PE Resin Pelletizing Processes

Application Example
Polyolefins / Bulk Polymer Compounding:
Production of PE pellets LDPE, LLDPE, HDPE

Process
There are a number of well known PE polymerization licenses which are applied in 80% of the
worlds PE Base Resin production lines. The main licenses are Unipol, Himont and Borstar.
Two examples are shown at right.

In each case there is a continuous stream of PE powder (fluff) being produced, which must be
pelletized. It is in this pelletizing process that K-Tron feeders play a key role in metering the PE
powder being fed into the compounder for the pelletizing process.
* This process specifies a loss-in-weight feeder but K-Tron has had success using the Smart
Flow Meter instead.

Main Component: PE Base Resin Powder

Additives: Antioxidant, Stabilizers, Fillers, etc.

Typical Production Rate: 10 000 - 55 000 kg/hr (22 000 - 120 000 lb/hr)

Industries: Automotive, Building & Construction, Appliances & Housewares, Electronics,

Furniture, Health & Hygiene, Leisure & Sport, Packaging, Pipes, Textiles

Higher Feeding Accuracy

For Better Product Quality

Feeding Process
The main component, PE powder, is accurately and gently fed into the pelletizing extruder by a
Smart Flow Meter at rates of up to 25 000 kg/hr (55 000 lb/hr). Some licenses, such as Unipol,
typically specify loss-in-weight screw feeders for the main component but K-Tron has been very
successful in the use of the Smart Flow Meter for feeding the PE powder instead of using an
LWF.

The K-SFM design is very compact: it needs 80% less building height than a comparable LWF.
Another advantage is the gentle handling of the product with a continually free path. The lack of
moving parts almost eliminates the need for maintenance. At the same time the integrated online
auto-tare feature means the K-SFM can be tared without interrupting the product flow and
changes in bulk density have no effect on accuracy. The K-SFM operates at pressures of +/- 0.1
bar.

Depending on the formulation, between one and seven loss-in-weight feeders accurately feed
the additives at a constant ratio to the main stream of PE powder.

Typical Scope of Supply

Main ingredient: PE powder or PE fluff is fed by a Smart Flow Meter 275 or 350 in combination
with a rotary valve at rates of 1 000 - 25 000 kg/hr (2 200 - 55 000 lb/hr). The size of the rotary
valve depends on the required minimum/maximum feed rates. To avoid pulsation K-Tron
recommends a minimum speed of 30 vanes/min. at the minimum feed rate. A screw conveyor
could also be used.
Additives: Irganox, calcium carbonate, stabilizers and other additives are fed by Loss-in-weight
screw feeders such as the K2-ML-T20 or K2-ML-T35 at rates of 1 - 100 kg/hr (2 - 220 lb/hr)
depending of the material and feeder.

Refill: For free flowing products Hurricane vacuum loaders or receivers can be used to keep the
feeders well supplied. Thanks to the patented dual cyclone technology, most materials can be
fed without needing a filter.

For sticky materials such as Irganox, Tinuvin, or CaCO3 refill hoppers or bag dumping stations
are necessary.

Control System
The throughput measured by the Smart Flow Meter provides the master signal for the rest of the
feeder line. The loss-in-weight feeders dose the additives in preset ratios based on the master
signal (master/slave).

The on-machine Smart Control Module (SCM) combines the function of motor drive and feeder
control in a compact package.

In this example the K-Tron Smart Line control unit (KSL) provides a single user interface for up to
8 feeders. The integrated K-Link feature allows for communication with the host DCS system
via Modbus (Modicon) RTU, Allen Bradley DF1 or Siemens (3964R). Alternatively, a K-Tron
Smart Commander could be used for up to 30 feeders and 8 lines.

Environmental Conditions
PE pelletizing processes are typically classified as IP55/NEMA12. The system and all feeders
are generally blanketed with N2 (5-10 mbar) .

Depending on the license, gas explosion protection may be required, i.e. Zone 1, Temperature
class T3 for Europe and Zone 1, Division 2 for USA. In this case standard K-Tron XP executions
must be applied.
Typical Feedrates
K-SFM Advantages

+ accuracy of 0.5%

+ continually free path

+ gentle handling of bulk material

+ easy to clean

+ no energy needed to transport bulk material

+ practically maintenance free

+ independent of bulk density

+ integrated autotare system

+ no moving parts

+ simple, robust design

Competing Technology
Large loss-in-weight screw feeder or belt feeder
- high maintenance
- high cost

Coriolis flow meter

- no free path
- each bulk material must be calibrated
- much stress exerted on bulk material
Impact plate
- each bulk material must be calibrated
- dependent on bulk material and flow conditions
- low accuracy

Diverting chute
- dependent on bulk material and flow conditions
- low accuracy
- no autotare

References
Over 100 K-Tron Smart Flow Meters have been successfully installed in similar process lines
worldwide. Your K-Tron Sales staff can provide you with the latest reference list. We will also be
glad to provide contact information or arrange visits to reference sites.

Economic Assessment
New PE lines generally include high performance compounders such as those supplied by
Coperion, JSW, Farrell, and Kobe Steel.

The K-SFM, with its compact design and fast weight measurement, combined with the state-of-
the-art algorithms of the SCM help the customer reduce building height while also reducing the
amount of waste material created during start-up and shut-down periods of the production line.

Future Potential
There are a number of PE plants all over the world. This market is still growing by about 3-5%
annually. PE is an important base material in more and more processes.

Retrofitting and debottlenecking existing PE lines also offer potential for new projects.

Typical Producers
BP, Basell, Exxon, Elf Atochem, Borealis, DSM, Solvay, Fina, ICI, Targor, BASF, Elenac, DOW,
and more...

Resellers & Engineering Firms

Technimont, Kvaerner, Uhde, Bechtel, Technip, Parsens, JGC, JSW, Toyo, Jacobs Engineering,
Wschle, Zeppelin, Neu, Fluor Daniel, Kellog Brown and more...

Typical installations:
Testing Facilities
K-Tron has well-equipped testing facilties to test high rates of PE powder and additives. We can
handle up to 20 t/hr of PE powder for accuracy testing. Long term testing is also available since
material can be recirculated.

Services
Additional services are also available, such as:

- System Engineering

- Installation Start-up

- Operator and Maintenance Training

For more information see K-Tron Soder Product Specification Sheets.