Inspection

Report

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Content

Page

INTRODUCTION.......................................................................................................................................................3

UTILITY SPECIFICATION (VALID FOR BOTH SSP UNITS)............................................................................4

2.1
2.2
2.3
2.4

ELECTRICAL POWER............................................................................................................................................4
COOLING WATER................................................................................................................................................. 4
COMPRESSED AIR................................................................................................................................................4
NITROGEN............................................................................................................................................................4

RAW MATERIAL HANDLING.................................................................................................................................5

LINE 01 45 TON/DAY........................................................................................................................................... 7
4.1 PROCESS FLOW DIAGRAM...................................................................................................................................7
4.2 PRE-CRYSTALLIZATION LOOP...............................................................................................................................8
4.3 CRYSTALLIZER LOOP............................................................................................................................................9
4.4 PREHEATER....................................................................................................................................................... 10
4.5 HOT CONVEYING................................................................................................................................................10
4.6 REACTOR...........................................................................................................................................................11
4.7 COOLER.............................................................................................................................................................12
4.8 NPU...................................................................................................................................................................12
4.8.1 Gas coolers.............................................................................................................................................12
4.8.2 Catalyst system.......................................................................................................................................13
4.8.3 Gas dryer.................................................................................................................................................14
5 LINE 02 60 TON/DAY.........................................................................................................................................15
5.1 PROCESS FLOW DIAGRAM................................................................................................................................15
5.2 PRE-CRYSTALLIZATION LOOP.............................................................................................................................16
5.3 CRYSTALLIZER LOOP......................................................................................................................................... 17
5.4 PREHEATER....................................................................................................................................................... 18
5.5 HOT CONVEYING................................................................................................................................................18
5.6 REACTOR...........................................................................................................................................................19
5.7 COOLER.............................................................................................................................................................20
5.8 NPU...................................................................................................................................................................21
5.8.1 Gas coolers.............................................................................................................................................21
5.8.2 Catalyst system.......................................................................................................................................21
5.8.3 Gas dryer.................................................................................................................................................22
6 UTILITY CONSUMPTION.....................................................................................................................................23
7 FINAL MATERIAL HANDLING........................................................................................................................... 23
8 CONCLUSIONS AND RECOMMENDATIONS.................................................................................................24

Introduction
SSP-1
1995 Start-up. Design capacity = 45 tons/day
1997 Plant was dismantled and re-assembled in a different location (close to SSP-2).
Until 2012 Continuous capacity increasing. Maximal throughput achieved was 60 tons/day (BG).
Main bottlenecks for higher capacities were: raw material shortage and rotary valves.
20112012 Several campaigns with RPET material supplied by different customers.
Typical process conditions used for RPET processing:
SSP throughput: 2200 kg/h 2400 kg/h
IVinlet:

0.620 0.650 dl/g

IVoutlet: 0.845 0.855 dl/g

Reactor temp.: ~200C

SSP-2
1997 Start-up. Design capacity = 60 tons/day
Until 2012 Continuous capacity increasing. Maximal throughput achieved was 76.8 tons/day
(BG).
Main bottlenecks for higher capacities were: raw material shortage and rotary valves.
20102011 Processing of Technical Yarn (TY) grade supplied by spanish customer.
Typical process conditions for TY:
SSP throughput: 1300 kg/h 1500 kg/h
IVinlet:

0.620 dl/g

IVoutlet: 1.050 dl/g

Reactor temp.: ~200C
After several attempts to keep the SSPs running Elana decided to stop activities Mai 2012.
The observations and activities carried out during plant inspection are described in the next chapters
from this report.

Utility Specification (valid for both SSP units)

2.1 Electrical Power
Power Voltage

220/380 V (10 %)

50 Hz (1 %)

Control Voltage

24 V

DC

Instrument power supply

24 V

DC

Analog signals

4 20 mA

3 phase

for controllers

2.2 Cooling Water

Inlet max.

Outlet max.

Temperature

25C (summer condition)

35C

Pressure

5 bar g

closed system

2.3 Compressed Air

Temperature

ambient

Pressure (min)

4.5 bar g

Dew Point

-20 C

Condition

Oil free

2.4 Nitrogen
Temperature

ambient

Pressure (min)

4.5 bar g

Pressure fluctuation

0.5 bar

Atm. Dew Point

- 20 C

Purity

99.5 vol %

Condition

Oil free

Raw material handling

Plant has a truck and big-bag unloading systems which convey pneumatically raw material straight to the
amorphous silos.

Fig. 3-01: Overview of SSP building and raw material handing area.

A classifier located downstream raw material silo removes oversized particles (Elana used to process
material from batch system) and dust from feedstock before convey it to the top of the SSPs.

Fig. 3-02 and 3-03: Classifier downstream raw material silos (left: SSP-45tpd; right: SSP60tpd).

Conveying systems designed by Buhler

Design capacity:

SSP-01: 2.5 tons/hour (60 tons/day)

SSP-02: 3.0 tons/hour (72 tons/day)

Maximal capacity achieved:

SSP-01: 2.7-2.8 tons/hour (> 60.0 tons/day)

SSP-02: 3.4-3.5 tons/hour (> 72 tons/day)

Raw material silo capacity: 100 m3 (approx.. 70 tons)

Big-bag unloading: hoist for 1500 kg

Fig. 3-04 and 3-05: big-bag unloading system and pneumatic conveying line to raw material silos.

Line 01 45
ton/day
4.1 Process Flow Diagram

Fig. 4-01: SSP-01 45 tons/day PFD.

4.2 Pre-crystallization loop

Pre-crystallizer:

OTWK-180 under air

Fan:

Reitz RGE-125-040030 (110 kW; 380V AC; 50 Hz)

Heater:

SAN Electrical heater (142 kW; 380V AC)

Cyclone

OKRB-175

Fig. 4-02 and 4-03: Pre-crystallizer OTWK-180 and Pre- & Crystallizer fans

The Pre-crystallizer was fairly clean and fluidization sieve does not have signs of damage (the sieve
holes were not clogged with dust and/or pellets)

4.3 Crystallizer loop

Crystallizer:

OTWG-280 under air

Fan:

Reitz RGE-080-028030 (55 kW; 380V AC; 50 Hz)

Heater:

SAN Electrical heater (70 kW; 380V AC)

Cyclone

OKRB-150

Fig. 4-04: Crystallizer OTWG-280

Fig. 4-05: sieve plate: front section has signs of deformation.

The Pre-crystallizer is in a good condition: gas flaps, product lever and "pulsator" are working properly
and sight glasses are free of scratches / dirty.
The fluidization sieve has have signs of deformation in the front section (it is recommend to replace the
OTWG sieve). The sieve holes were not clogged with dust and/or pellets customer never
observed product entrainment is this loop.

4.4 Preheater

Preheater:

OKTD-18-III-02 compartments under Nitrogen

Fan:

Reitz RGE-080-007130 (15 kW; 380V AC; 50 Hz)

Heaters:

Main SAN Electrical heater (70 kW; 380V AC)

Inter. SAN Electrical heater (25 kW; 380V AC)

Jet-filter

PGFZ-52/18

It was not possible to inspect the OKTD internally:

As usual all sight glasses were completely covered by oligomer. Normal condition after years in
operation.

Manhole on top of the OKTD was not opened during the plant visiting

4.5 Hot conveying

Blower:

Dresser + Holmes 404 RGS-J Whispair (4kW ; 380V AC;

50 Hz) Flow rate: 1.7 Nm3/min

p: 605 mbar

Heater:

SAN Electrical heater (10 kW; 380V AC)

Fig. 4-06: hot conveying system using D+H blower fluid-lift conveying.

Design capacity: 2 tons/hour (48 tons/day)

Maximal capacity achieved: 2.5 tons/hour (60 tons/day)

4.6 Reactor

Reactor:

total holdup (full):29 tons @ bulk density = 830 kg/m

Active holdup (full):28 tons @ bulk density = 830 kg/m

Gas flow rate to reactor: 2426 Nm /min k-value = 0.55-0.60 @ 45 tons/day

Heater:

OKTN-19-130
3
3

SAN Electrical heater (74 kW; 380V AC)

Fig. 4-07 and 4-08: reactor OKTN-19-130 conveying hopper and temperature probes / load cell.

Fig. 4-09 and 4-10: reactor OKTN-19-130 internal view and product distributor.

The Reactor was inspected internally (manhole located on its top). No signs of deformation or damage
were observed. Note: the current reactor does not have any kind of inserts.
The original temperature sensors (rope sensor) were replaced by PT-100 installed in the reactor wall.
There is a small hopper installed on the top of the reactor.
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4.7 Cooler

Cooler:

OTWG-90 under Air

Fan:

Reitz RGE-063-010030 (15 kW; 380V AC; 50 Hz)

Cyclone

MGXD-95

Fig. 4-11: Cooler OTWG-90

Fig. 4-12: sieve plate: no signs of damage.

The product cooler was fairly clean and fluidization sieve does not have signs of damage (the sieve
holes were not clogged with dust and/or pellets)
Gas flaps, product lever and "pulsator" are working properly and sight glasses are free of scratches /
dirty.

4.8 NPU
4.8.1
Gas coolers
The original gas cooler upstream main blower (TAG: 327 BEM type) was replaced by new one
manufactured in Poland due to frequently clogging / corrosion on the water side. The new H.E. is made
of stainless steel.
Other heat exchangers like 343 (downstream main blower) and 318 (ECO) never had similar problem.

Fig. 4-13: Gas cooler upstream main blower (new)

4.8.2

Fig. 4-14: Gas cooler downstream main blower

Catalyst system

Catalyst vessel:
o

Catalyst amount:

OGR-10
0.26 m3

Air feeding unit:

OGAF-26

Nitrogen feeding unit:

OKUR-TM-230

According to the customer the current catalyst charge was in operation for approx. 05 years. Tests with
recycled material performed in 2012 apparently affected the catalyst charge: gunk was collected in 327
gas cooler and condensate water from gas dryer.

Fig. 4-15: Catalyst vessel

4.8.3

Gas dryer

Gas dryer type:

Delair GDCA-NES-0912

Fig. 4-16: Gas dryer skid unit

Line 02 60
ton/day
5.1 Process Flow Diagram

Fig. 5-01: SSP-01 60 tons/day PFD.

5.2 Pre-crystallization loop

Pre-crystallizer:

OTWK-180 under air

Fan:

Reitz RGE-125-040030 (110 kW; 380V AC; 50 Hz)

Heater:

SAN Electrical heater (142 kW; 380V AC)

Cyclone

OKRB-175

Fig. 5-02 and 5-03: Pre-crystallizer OTWK-180 and its fluidization sieve

Fig. 5-04: Pre- & Crystallizer fans

Analog to SSP-1 the Pre-crystallizer was fairly clean and fluidization sieve does not have signs of
damage (the sieve holes were not clogged with dust and/or pellets).

5.3 Crystallizer loop

Crystallizer:

OTWG-280 under air

Fan:

Reitz RGE-080-028030 (55 kW; 380V AC; 50 Hz)

Heater:

SAN Electrical heater (67 kW; 380V AC)

Cyclone

OKRB-150

Fig. 5-05: Crystallizer OTWG-280

Fig. 5-06: sieve plate: rear section has signs of deformation.

Similar to SSP-1, the Crystallizer from line 02 is in a good condition: gas flaps, product lever and
pulsator are working properly and sight glasses are free of scratches / dirty.
The fluidization sieve has have signs of deformation in the outlet section (it is recommend to replace the
OTWG sieve). The sieve holes were not clogged with dust and/or pellets customer never
observed product entrainment is this loop.
Visual inspection did not detect any irregularity with respect to the crystallizer fan.

5.4 Preheater

Preheater:

OKTD-18-III-03 compartments under Nitrogen

Fan:

Reitz RGE-080-007130 (15 kW; 380V AC; 50 Hz)

Heaters:

Main SAN Electrical heater (70 kW; 380V AC)

Inter. 01 SAN Electrical heater (14 kW; 380V AC)
Inter. 02 SAN Electrical heater (18 kW; 380V AC)

Jet-filter

PGFZ-52/18

It was not possible to inspect the OKTD internally:

As usual all sight glasses were completely covered by oligomer

Manhole on top of the OKTD was not opened during the plant visiting

Customer never observed presence of pellets inside intermediate heater or material collected from
PGFZ filter.

5.5 Hot conveying

Blower:

Dresser + Holmes 404 RGS-J Whispair (7.5 kW ; 380V AC;

50 Hz) Flow rate: 2.3 Nm3/min

Heater:

SAN Electrical heater (10 kW; 380V AC)

Fig. 5-07: hot conveying system using D+H blower fluid-lift conveying.

Design capacity: 2.5 tons/hour (60.0 tons/day)

Maximal capacity achieved: 3.45 tons/hour (76.8 tons/day)

5.6 Reactor

Reactor:

total holdup (full):34 tons @ bulk density = 830 kg/m

Active holdup (full):33 tons @ bulk density = 830 kg/m

Gas flow rate to reactor: 2630 Nm /min k-value = 0.45-0.52 @ 60 tons/day

Heater:

OKTN-19-150 (without internals)

3
3

SAN Electrical heater (74 kW; 380V AC)

Fig. 5-08 and 5-09: reactor OKTN-19-150 top section and temperature probes / load cell.

Fig. 5-10: reactor OKTN-19-150 internal view.

The Reactor was inspected internally (manhole located on its top). No signs of deformation or damage
were observed. Note: the current reactor does not have internals.
The original temperature sensors (rope sensor) were replaced by PT-100 installed in the reactor wall.

5.7 Cooler

Cooler:

OTWG-160 under Air

Fan:

Reitz RGE-063-010030 (30 kW; 380V AC; 50 Hz)

Cyclone

MGXD-95

Fig. 5-11: Cooler OTWG-160

Fig. 5-12: sieve plate: no signs of damage.

The product cooler was fairly clean and fluidization sieve does not have signs of damage (the sieve
holes were not clogged with dust and/or pellets)
Gas flaps, product lever and pulsator are working properly and sight glasses are free of scratches /
dirty.

5.8 NPU
5.8.1
Gas coolers
The original gas cooler upstream main blower (TAG: 327 BEM type) was replaced by new one
manufactured in Poland due to frequently clogging / corrosion on the water side. The new H.E: is made
of stainless steel.
Other heat exchangers like 343 (downstream main blower) and 318 (ECO) never had similar problem.

Fig. 5-13: Gas cooler upstream main blower (new)

5.8.2

Catalyst system

OGR-10

Catalyst vessel:
o

Catalyst amount:

0.26 m3

Air feeding unit:

OGAF-26

Nitrogen feeding unit:

OKUR-TM-230

According to the customer the current catalyst charge was in operation for approx. 05 years.

Fig. 5-14 and 5-15: Catalyst vessel and catalyst panel resp.

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5.8.3

Gas dryer

Gas dryer type:

Delair GDCA-NES-1212

The gas dryer from SSP-02 has a spare charge supplied by Delair

Fig. 5-16: Gas dryer skid unit

Fig. 5-17 & 5-18: desiccant charge (spare) for SSP-2 gas dryer

Utility consumption
Data for both SSP lines in steady production condition (including conveying systems):

Power consumption:

180 kWh/ton (information supplied by current owner)

SSP-1 (motors/heaters):

175 kW / 335 kW (installed: 270 kW / 480 kW)

SSP-2 (motors/heaters):

179 kW / 380 kW (installed: 275 kW / 550 kW)

Compressed air:

Nitrogen:

Cooling water:

117 m /ton
3

19.1 m /ton approx. 109 Nm /h (both lines)

0.0175 m /ton

Final material handling

Final conveying systems designed by Buhler

Design capacity:

SSP-01: 2.5 tons/hour (60 tons/day)

SSP-02: 3.0 tons/hour (72 tons/day)

Maximal capacity achieved:

SSP-01: 2.5 tons/hour

SSP-02: 3.2 tons/hour

Truck and big-bag loading systems

SSP-1: 2x stainless steel silos of 100 m capacity each total storage capacity: 140 tons

SSP-2: 3x stainless steel silos of 125 m capacity each total storage capacity: 270 tons.

3
3

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Fig. 7-1: final material handling

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Conclusions and recommendations

The inspection performed on 25.07 26.07 confirmed that the both SSPs are being kept in very good
condition. If required both installations could be re-started promptly.

It is not necessary to carry out any modification or repairing for bottle and technical yarn grades
processing except in case of further capacity increasing (plant debottlenecking).

However, some modifications in the gas purification unit (NPU) are required if new owner plans to
process recycled material (RPET).