SOLID STATE

POLYCONDENSATION
LINES FOR PET
BOTTLE GRADE RESIN
Boryszew S.A. 96-500 Sochaczew ul. 15 Sierpnia
Oddzia Elana w Toruniu
ul. M.Skodowksiej Curie 73
87-100 Torun
Poland

Solid State polycondensation lines for PET bottle grade resin

Solid State polycondensation lines for PET

bottle grade resin
1

Solid State polycondensation lines for PET bottle grade resin

Content:
1.

Description of the lines ..................................................................................................... 3

2.

Characteristic data ............................................................................................................ 4

3.

1.1.

Unit 1 ........................................................................................................................... 4

1.2.

Unit 2 ........................................................................................................................... 6

1.3.

Unit 3 ........................................................................................................................... 7

1.4.

Unit 4 ........................................................................................................................... 8

Technical specification...................................................................................................... 9
3.1

Installed Power ............................................................................................................. 9

3.2

Utilities ......................................................................................................................... 9

3.3

Staff ............................................................................................................................ 10

3.4

Main equipment for each line ................................................................................... 10

Solid State polycondensation lines for PET bottle grade resin

1. Description of the lines

These are two technological lines for the manufacturing (additional polycondensation) of the
bottle grade PET resin which is used in the production of popular PET bottles for beverages. They
are based on the solid state polycondensation technology developed by the famous Swiss
BUHLER company. The production process depends on thermal treatment of the raw material
(amorphous polymer A-PET of the Initial IV about 0.6 dl/g) in the equipment of the lines. The
lines consist of five basic process loops each, where the material is treated by the temperature in
the specified conditions for a certain period of time. During processing amorphous material, its
molecular weight changes to the value expected for bottle grade, or higher, up - even to 1.0 dl/g.
There is ability to process R-PET materials on these lines, too. Beside the standard bottle grade
we have experienced processing R-PET and the fiber grade homo-polymers to the values of 0.96
1.0.
Nominal capacities of the lines were increased to the following values: Line 45 up 60 t/d and Line
60 up to 76,8 t/d.
Main process Loops:
-

precrystalisation;

crystalisation;

preheating;

polycondensation;

cooling.

The technological process is visualized by the drawing (appendix No.1).

On the stages of preheating and polycondensation, the process takes place in the atmosphere of
pure nitrogen. This is for the protection of the material against the color degradation in high
temperature conditions. The nitrogen loop is closed, equipped with a special cleaning system
based on the Pt-ctalyst. This is a system where main byproducts of the process are removed from
the gas. These byproducts are acetaldehyde and ethylene glycol. They are burned and
transformed into environmentally safe water and carbon dioxide. The dust (which is a product of
a constant friction of the pellets) has to be removed from the process gas, too. For that purpose,
systems of cyclones and special type filters are installed there. The loop has to be constantly feed
with pure, fresh nitrogen. The gas is dried in the Gas Dryer system. The process of solid state
3

Solid State polycondensation lines for PET bottle grade resin

polycondensation is a continuous one. Friction of the pellets was eliminated as much as possible
through installing specially constructed equipment. This helps to keep the material consumption
at the lowest possible level and limit the amount of waste. For the production of 1000kg of the
final product we need 1005kg of the raw material (amorphous PET). A complex of raw material
silos (1 for 45t/d & 1 for 60 t/d line) can store 120 tons of amorphous pellets. The final product
stations can store 440 tons of the product (140 t for 45/d line and 300t for 60t/d line). The final
product complexes are also equipped with so called big - bag stations for each line with electronic
scales that enable to pack the final product into special 1000-1200 kg big- bags. Filling the autotrack-silo is possible, too. It is enabled thanks to the special equipment installed under the silo
group.
It is also possible to unload trucks with raw material deliveries straight to the raw-material silo as
well as to feed the line straight from the big bags.
The whole process goes in a hermetic equipment and is controlled by computer systems (Simens
S-5, visualization on two independent PCs on the Factorylink platforms). Additional control of the
process is possible through sight-glasses placed on each equipment unit. It enables to reach stable
quality parameters of the product.

2. Characteristic data
-

Technology: Buhler AG Switzerland

Supplier: Buhler AG Switzerland

Daily capacity (throughput): after increasing - 60 t/d for SSP 45 and 76,8 t/d for SSP 60

The line 45 t/d was put into operation in 1995 and line 60 t/d in 1997. The main units
of the whole integrated lines are:

1.1. Unit 1

Two main buildings where both lines are placed. Buildings are based on steel structure with five
levels and they are connected together with one wall. On the level 0.0 in the floor there are
technological channels installed. Lines are equipped in the following systems:

1. Electrical
4

Solid State polycondensation lines for PET bottle grade resin

2. Nitrogen feeding
3. Compressed air
4. Cooling water
5. Drinking water
6. Lightning protection

Buildings are 29 meters high. Data for two buildings:

1. Land development area

329 m2

2. Usable area

1544 m2

3. Cubic capacity

9280 m3

Two main buildings:

Solid State polycondensation lines for PET bottle grade resin

1.2. Unit 2

Integrated objects of two steering rooms, two trafo - station, two swiching station for the
lowvoltage and social rooms. These are one level buildings of traditional construction. Buildings
are equipped with central heating, canalization, telephone and ventilation installations.

Data for 6 objects together:

1. Land development area

305 m2

2. Usable area

265 m2

3. Cubic capacity

1168 m3

Steering rooms:

Solid State polycondensation lines for PET bottle grade resin

1.3. Unit 3

Unit consisted of raw material silo station and two umbrella roofs for storage.
Raw material silo station Stand for two raw material silo (amorphous) made from stainless steel
of capacity 100m3 each. Support steel structure construction with technological ladders and
platforms. Is equipped with electrical power, pressed air and central heating systems, lighting
protection and ventilation.
1. Land development area

107 m2

2. Usable area

101 m2

3. Cubic capacity

749 m3

Umbrella roofs for storage - steel structure construction faying to raw material silo station
covered with sheet metal plates, equipped with moving electrical hoist of capacity 1500 kg.
1. Land development area

269 m2

2. Usable area

257 m2

3. Cubic capacity

1829 m3

Raw material silo station and two umbrella roofs for storage:

Solid State polycondensation lines for PET bottle grade resin

1.4. Unit 4
Unit consisted from two objects of final product silo stations.

Final product silo station for SSP 45 t/d stand for two stainless steel silo of 100 m3 capacity
each. Steel structure support construction with ladders and technological platforms. Area is
equipped with pressed air and electrical systems as well as lighting protection and ventilation
installations. Storage capacity of final product is about 140 tones.

Final product silo station for SSP 60 t/d - stand for three stainless steel silo of 125m3 capacity
each. Steel structure support construction with ladders and technological platforms. Equipped
with pressed air and electrical systems as well as lighting protection and ventilation installations.
Storage capacity of final product is about 300 tones.

Data summarized for two buildings:

1. Land development area

113 m2

2. Usable area

104 m2

3. Cubic capacity

552 m3

Final product silo station:

Solid State polycondensation lines for PET bottle grade resin

3. Technical specification
3.1 Installed Power
Installed Power
SSP 45

Power voltage

220/380 V

Frequency
Electric motors:

50Hz

Installed motor power

270 kW

Consumption

175 kW

Control system

10kW

Heaters:
Installed heater power

480kW

Consumption

335 kW

Installed Power
SSP 60
Power voltage

380 V (10 %)

Frequency
Electric motors:

50Hz

Installed motor power

275 kW

Consumption

179 kW

Control system

10kW

Heaters:
Installed heater power

550kW

Consumption

380 KW

3.2 Utilities
Utilities Specifications & consumptions
SSP 60
Cooling Water

Pressure 6 bar

Pure nitrogen (99,5%)

Pressure 5,5 bar; dew point (-20C)

Instrument air

Pressure 5,5 bar

Plant air

Pressure 7 bar

Solid State polycondensation lines for PET bottle grade resin

Utility Consumption (evaluating for two running lines in constant

production):
Electrical power

0,18 MWh/t

Pressed air

117 m3/t

Pure nitrogen (99,5%)

19,1 m3/t

Cooling water

0,175 m3/t

3.3 Staff
Staff (for two running lines):
Line crew (technology, steering &
controlling)

3/2 operators (1 leader)/shift

Raw material station crew

2 man/shift (one for lift operator)

Big bag station crew

3 man/shift (one fork lit operator)

Supervising the handling crew

1 person/shift

3.4 Main equipment for each line

Preclystalizer;

Crystalizer;

Preheater;

Reactor;

Cooler;

Nitrogen filter;

Nitrogen dryer;

Main nitrogen blower;

Blowers for precrystalisation & crystallization loops , preheater & final product
cooler;

Pt-catalyst with steering panel;

Hot conveying loop blower;

Cyclones;

Big bag weighting station + set of silo for the final product with an option to fill
BIG-BAG & loading auto-silo-trucks;

Raw material station + one silo for the raw material amorphous resin with an option
to unload silo-trucks and BIG BAGs;

Cooling water system with two water coolers, pumps and water gathering container
with air coolers
10

Appendix 1

TECHNOLOGICAL SCHEME OF THE SSP LINE

PROCESS
SSP

RAW
MATERIAL
DELIVERY
UNLOADING
SILO TRUCKS

UNLOADING BIG
BAGS

FINAL
PRODUKT

RAW
MATERIAL
SILO
GROUPE

PRECRYSTALYSATION

CRYSTALISATION

PREHEATING

NITROGEN
CLEANING LOOP

REACTOR

COOLING

FINAL
PRODUCT
SILO
GROUPE

SILO TRUCK
LOADING

BIG-BAG
LOADING

Solid State polycondensation lines for PET bottle grade resin

Precrystalizer
SSP 45

Catalizer

Preheater

SSP 60

SSP 60

Solid State polycondensation lines for PET bottle grade resin

Reactor

Reactor

SSP 60

SSP 60

Solid State polycondensation lines for PET bottle grade resin

Air cooler
SSP 45

Nitrogen Dryer
SSP 60

Solid State polycondensation lines for PET bottle grade resin

Crystalizer
SSP 60

Main Nitrogen Blower

SSP 60