) and overflows in the collecting compartment of the EGS drain tank 37S90.
In the same way, virgin and spent EG from the polymerisation reaction are combined
in the EG hotwell (DC) and overflows into the same collecting compartment of the
drain tank 37S90. The collected EGS is sent direct to the EG mixing tank 18S16
using pump 37P91.
EG and oligomer residues from cleaning plate heat exchangers, EG sample
disposal, pump draining, hotwell draining or EG overflow during abnormal drain
operations are collected in the second compartment, from where the liquid can be
routed by transfer pump 37P90 to the process column 20T12 for recycling or to the
EGS collecting tank 37S92 for temporary storage. The collecting tank 37S92 is used
only during start-up and / or abnormal arising situations. From the collecting tank
37S92 the EGS can be transferred back into the collecting compartment of the drain
tank.
2.10

VACUUM SYSTEM POLY

Refer to PFD Document No.: 09035-24-PFD-PR001

2.10.1

Basic Objective
To generate vacuum required by the polycondensation reaction in the ESPREE
reactor 20R10 and DISCAGE reactor 22R20 by means of a steam ejector system
using process steam, generated by the esterification reaction in the ester reactor.
To collect all reaction water of the process and all the process vent stream gases.
To strip-out the majority of the low boiling hydrocarbons (HCs) from the waste water,
for its elimination together with the process vent stream gases, by combustion in the
HTM plant.

2.10.2

Major Equipment
24B61A/B BLOWERS (STRIPPER)
to supply ambient air and process vents to the stripper column
24D53

SEAL POT (VACUUM)

to collect all condensed process reaction water and for barometric
sealing of the vacuum system

24E51A/B FIRST CONDENSERS

1 stage condenser for booster group to condense process vapor and
motive steam
24E53A/B FINAL CONDENSERS
3 stage condenser for vent group to condense process vapor and motive
steam
24E61

OFF GAS HEATER

to reheat gas from the stripper to avoid condensation

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VACUUM AGGREGATES

/24J46A/B consisting of vacuum jet 24J36, 24J46/47 and 24J51/52/53

/24J47A/B multi stage vacuum unit to generate the required vacuum
/24J51A/B in the postesterification, prepoly and DISCAGE reactor
/24J52A/B
/24J53A/B
24P53A/B STRIPPER FEED PUMPS
to feed process water to the stripper column
24P61A/B REFLUX PUMPS

B1

to feed the process water as reflux to the process column

24T61

STRIPPER COLUMN
to eliminate low boilers from process water by a counter current process
flow

2.10.3

Process Summary
The vacuum aggregates consist of two groups.
Group one is the compression group and consists of 1 heated booster ejectors
(24J36A/B) for 20R10 prepolycondensation and 2 heated booster ejectors
(24J46A/B and 24J47A/B) for the DISCAGE reactor and a common surface
condensers (24E51A/B).
Group two is the vent group and consists of three ejector stages (24J51A/B /
24J52A/B / 24J53A/B) combined with a three stage surface condensers (24E53A/B).
The vacuum in postesterification section is generated by sucking the non
condensable reaction vapor (after condensing in spray condenser 20E23) between
second and third stage of the vent group into the surface condensers 24E53A/B.
The process vapor and motive steam from the booster ejectors are condensed in the
common condensers 24E51A/B. The motive steam from the vent group ejectors are
condensed in the condensers 24E53A/B, which is internally divided in three sections.
WCL runs through both surface condensers in series.
The condensed vapor and motive steam together with the remaining process
reaction water are collected in the seal vessel 24D53.
The water pumps 24P53A/B feeds the process water to the stripper column 24T61
where it is sprayed on a packing bed. Process vents are collected from various offgas points in the plant and blown together with fresh air from the bottom of the
stripper column to top in a counter current stream through this packing bed by
means of blowers 24B61A/B. A considerably lower COD value in the process water
is obtained. The air/off-gas mixture is then sent through the off gas heater 24E61 to
the HTM burner for combustion. In case of low load or purging of one HTM burner
with fresh air, the off gas is sent to open atmosphere (usually only for a very short
time) via a control-butterfly valve.
The reflux pumps 24P61A/B feeds the stripped process water to the process column

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20T12, where it is used as column reflux. The stripped excess process water leaves
the stripper sump to the waste water treatment plant, where it is neutralized in the
collection basin.
2.11

MELT DISTRIBUTION
Refer to PFD Document No.: 09035-26-PFD-PR001

2.11.1

Basic Objective
To filter polymer melt and to distribute the melt to the chipping unit.

2.11.2

Major Equipment
26M50

VISCOSIMETER
for continuous online measurement of viscosity

26F51

POLYMER NONSTOP FILTER

for uninterrupted polymer filtration

26Q51

FILTER LIFTING DEVICE

for handling the melt filter inserts

26YP50

MELT TRANSFER PIPE

to distribute the melt to the chipping unit

2.11.3 Process Summary

The melt is discharged from the DISCAGE by a specially designed gear
pump, the polymer discharge pumps 22P22A/B, which supplies sufficient
pressure to feed the melt through the polymer nonstop filter 26F51. The
polymer melt is diverted by a special melt valve to be fed to the following
consumers:
- Direct fiber spinning line
- Direct filament spinning line
- Pelletizer unit
The polymer nonstop filter 26F51 is a twin type, high pressure polymer filter
allowing uninterrupted filter change over. The melt filter has an incorporated
hydrolysis cleaning system, for in-situ cleaning of the filter candles. The
product lines, filter and die heads are jacketed and heated by liquid HTM
(HSB system).
The melt line downstream the discharge pump is equipped with an online
viscosimeter 26M50, which controls the viscosity by setting the corresponding vacuum in the DISCAGE reactor in a range of approx. 0.8 - 2 mbar.
The polymer melt is diverted by a special melt valve to a direct filament
spinning line, direct staple fiber line and to a chipping unit 30M11.

B1

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CHIPS PRODUCTION
Refer to PFD Document No.: 09035-30-PFD-PR001

2.12.1

Basic Objective
- To convert molten polymer into pellets (chip)
- To transport and store the chip in readiness for dispatch
- To bag the chip into big-bags

2.12.2

Major Equipment
30B12

VENT BLOWER
for aspiration the air from the pre-dryer

30D15

PROCESS WATER TANK

for storage chipping water used for the chips cutter circuit

30P15A/B PROCESS WATER PUMPS

for circulation of process water
30E15A/B PROCESS WATER COOLERS

B1

to cool down the process water

30F15

PROCESS WATER FILTER

for filtration the process water

30H11

EXTRUSION HEAD

30M11

UNDERWATER STRAND GRANULATOR

consisting of
- strand guide and cooling section with starting device
- cutting machine (cutter head)
- process water measuring and distribution system
- quench line for chip cooling with separator and chip collecting basket

30M12

PRE-DRYER
for chips dewatering

30M13

CHIP SCREEN
to remove oversized chip

2.12.3

Process Summary
One under water strand granulator, pre-dryer and chip screen is provided. The
process water circulation unit supplies water to the pelletizer unit.
Molten polymer from the DISCAGE reactor, discharged by means of discharge
pumps 22P22A/B is passed through polymer nonstop filter 26F51, fed to the

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extrusion head 30H11 and finally pressed through the spinneret. Strands of polymer
emerging from the spinneret are cooled by water in the strand guide section, which
guides the strands into the cutting head. Water is sprayed onto the strands by spray
nozzles for uniform cooling.
Feed rolls on the cutting head deliver the strands to the rotary cutter which cuts them
into cylindrical chip. A stream of conveying water further cools the chip preventing
them from sticking together during passing the glass transition temperature.
The process water i.e. overflow water, spray water and conveying water is provided
by a closed recirculation system containing demineralized water. The system
consists of a process water filter 30F15, a process water tank 30D15, a process
water circulation pumps 30P15A/B, and a process water coolers 30E15A/B, which is
cooled by cooling water.

B1

The pellet/water mixture flows into the pre-dryer 30M12. Most of the water is
removed from the chip by means of screens within the pre-dryer. The chip are
internally conveyed by blowing an air stream along meandered channels having
perforations, where the water is stripped off. The remaining surface water is
evaporated by the residual heat in the chip. An ambient air stream flows in countercurrent stream to the chip flow and removes the remaining surface humidity. This air
flow also prevents, that humid air from the pre-dryer, dragged by the chip flow, enters
the chip intermediate silo 33S10, where the water vapor would condensed.
After the pre-dryer the chips passes the chip screen 30M13 which retains oversized
material on a vibrating screen and transfers the chip into the chip intermediate silo
33S10.
The process water leaving the pre-dryer is guided over a process water filter (band
filter type) and collected in the process water tank 30D15. The non-woven fabric
removes fine cutting dust which otherwise would accumulate in the process water
circuit.
2.13

CHIPS STORAGE AND BAGGING

Refer to PFD Document No.: 09035-33-PFD-PR101

2.13.1

B1

Basic Objective
To convey chips to chip storage silos or to the off-spec silo for chips bagging

2.13.2

Major Equipment
33Q10

PET CHIP CONVEYOR

33QB01A/BCHIP TRANSFER BLOWERS

to transport chip from intermediate silo to storage silos
33QF01

BAG FILTER

33QQ01

PET CHIP ROTARY FEEDER

to transport chip from intermediate silo to storage silos

33Q46

CHIP PACKING UNIT

for packing chip from storage silo to big bags

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CHIP INTERMEDIATE SILO

to buffer and to feed chip to transport system

2.13.3

33S11

CHIP STORAGE SILO

33S51

CHIP OFF-SPEC SILO

B1

Process Summary
The pellets coming from the chipping unit passes the chip screen 30M13 for
separation oversized pellets, pellet string, agglomerates and falls into the chip
intermediate silo. This intermediate silo serves as a buffer. A small portion of air
stream from the chip transfer blower is blown into the intermediate silo. This air
stream helps to remove residual chip surface water and prevents condensation and
collecting of water at the bottom of the silo. The air leaving the intermediate silo is
fed to the pre-dryer to create a counter current air flow to the pellet dryer in order to
enhance removal of moisture from the chip surface as well.
The chip transfer blower transfers the chip from intermediate silo into the chip
storage silo or if required, temporary into the off-spec silo. The target silo can be
selected from the process control system. From the storage silo the chip are filled
into big bags using a bagging unit.

2.14

PRODUCT DRAIN
Refer to PFD Document No.: 09035-39-PFD-PR001

2.14.1 Basic Objective

-

To drain product from reators

To fill / distribute TEG for cleaning the raetors

To collect process vapours from safety relief valve

2.14.2 Major Equipment

39D81

TEG RESIDUE VESSEL

for storage of TEG/polymer residues

39D95

BLOW DOWN VESSEL

to receive vapors from safety valve / rupture disks

39P80

TEG BARREL PUMP

to transfer TEG from TEG barrels to reactors and hotwells

B1

2.14.3 Process Summary

In case of an unexpected overpressure in the esterification reactor, the safety relief
valve release EG/water vapours into the blow down vessel 39D95. An interlock
opens spray water in order to condense the EG/water vapours and nitrogen
blanketing in order to avoid the formation of an explosive atmosphere.
Monomer is drained from the esterification reactor through the melt valve 570-032,

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prepolymer through melt valve 570-034 and final polymer drained from the discage
reactor through the breeches pipe and / or melt valve 570-054 into the residue pit.
During normal plant operation the drain pipes are not heated, because there is no
need for keeping the drain lines heated at high temperature all the time. Therefore
prior the drain procedure all drain pipes must be heated with primary HTM (HPD).
During the drain procedure, the sprinkler nozzle above the residue pit must be put in
operation in order to condense the EG vapours.
If the reactors has to be cleaned with TEG, TEG is filled into the hotwells as well as
into the reactors. The temperature is increased in the reactors until TEG starts to boil
(approx. 280 - 285C).
After boiling the residue sump product is drained into the TEG residue vessel 39D81.
2.15

B1

FILTER CLEANING
Refer to PFD Document No.: 09035-93-PFD-PR001

2.15.1

Basic Objective
- To clean the melt filter candles from filter unit 26F51
- To check for any defects of the melt filter candles for filter pack disassembly and
assembly

2.15.2

Major Equipment
93D14A/B BACKFLUSH UNITS

B1

for backflushing of the filter candles with steam

93D16

ACID CLEANING BATH

for dissolving of finest TiO2 particles remaining in the filter mesh

93D17

ALKALI CLEANING BATH

for saponification of remainig polymer residues which have not been
completely removed during HYPOX-cleaning

93D18

RINSING BATH
to rinsing the filter candles treated in the acid or alkali cleaning bath

93P16

HAND PUMP

93V11A/B ULTRASONIC CLEANING UNIT

for removal of insoluble solid particles
93V12A/B WORKING TABLES
93V13

FLUSH VESSEL
for final flushing with demineralised water

93V14

BUBBLE POINT TESTING DEVICE

to check the filter candles for mechanical damages

93V15A/B HIGH PRESSURE WATER PUMPS

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DESCRIPTION OF
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2.15.3

93V16

BASKET

93V20

TRANSPORT TROLLEY

93V26

SUCTION HOOD

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B1

Process Summary
Before filter cleaning the filter candles are cleaned in the hydrolysis cleaning system
(HYPOX) integrated in the filter unit 26F51.
HYPOX cleaing process is based on the hydrolysis at high temperature.
(HYPOX = HYdrolysis, Pyrolysis, OXidation)
The cleaning process consist of a controlled temperature programme. The polymer is
drained from the filter housing using nitrogen. Afterwards the filter housing with the
filter candles is treated with superheated steam and later with air. In this way the
polymer is degraded completely.
After the HYPOX cleaning process, the filter insert is removed from the housing and
the single filter candles are dismounted in the filter cleaning workshop.
In a first step each filter candle is treated in the backflush unit 93D14A/B with
medium pressure steam for a minimum of 2-5 minutes. Afterwards, the filter candles
are treated in the acid cleaning bath 93D16, using 20 wt% nitric acid solution (HNO 3)
for about 15 minutes. This treatment is necessary to remove/dissolve traces of
remaining TiO2 particles from the filter mesh.

B1

After rinsing with demineralised water, the candles are treated in the alkali cleaning
bath 93D17 using 30 wt% caustic soda solution (NaOH) for about three hours. In
order to accelerate the saponification process, the bath is heated with steam to max.
75C for approx. 3 hours.
After a further flushing with water, each candle is treated in the ultrasonic cleaning
unit 93V11 for at least 20 minutes using detergent in order to remove undissolved
particles such as carbonized polymer residues.
After a final cleaning procedure in the flushing unit 93V13 (to clean the candles from
detergent) and in the backflush unit, the filter candles are tested for mechanical
damages in the bubble point testing device 93V14 using isopropyl alcohol (lower
surface tension compared to water).
After the bubble point test, the filter candles are flushed with water to remove the
isopropyl alcohol and then dried in the infrared drying oven at a temperature of about
150C for at least 3 hours.
After cooling down to room temperature, each single filter candle is weight on a
balance and their weight is recorded on a data sheet and compared with its original
weight. Any difference in weight indicates remaining residues inside the filter candle.
If so, the cleaning procedure has to be repeated.
Finally, the filter candles are assembled again, ready to reuse in the melt filter unit.
2.16

HTM HEATING
Refer to UFD Document No.: 09035-61-UFD-PR001~004

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Basic Objective
To heat and maintain temperature of polymer melt applications

2.16.2

Major Equipment
Later (after receipt of vendor information)

2.16.3

Process Summary
Primary Heat-Transfer-medium (HTM-System)
The primary Heat-Transfer-Medium (HTM-System) is a forced circulation system
supplying the polycondensation plant with the required heating energy. The heat
transfer medium is circulated by primary HTM pumps and heated in a tubular heater.
It transfers its heat, as required, to the various consumers in the esterification and
polycondensation. To ensure adequate flow and temperature in the heaters during
commissioning or in the event of low heat requirements, a direct connection (bypass) with a control valve is provided between supply and return line parallel to the
consumers.
The entire system is pressurized with nitrogen to prevent vaporization of HeatTransfer-Medium in the primary system (hazard of cavitation in circulation pumps).
The nitrogen connection is provided at the HTM expansion vessel which is
connected to the system at the suction side of the primary HTM pumps. A HTM
collecting tank is provided for partial or complete draining of the different HTM
systems. All heat exchangers (HTM evaporators) can be isolated and drained or
filled separately. Filling is accomplished by the HTM refilling pump and the
independent filling system.
The HTM collecting tank is connected to the atmosphere via a vent condenser. Hot
ascending HTM vapor are condensed in this condenser and returned to the HTM
collecting tank, this to avoid HTM losses and air pollution. The tubular heater is a
cylindrical unit with refractory lining which will be fired with fuel gas. The flue gas
leaves the heater via air preheater (energy recovery) through a stack to the
atmosphere.
The heating plant is arranged for open-air installation. Combustion air is partly taken
in from the atmosphere by the air ventilator and passes the air preheater to the
combustion chamber. This air collects most of the low boiling by-products from
esterification and polycondensation reaction. These hydrocarbons shall be burnt in
the heating plant for ecological reasons.
Secondary HTM Systems
The secondary systems are connected direct to the primary system by supply and
return lines and work as direct injection systems. The supply line, in which a
temperature control valve is installed, connects the primary supply to the secondary
suction side. Temperature of the secondary system is controlled by mixing of hot
HTM from the primary system into the colder secondary systems. The provision of
separate expansion vessels is therefore not necessary. The heat transfer medium
system is circulated by pumps. The secondary system B (HSB) generally is heating
the product lines and its operation of the heating system several auxiliary systems,
such as vent systems, drain systems and a filling system, are provided.

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3. STAPLE FIBER PRODUCTION UNIT

3.1

BASIC OBJECTIVE
The supplied melt from the polycondensation unit is directly conveyed via the
jacketed melt pipe to the staple fiber production lines. Final product is staple fiber,
which is baled in standard bags.

3.2

MAJOR EQUIPMENT
Later (after receipt of vendor information)

3.3
3.3.1

PROCESS SUMMARY
Melt Conveying System
The melt coming from the melt take-over point located directly behind the
polycondensation plant is led through the main polymer melt pipeline to a 3-way
valve where the melt is distributed to two polymer melt transfer pipelines (heated by
HTM).
Behind the 3-way valves the melt is conveyed by booster pumps and through
polymer coolers (heated by HTM, cooled by air) to the 48 spinning position of each
line. There the melt will be transferred in a further polymer melt transfer pipeline
(heated by HTM) to the melt distribution pipeline.

3.3.2

Melt Distribution and Spinning System

Including melt distribution pipeline, spinning beams, spin packs, spin pumps,
quenching, finish application. At each spinning position, the melt throughput can be
manually shut off by means of a valve.
- HTM systems for melt pipe & spinning beam
The melted polymer is uniformly distributed in a jacket heated melt distribution pipe
system designed in such a way that an equal retention time of the melt for each
position is guaranteed.
A HTM system keeps the melt under controlled temperature condition in the
manifolds and spinning beams. Liquid HTM is supplied in barrels and the first filling
is pumped into the HTM heater. The liquid HTM gets vaporized in the heater. The
vapor transfers the heat to the pipe system and spinning beams and provides an
absolutely uniform temperature in the heated areas. The condensate returns to the
heater in a closed circuit. After heating up with intermediate venting, the system is
ready for operation. Two heaters are serving one line. One heater is used for the
spinning beams, one heater for the manifold.
- Static mixers

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The static mixers in the pipe system guarantee a uniform temperature profile in the
melt, without creating any dead spots in the system. They are located before the
distribution of the melt to the three spinning beams and before the distribution of the
meld to the two inlets of each spinning beam.
- Spinning beam
In the spinning beam the melt is distributed from the melt inlet to the individual
spinning section.
- Spinning pump
The meld throughput of each spin position is accurately maintained by one single
driven precision gear pump. This spinning pump pumps the melt through the spin
racks, where it is filtered, and then through the spinneret holes, in which the melt is
transformed to filaments.
- Spin rack
Consisting of upper part and distribution plate and spinneret, the melt will be filtered
by means of metal powder and sieves. The spin packs are mounted from top by a
mounting system.
- Quench air duct & quench air unit
The freshly spun filaments then pass through quench air duct where the laminary
quench air flow is distributed with regulated velocity and controlled temperature and
humidity. The quench air is prepared for the necessary process conditions in the
quench air unit. The air-volume is controlled by speed adjustment of the blower fan
within the limits of optimal pressure diagram. The individual air-volume per
quenching chamber is regulated and adjusted automatically by an air volume
control system. The filaments are solidified with a uniform cross-section.
- Spin finish system quench air duct
Passing the quench air duct the filament bundles are guided over finish-oiled guide
rings. From the quench air ducts, the filaments are led through the spinning tube
down to the fiber draw-off wall.
3.3.3

Draw-off wall and canning system

- Spin finish application
After leaving the spinning tubes, the filament bundles of each position pass through
a spin finish nozzle application system for uniform spin finish application.
- Tow threading & plying

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The filaments of each position are then guided by non-driven guide rolls and finally
gathered into one combined tow.
- Feed Unit
The combined spun tow from all positions is then pulled by the speed controlled
feed roller with 6 rolls to the stationary sunflower wheel and doffed into cans. This
system is equipped with an automatic cutting device that cuts the tow during the
doffing of the cans.
- Can traversing unit
Both transversing directions of the can are effected by the servomotor driven can
traversing unit. The can doffing process is carried out fully automatically. The length
of the tow supplied to the can is metered. The shape of the can is square.
3.3.4

Fiber line
- Tow can conveying
The cans are discharged by a fork lift truck to the creel at the fiber line.
- Can Creel
The tows from the cans in the creel are guided to the inlet thread guide to form three
uniform tow bands. These bands are then taken over the rollers of the tow guide
stand that ensures constant tension before the tow enters the heated immersion
bath, receiving the necessary finish oil and a uniform temperature.
- Drawing
The tows from the cans in the creel are guided to the inlet thread guide to form three
uniform tow bands. Theses bands are then taken over the rollers of the tow guide
stand that ensures constant tension before the tow enters the heated immersion
bath, receiving the necessary finish oil and a uniform temperature.
- Heat seating
For high and medium modulus fiber types, the calendar drier is used for heatsetting
under tension and high temperature. For high modulus fiber, the material has to be
cooled under tension by spraying demineralized water onto the tow between
calendar drier and draw stand 4 (also called cooling stand).
- Crimper
Then the three uniform tows are stacked to one uniform tow with the proper width to
enter the crimper. Then the tow passes the dancer roller 1 that guarantees a
constant tow tension in front of the crimper by controlling the crimper speed. Before

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entering the crimper, the tow passes the steam box where it is heated up.
- Plate belt drier
After crimping, the tow is uniformly dried and cooled under relaxed conditions in the
plate belt drier.
- Cutting machine
Leaving the drier, the tow is fed under uniform tension into the cutting machine
where the tow is cut into the required staple length. The cutting machine is
positioned on top of the baling press and the fiber transport is done by gravity
through the fiber distributor to the balers. Baling presses pressure of the nip rolls
and the stuffing box.
- Bailing press
After cutting, the fiber is conveyed to the baler to product bales. Baling is two-step
process with pre-press & final press.
- Bale transport
The strapped and wrapped bale will be ejected out of the baling press. A fork lift
truck will pick-up the bale for transportation.
3.3.5

Spin finish preparation and application system

During the spinning and drawing procedure of synthetic fibers, the fibers must be
coated with a liquid several times. Apart from being moisturized, the synthetic yarn
is kept supple for the drawing and the yarn is protected against contamination. This
liquid is described as a spin finish solution. The production of the spin finish solution
is effected in a so called spin finish kitchen in which a spin finish concentrate
(powder or paste) is diluted to a working solution.
The process desired concentration of spin finish is achieved in the heated spin
finish mixing tank where the high concentrated spin finish solution is diluted with
demineralized water to a certain ratio. The total content of homogenous spin finish
solution is transferred from the mixing tanks to one of the storage tanks. From here
the spin finish solution is fed by means of circulating pumps to different processing
points as follows:
- Spin finish application rings in the quench air ducts
- Spin finish nozzles at fiber draw-off wall
- Moisturizing unit
- Draw chest 1
- Spraying device 2

FILAMENT PRODUCTION UNIT

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4.1

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BASIC OBJECTIVE
The polymer melt from the polycondensation unit is directly transferred to filament
production lines. First product is partially oriented yarn (POY) filament, and then
POY is transferred to Texturing machines. Final product is Draw textured yarn
(DTY) filament.

4.2

MAJOR EQUIPMENT
Later (after receipt of vendor information)

4.3
4.1.1

PROCESS SUMMARY
POY filament spinning
After leaving the final reactor of Polycondensation unit, the polymer melt is directly
transferred and distributed to each spinning line via the polymer distribution system.
To assure a homogeneous polymer melt quality for all spinning sections, in front of
each distribution, static mixer are installed.
Due to the final arrangement of the production program, the product distribution
system will adapted accordingly to give the required flexibility combined with
highest product quality and productivity. To adjust the melt temperature to the
specific required condition for each product, polymer heat exchangers are installed
for each spinning line. For constant melt pressure in front of each spinning pump,
booster pumps at specific points are required. The final necessity of polymer heat
exchanger as well as booster pumps has to be calculated during project execution
according to the requested production program.
When the polymer melt is entering the spinning manifold, it is transferred with the
metering spinning pumps to each spin pack. The spinning pumps ensure a high
consistency of melt throughput for each spin pack. This is one basic of a very
homogeneous production.
Inside the spin pack a homogeneous polymer distribution to the spinneret takes
place. The spin pack formation can be adapted to the final product, to ensure the
best and reproducible quality of the products.
After leaving the spinneret, the melt is solidified by the quench air system under
constant conditions. For the quench air supply, separate units are installed. With
this quench air AC-units a constant and adequate air quality regarding temperature
and humidity is adjusted.
When the filament yarn is solidified, it passes the spin finish unit, where special
oil/water mixtures are added onto the yarn for less friction, reduced static charge as
well as high yarn cohesion. The spin finish will be prepared in the spin finish
preparation area, according to the final products and down stream processes.
As a connection between the spinning section and the take up section, the so called
spinning duct is installed. This spinning duct will protect the yarn against air streams
form the surrounding.
While entering the take up section, the yarn is passing the suction and cutting
device. In case of yarn break, all yarns are cut and transferred via pipes to a waste

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collecting bin. This suction and cutting device is connected to the yarn detector for
each filament yarn near the winder. Behind the suction and cutting device, the
filament yarns are passing the godet units.
The Godet units are installed for optimum process reliability and best adjustment
possibilities of the overall process in respect to the yarn quality. Finally the yarn is
wound up on bobbins by an automatic winding system.
4.1.2

DTY Texturing Process Explanation for PET

Polyester is a category of polymers which contains the ester functional group in
their main chain, commonly being referred to as polyethylene terephthalate (PET).
PET is the main source for production of manmade fibers. The latter implies that
polymer melt is directly converted into textile fibers or filaments without the
common step of palletizing. It is also called filament yarn.
To make use of filament yarn in downstream operation the intermediate has to
have certain properties which are being applied during the process of spinning, the
intermediate itself is called POY. In the subsequent downstream process the
intermediate is given different properties like volume, crimp and elasticity, which
result for the final consumer in the desired features like insulation, touch and
comfort.
This subsequent process is called draw texturing and the final product draw
textured yarn (DTY). Hereinafter this process is described.
POY is fed via the 1st feed unit and simultaneously drawn by the 2nd feed unit. At
the same time twist is being inserted via friction aggregates located between 1 st
and 2nd feed unit. The twist moved backward in direction of 1 st feed unit into the
upper heater and cooling, where the PET is being thermoformed and fixated in its
twisted form. To lower the internal stress of the already crimpy yarn and to adjust
elasticity and tenacity, a further heat set process between 2nd and 3rd feed unit
helps relax the yarn. After the 3 rd feed unit the yarn is wounded up in packages
suitable for further downstream processes like weaving and knitting.