Design 900 Tons/Day Pet Manufacturing Plant and Study Acetaldehyde Formation During Manufacturing Process

DESIGN 900 TONS/DAY PET
MANUFACTURING PLANT AND STUDY

ACETALDEHYDE FORMATION DURING
MANUFACTURING PROCESS
HAFIZA WAJIHA NAZ B1833015
MUHAMMAD AAMIR B1833024
UZAIR AHMED QURESHI B1833048
WAQAS AHMED B1833050
DEPARTMENT OF CHEMICAL ENGINEERING

UNIVERSITY OF KARACHI
KARACHI, PAKISTAN
2023
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CERTIFICATE
This is to certify that the project report on Design of PET manufacturing plant for
900 tons/day and to study acetaldehyde production is compiled and written by the
students of Final Year under the supervision of Engr. Mudassar Ahmed. This
project is submitted to the Department of Chemical Engineering, University of
Karachi, for the partial fulfillment of the Bachelor‘s Degree in Chemical
Engineering.
HAFIZA WAJIHA NAZ B1833015
MUHAMMAD AAMIR B1833024
UZAIR AHMED QURESHI B1833048
WAQAS AHMED B1833050
Project supervisor (internal) Project supervisor

(External)
In charge
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ACKNOWLEDGEMENT
We have taken full efforts in this project. However, it would not have been possible
without the kind support and help of many individuals. We would like to extend
our sincere thanks to all of them especially our teacher, and internal supervisor,
Engr. Mudassar Ahmed for his kindness, encouragement and for putting his efforts
in to this project.
We would like to express our gratitude towards our parents & our teachers for their
kind co- operation and encouragement which helped us in completion of this
project. We would like to thank our incharge Dr. Shagufta Ishteyaque & former
chairman Dr. Fasiullah Khan.
Our thanks and appreciation also goes to our colleagues in helping us for
developing the project and people who have willingly helped us out with their
abilities.
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EXECUTIVE SUMMARY
Polyethylene Terephthalate (PET) is one of the most widely used polyester in the
world because of its excellent mechanical strength and good barrier properties.
The objective of our project is to design PET manufacturing plant with the capacity
of 900 tons/day.
This report presents the equipment sizing, plant layout, simulation, piping and
instrumentation diagram and costing of the PET manufacturing plant. The main
reaction, and sub reaction stages are described in detail and proposed process
including design data sheets are introduced. GATRO-NOVATEX is currently
using five-reactor technology to produce PET although there are some
manufacturing plants in Europe which are using three reactor technology to save
the equipment cost.
According to this early analysis, the method appears to be quite doable; however,
a few additional studies can be conducted to increase profitability even more. This
process could be modified to use less heating and cooling overall, which could
save a few million pounds annually but presumably necessitates a minor increase
in project expense. Recovering and purifying the utilized EG while also recovering
the Acetaldehyde created during the process is another cost-saving option. A few
million pounds could be saved annually if this recovered acetaldehyde were sold
to offset the cost of manufacture, and reclaimed EG could then be utilized as the
raw material once more.
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CONTENTS
CHAPTER 1: INTRODUCTION ......................................................................................................... 10
1.1 PROJECT BACKGROUND: .............................................................................................. 10
1.2 PROBLEM STATEMENT: ................................................................................................ 10
1.3 OBJECTIVE: ....................................................................................................................... 10
1.4 SCOPE:................................................................................................................................ 11
CHAPTER 2: LITERATURE REVIEW ............................................................................................. 12
2.1 POLYESTERS: ................................................................................................................... 13
2.2 POLYETHYLENE TEREPHTHALATE (PET) ................................................................. 14
CHAPTER 3: TECHNOLOGY SELECTION .................................................................................... 16
3.1 AVAILABLE TECHNOLOGIES: ...................................................................................... 17
3.2 WHY CHOOSING ZIMMER TECHNOLOGY? ............................................................... 18
CHAPTER 4: PERT CHART ............................................................................................................... 19
4.1 DESCRIPTION OF PERT CHART: ................................................................................... 20
CHAPTER 5: PROCESS DESCRIPTION:......................................................................................... 23
5.1 RAW MATERIALS ............................................................................................................ 23
5.2 PASTE PREPARATION TANK: ....................................................................................... 24
5.3 ESTERIFICATION REACTORS: ...................................................................................... 24
5.5 PREPOLYMERIZATION REACTOR I: ........................................................................... 25
5.6 PRE-POLYMERIZATION REACTOR II: ......................................................................... 25
5.7 DISK RING REACTOR (DRR): ........................................................................................ 26
5.8 SCRAPPER CONDENSOR: ............................................................................................... 26
5.9 FILTER................................................................................................................................ 27
5.10 CUTTER............................................................................................................................ 27
5.11 DRYER.............................................................................................................................. 27
5.12 VIBRO SCREENING ....................................................................................................... 27
CHAPTER 6: MATERIAL AND ENERGY BALANCE ................................................................... 28
6.8 ENERGY BALANCE ......................................................................................................... 35
CHAPTER 7: BLOCK FLOW DIAGRAM ........................................................................................ 37
CHAPTER 8: PROCESS FLOW DIAGRAM .................................................................................... 38
CHAPTER 9: PIPING & INSTRUMENTATION DIAGRAM ......................................................... 42
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CHAPTER 10: HAZOP STUDY .......................................................................................................... 43
10.1 SLURRY PREPARATION TANK (11-TA01): ............................................................... 45
10.2 ESTER-1 (12-R01): ........................................................................................................... 47
10.3 DISTILLATION COLUMN: ............................................................................................ 49
10.4 PRE-POLY REACTOR (12-R01):.................................................................................... 51
10.5 PRE-POLY FILTERS (16-F01): ....................................................................................... 52
10.6 SCRAPPER CONDENSER (15-E01):.............................................................................. 53
CHAPTER 11: LINE SIZING .............................................................................................................. 54
CHAPTER 12: EQUIPEMENT DESIGN ........................................................................................... 60
12.1 ESTERIFICATION –I:...................................................................................................... 60
12.2 ESTERIFICATION –I I: ................................................................................................... 61
12.3.4 PRE POLYCONDENSATION REACTOR –I: ............................................................. 62
12.5 DISC RING REACTOR: .................................................................................................. 62
12.6 SLURRY PUMP: .............................................................................................................. 64
12.7 DISTILLATION COLUMN: ............................................................................................ 65
CHAPTER 13: MATERIAL OF CONSTRUCTION ......................................................................... 66
CHAPTER 14: PLANT LAYOUT ....................................................................................................... 73
CHAPTER 15: ACETALDEHYDE FORMATION DURING PET MANUFACTURING ................. 82
CHAPTER 16: SAFETY ISSUES AND HAZARDS ANALYSIS ....................................................... 85
16.1 IDENTIFICATION OF MATERIAL AND CHEMICAL HAZARDS ............................ 92
16.3 ENVIRONMENTAL QUALITY ACT (EQA) 1974: ....................................................... 96
CHAPTER 17: COSTING .................................................................................................................. 100
REFERENCES
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LIST OF FIGURES:
FIGURE 4.1: Pert Chart
FIGURE 7.1: Block flow diagram
FIGURE 8.1: Process flow diagram
FIGURE 8.2: Process flow diagram of esterification reactors.
FIGURE 8.3: Process flow diagram of PP-1 & PP-2
FIGURE 8.4: Process flow diagram of DRR and cutter
FIGURE 9.1: P&ID of mixing vessel
FIGURE 9.2: P&ID of Ester-1 and Ester-2
FIGURE 9.3: P&ID of distillation column
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LIST OF TABLES:
Table 2.1: Properties of PET
Table 3.1: Details of Zimmer technology
Table 5.1: Ester-1 Specifications
Table 5.2: Ester-2 Specifications
Table 5.3: PP-1 Specifications
Table 5.4: PP-2 Specifications
Table 5.5: DRR Specifications
Table 6.1: Raw materials quantities
Table 6.2: Ester-1 material balance
Table 6.3: Ester-2 material balance
Table 6.4: PP-1 material balance
Table 6.5: PP-2 material balance
Table 6.6: DRR material balance
Table 12.1: Mechanical strength properties of metals and alloys (at room
temperature)
Table 12.2: Common available grades of stainless steel
Table 13.1: Plant layout
Table 16.1: List of chemicals involved
Table 16.2: Summary of Types of hazards/exposure of PTA
Table 16.3: Summary of Types of hazards/exposure of Ethylene glycol
Table 16.4: Summary of Types of hazards/exposure of BHET
Table 16.5: Summary of Types of hazards/exposure of PET Table 16.6: Hazards
identification of chemicals involved
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NOTATIONS:
PET Polyethylene Terephthalate
BOPET Bi-axial Polyethylene Terephthalate
EG Ethylene Glycol
PTA Purified Terephthalic Acid
Sb2O3 Antimony Triacetate
IPA Iso-Phthalic Acid
BHET Bis-Hydroxy Ethyl Terephthalate
H3PO4 Phosphoric Acid
MT Metric tons
DRR Disk Ring Reactor
SSP Solid State Polymerization
g/dL Gram per deciliters
lb/hr Pounds per hour
IV Intrinsic Viscosity
Cp Centipoise
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CHAPTER 1
INTRODUCTION
Novatex Limited is a leading name in polyester filament yarn, polyester chips, and
PET resin in Pakistan. The company is principally engaged in manufacturing and
sale of PET Resin and other types of Resin, PET Preforms and BOPET films. The
plant is equipped with advanced technology and state of the art facilities to ensure
optimum productivity with the required quality standards. The business exports its
goods to New Zealand, South and North America, South Asia, Europe, the Middle
East, North Africa, and East Africa. The power sector is another area where
Novatex is attempting to diversify by investing in Thal Nova Power Thar (Private)
Limited (TNPTL). The Ghani and Tayub group of businesses, which has been
around for more than 70 years and operates in a number of industries, including
textile, plastic resin, and power generating, includes Novatex.
1.1 PROJECT BACKGROUND:

Plastic is being used in our daily lives by different means and that is the reason
that the demand of plastic is steadily rising.. Total local demand of PET Resin is
reached approximately 100,000 MT per annum. So here Novatex is manufacturing
different types of resins and plastic films and also recycling the used ones. So, the
goal is to increase the production of these PET resins to meet the global demand.
1.2 PROBLEM STATEMENT:

The demand of PET resin is steadily rising as the world is moving forward. The
PET manufacturing plant in Novatex is producing 800 tons per day of PET resin
currently, and our focus is to design the PET production plant of 900 tons per day
to meet the market demand.
1.3 OBJECTIVE:
The objective of our project is to maximize the PET resin production by designing
the production plant having capacity of 900 tons per day and to study of
acetaldehyde formation during PET production.
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1.4 SCOPE:
According to a new report, the global market for Polyethylene Terephthalate (PET)
Resin was 80.9 million tons in 2021 and is anticipated to increase to 114.7 million
tons by the year 2028, with a CAGR (compound annual growth rate) of 5.2% over
the study period of 2022–2028. The wide range of characteristics displayed by
PET resins can be largely blamed for the growth of the polyethylene terephthalate
(PET) resin industry. These have no color and are quite light in weight. Because
they don't leak any chemicals, these plastics are noted for being reusable. They are
also the best material for producing food packaging products because they are safe
for humans. Consequently, the global PET resin market is anticipated to grow
significantly during the forecast period 2022-2028.
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CHAPTER 2
LITERATURE REVIEW
A polymer is a large molecule made up of repeating units, called monomers. These
monomers are chemically bonded together to form the polymer. Polymers can be
natural, such as cellulose in plants, or synthetic, such as plastic materials. They
have a wide range of properties and can be used for a variety of applications, such
as in plastics, rubber, fibers, and adhesives. Examples of natural polymers include
proteins, Carbohydrates, and Deoxyribose nucleic acids (DNA), synthetic
polymers are, for example, epoxies (EP).
Different synthetic plastics have different polymer chain structures that define
many of them physical properties. Polymers include thermoplastics, thermosets,
and elastomer.
Thermoplastics are a type of polymer that can be melted and reshaped multiple
times without any significant change in their properties. They are often used in
products that need to be repeatedly recycled, reshaped, or remolded. Examples of
thermoplastics include polyethylene, polypropylene, and polyvinyl chloride
(PVC).
Thermosets, on the other hand, are a type of polymer that cannot be melted or
reshaped after they have been initially molded. Once they have been set or cured,
they will retain their shape and cannot be remolded. They are often used in
products that require high strength and stability, such as in automotive and
aerospace applications. Examples of thermosets include epoxy, polyester, and
phenolic resins.
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2.1 POLYESTERS:
2.1.1 Introduction:
Polyester is a type of polymer that belongs to the family of thermoplastic polymers

known as polyester resins. It is a synthetic polymer made from the esterification
of dicarboxylic acid and dihydric alcohol. Polyester fibers and resins are versatile
materials that have a wide range of properties and applications.
One of the most well-known applications of polyester is in the production of

textiles, such as clothing and upholstery. Polyester fibers are strong, durable, and
resistant to shrinking, wrinkling, and fading. They are often blended with other
fibers, such as cotton, to create fabrics that have a combination of properties.
Polyester resins are also used in the production of various industrial and consumer
goods, such as automotive parts, electronic components, and food packaging. They
have good chemical resistance, high strength and good dimensional stability. They
are also used in the manufacturing of FRP (fiber reinforced plastic) products.
2.1.1 History:
The first synthetic fiber, nylon, was created as a result of research into big
molecules and synthetic fibers conducted by the American business E.I. du Pont
de Nemours and Co. in 1926. The polyester fiber known as Terylene was
developed by British research chemists at Calico Printers Association, Ltd.
between 1939 and 1941.
After further research and development, DuPont started marketing this polyester
fiber as Dacron in 1951 after acquiring the rights to produce it in the United States
in 1946. Since then, other businesses have created their own variations of polyester
fibers for various applications. PET (polyethylene terephthalate) and PCDT are
currently the two primary varieties of polyester (poly-1, 4-cyclohexylene-
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dimethylene terephthalate). PCDT is more elastic and resilient than PET, which is
more widely used and stronger. PET can be used alone or combined with other
fabrics to create apparel that is wrinkle- and stain-resistant and maintains its form,
whereas PCDT is used for heavier consumer goods like draperies and furniture
covers.
2.2 POLYETHYLENE TEREPHTHALATE (PET)

2.2.1 General:
PET, also known as polyethylene terephthalate, is a thermoplastic polyester resin

that comes in two viscosities: low and high. Low-viscosity PET, often known as
"staple" PET, has an intrinsic viscosity of less than 0.75 and is utilized in bottles,
photographic film, and textile applications. Tie cable, seat belts, and other items
employ high-viscosity PET, which is also known as "industrial" or "heavy denier"
PET and has an internal viscosity of 0.9 or higher. Winfield and Dixon in the UK
were responsible for the creation of polyethylene terephthalate fibers (Dacron,
Terylene). In 1953, the first Dacron polyester manufacturing facility opened.
Direct polycondensation and ester exchange are the two processes used to
manufacture PET. While direct polycondensation provides a more pure
terephthalic acid than ester interchange, it has recently replaced ester interchange
as the favored method for manufacturing PET.
2.2.2 Applications of PET:
• Polyester fibers, which make up the majority of the synthetic fiber market,
are produced using PET on a vast scale.
• PET is commonly used in food packaging, including beverage bottles and

frozen food trays that can be heated in a microwave or traditional oven. PET
is a pure and regulated material that complies with FDA food contact
guidelines.
• A wide range of goods and beverages, such as wine, salad dressing,

mouthwash, syrups, peanut butter, and pickled foods, are packaged in PET
bottles.
• PET is also used in molding resins, food packaging film, magnetic tape,
electrical insulation, and other photographic and photographic film products.
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PROPERTIES
Molecular Structure
Poly(oxy-1,2-ethanediyloxycarbonyl-1,4-
Other names phenylenecarbonyl)
Poly(oxyethylene oxyterephthaloyl)
Molecular Formula (C10H8O4)n
Polymer types Polyester
Density 1.3-1.4 g/cm3
Melting point 245-2580C (melt, 3000C)
Glass transition
730C (melt, 3000C)
temperature
At 1200 and 2000, crystallization from the glassy state
Morphology is possible. The structure may be mesomorphic and is
not a straightforward biphasic system.
FLAMMABILITY:
It is entirely flammable and leaves little residue.

compared to coal and other fossil fuels, burns
more cleanly.
CHEMICAL STABILITY: includes strong

resistance to organic alcohols, hydrocarbons, and
Stability oils and fats. Insufficient resistance to phenols,
ketones, esters, and chlorinated organic solvents.
HYDROLYTIC STABILITY: Decent resistance

to concentrated bases, but poor resilience to
diluted acids and alkalis.
RECYCLABILITY: De-polymerization enables

recycling.
Material class Thermoplastic
TABLE: 2.1 Properties of PET.
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CHAPTER 3
SELECTION OF TECHNOLOGY
3.1 AVAILABLE TECHNOLOGIES:

1) INVISTA
2) M&G
3) BUHLER
4) China Textile Industrial Engineering Institute (CTIEI)
5) Zimmer
Objective Developed for the production of bottle-grade

resin from a base polymer
IV
Advantages Reduced CAPEX, OPEX and space
requirements due to reduced number of vessels
2) Reduced AA concentrations.
3) Lower production cost: decreased pressure drop

required.
Disadvantages 3) Low reaction rates
Types of Catalyst Antimony Trioxide, Sb2O3

Waste Generation Small amount of Nitrogen and water No
contaminations found in the product.
Conversion Rate Approx. = 99 % - 99.5%
Unit Operations 1) Pre-crystallizer (Fluid-bed-type HX) Operating

& Temperature: 190 oC
2) Crystallizer (Horizontal Mechanical HX)
Parameters Operating
Temperature: 190- 220oC
TABLE 3.1: ZIMMER’S TECHNOLOGY DETAILS
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3.2 WHY CHOOSING ZIMMER TECHNOLOGY?
3.2.1 Zimmer technology:
For more than 60 years, Zimmer® has been collaborating with PET poly
condensation facilities. It constructs a variety of facilities, from small batch
operations for specialized products to single-line factories for commodities with
capacity of up to 2,000 tons of PET per day.
3.2.2 The pet production process:
It is a five-reactor technology having two staged esterification reactor, two staged

pre polymerization reactors and final reactor which is called Disc Ring Reactor
(DRR).
3.2.3 ADVANTAGES OVER OTHER TECHNOLOGIES:
• Low temperature requirements:
Among all other technologies the Zimmer technology is the one operating on low
temperature with high intrinsic viscosity. It has low maintenance as well as utility
cost.
• Production rate:
It provides the lowest fixed cost with highest production rate and also the
conversion rate is very high.
• Fewer byproducts:
It produces by products which are unwanted less than all the other technologies.
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3.2.4 ADVANTAGES OF THE DISC RING REACTOR COMPARED TO
OTHER FINISHER
DESIGNS:
• Higher viscosity lift
• Lower process temperature
• Lower thermal stress and product degradation
• Exceptional availability and reliability
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CHAPTER 4
PERT CHART
FIGURE 4.1: PERT CHART
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4.1 DESCRIPTION OF PERT CHART:
1. PROJECT OVERVIEW AND LITERATURE REVIEW:
Different articles and research papers related to PET manufacturing process are
studied in detail which helps us to gain an understanding of the existing research
and methods relevant to our topic. Literature review helped us in building our
knowledge and we learned about important concepts, research methods, and
experimental techniques that are used in this particular manufacturing process.
2. INFORMATION GATHERING:
Relevant information and data is gathered through the research papers, books and
plant visits. Questionnaires are made in order to collect the necessary information.
3. TECHNOLOGY SELECTION:
There are a lot of technologies through which PET can be manufactured. The goal
is to select the most feasible technology amongst all. In our project, Zimmer
technology (also called five reactors technology, two of them are esterification
reactor, other two are pre-polymerization reactor and the last one is Disk Ring
Reactor) is used for manufacturing of PET because this technology has low
maintenance as well as low utility cost, uses less equipment, high production with
low possible cost. Also, the equipment used are not complex and uses less steps to
give the product compared to other technologies.
4. MATERIAL AND ENERGY BALANCE:
The data we collected from our research and some are provided by Novatex is used
to perform Material and Energy balance.
5. SIMULATION:
The data collected from plant are used to form a model of our process, it enables
to identify the process visually with all the reactors and lines present in the process.
Aspen Plus is used to design mathematical model of a process which helps to
predict the performance of a process.
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6. BFDs and PFDs:
Block flow diagram is used to give an overview of the process, it involves basic
steps used in the process. It is designed by using data collected from plant and this
block flow diagram is then converted into process flow diagram, which includes
the details of the process and illustrates the relationships between major
components at an industrial plant.
7. P& IDs:
The P&ID which includes more detailing than a PFD. It shows all the equipment
together and has all minor details from valves to controller. It gives the detailed
idea about the plant that how the equipment are installed.
8. EQUIPMENT DESIGNING/SIZING:
Sizing and calculations for each equipment was done separately. RC volume 2 and
volume 5 are used for designing purposes whereas Korf Hydraulics is used for line
sizing.
9. HAZOP STUDY:
Once the Piping and Instrumentation diagram is designed, HAZOP studies carried
out by using this. In HAZOP study, every variation in the work parameters is taken
into account for each step of the process once it has been divided into parts to
identify potential issues.
10. STUDY OF ACETALDEHYDE PRODUCED:
In PET manufacturing process, Acetaldehyde (AA) is produced during

polymerization process in liquid phase. The root cause of AA generation is
analyzed, its effects on the finished product and how the production of AA can be
minimized are studied in detail.
11. ENVIRONMENTAL CONCERNS:
The impacts of PET manufacturing are studied that how it can affect our
environment. There may be some negative impacts on our environment, the goal
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is to study that how these negative impacts can be minimized using different
technologies.
12. COSTING:
Using the collected data from plant, costing of the plant is being done. It includes
the equipment cost, raw materials cost and labor cost which gives us the overall
plant cost.
13. REPORT FINALIZATION:
It is the last step which is used to ensure that the data collected is synced and well
defined in our report. Also, the steps of the process must be mentioned separately
in chapters which gives a brief description about each and every step of the
process.
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CHAPTER 5
PROCESS DESCRIPTION
5.1 RAW MATERIALS
The main raw materials used in the production process are PTA (purified
terephthalic acid) and EG (ethylene glycol), which can be used in both mono and
di forms depending on the desired outcome. PTA typically comes in powder form
and is mainly sourced from LOTTE chemical Pakistan and other foreign
industries, while EG is produced in-house. Additionally, isophthalic acid (IPA)
may also be used in small amounts (up to 2%) to lower the melting point and slow
down the rate of crystallization, similar to the effects of using ethylene glycol.
CATALYSTS AND ADDITIVES:
The catalyst and additives that are used in the process are as follows:
BLUE TONER: It provides bluish tone to the chips (away from yellowish tone)
and also upholds the color of product.
RED TONER: It is PET Resin Toner (PRT) delivers reddish tone to the chips
(away from greenish tone).
PHOSPHORIC ACID (H3PO4): It is used as a heat stabilizer and added to stop

the chain exothermic reaction resulting in the formation of a stabilized compound.
ANTINOMY TRIACETATE: It is used as a catalyst to lesser the amount of

energy essential to start the reaction and reaction proceeds fast towards
completion.
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5.2 PASTE PREPARATION TANK:
The initial step in the production of PET is the preparation of paste. TPA and MEG
are the primary raw materials used in this step. TPA, which is in powder form, is
weighed and transferred to a paste preparation tank. The PTA treating unit includes
a rotary feeder, a vibration sieve, and a mass flow meter. The PTA powder is
treated by the feeder, and any foreign matter is separated out by a strainer. The
mass flow meter continuously weighs the PTA powder. MEG is added through a
pump, and other additives such as phosphoric acid (as a heat stabilizer), blue toner,
red toner, and the chosen catalyst, antimony triacetate, are also added to the tank.
Mixing is done continuously to form a homogenized slurry suspension with the
help of a propel-type impeller. The temperature inside the tank is maintained at
60°C. The pumps used are screw type, with two operating at the same time. The
slurry is then fed to the first esterification reactor. A flush valve is fitted on the
pipeline to flush it with EG liquid to prevent blockage. A sampling valve is also
fixed on the pipeline
5.3 ESTERIFICATION REACTORS:
REACTION:
PTA + MEG (in excess) ➔ Bis β-Hydroxy Terephthalate + 2H2O
The manufacturing process moves on to the unit process stage, which involves the
use of two CSTR-type reactors arranged in a series. The slurry enters the
esterification reactor which requires continuous mixing and a suitable temperature
to prevent the mixture from solidifying and blocking the reactor. The process
involves a high temperature to efficiently dissolve the free PTA in EG and esterify
it to create BHET and oligomers, and water is also produced as a byproduct. Both
reactors are heated by liquid HTM (Therminol 66) which is pumped into the coils
inside the reactor. An HTM evaporator is also used to generate vapor to heat the
body jacket and jacket pipe attached to the two reactors (ester-1 & ester-2). The
temperature of the material is a critical parameter for controlling the esterification
degree. The operating pressure of both reactors ranges between 1.5 to 1.95 bars.
The conversion rate for this step is 98%. A high conversion process requires a
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large reactor volume for optimal conversion, however, the combined volume of
the two reactors in series is smaller than the volume of one reactor to achieve the
same conversion. Therefore, two reactors are allocated for the esterification
process, with the first reactor having a lower conversion rate than the second.
5.4 DISTILLATION COLUMN:
The next step in the process is to use a column to separate the mixed vapor of water
and EG coming from the two esterification reactors and the condensate coming
from two scrapper condensers connected with PP1 and PP2. Feed is added to the
column's first plate, where it is condensed and the top of the column's water and
aldehydes are eliminated. There are 18 plates in the column. Around 180°C is kept
as the temperature at the bottom of the column. The two reactors receive the
relatively heavy portion of the EG, and the rest portion is transferred to a spent EG
collection tank. Less than 0.5 weight percent of the column's water is made up of
EG, and less than 1.5 weight percent of the column's water is made up of EG.
5.5 PREPOLYMERIZATION REACTOR I:

The substance is then moved to Pre-polymerization reactor 1 (PP1), a PFR (Plug
Flow Reactor) type reactor that operates at high temperature and low pressure. It
is made up of a hollow tank with two zones that are divided by a wall between the
columns. After going over the top of the second zone's wall, material enters the
second zone. This wall gives the residents enough time to prepare their responses.
While a vacuum is being formed to remove the water and EG from the reactor for
high conversion, the temperature is kept at around 277 C. Scrapper condenser and
liquid ring vacuum pump work together to create vacuum. Trans-esterification
begins at PP-1 and goes on from there (building up of IV). About 0.13g/dl of
intrinsic viscosity is achieved in the material. More EG and water are produced in
this reactor due to the esterification and trans-esterification reactions taking on
there, which causes bubbles to escape at low pressure and high temperature and
be delivered to the immersion vessel.
5.6 PRE-POLYMERIZATION REACTOR II:

After that, the material is brought to PFR or mixed type reactor PP2, which is a
horizontal tank with a number of disc rings attached to a single shaft and powered
25
by a single motor to aid in agitation. The disc has several holes that allow stuff to
pass through. Material enters under pressure differential from PP-1 to PP-2.
Short chains of PET, remaining oligomers and traces of EG enter the

polymerization reactor to be reacted to form long chains of PET polymers
according to the desired intrinsic viscosity. Phase in this reactor is also molten
phase, yet, the molten has a higher intrinsic viscosity than the pre polymerization
reactor I. The scrapper condenser and liquid ring vacuum pump work together to
maintain the system's vacuum while keeping the temperature about 282 C. Up to
0.30, the intrinsic viscosity increases. The material is then sent into the filter,
where contaminants and dust are removed to guarantee the material's purity
5.7 DISK RING REACTOR (DRR):

The only difference between a PFR or mixed type reactor like the DRR and a PP2
is that the DRR's single shaft is driven by two motors for agitation. As the shaft
rotates, the viscous material is stretched, surface to area volume increases, and
more EG bubbles are released from the molten polymer, increasing the intrinsic
viscosity to 0.60.
Due to the viscous nature of the substance and the need to keep the reactor's
temperature at 300°C, Heat Transfer Medium (HTM) vapors are present in the
jacket to melt the polymer that adheres to the wall. The scrapper condenser and
vapors jet ejector work together to keep the system under vacuum pressure.
5.8 SCRAPPER CONDENSOR:

Vapors of E.G. and water are introduced into the scrapper condenser through
connections between PP1, PP2, and DRR. In a container called a scrapper
condenser, which is shaped like a tomb, liquid EG is sprayed from the top of a
column that has umbrella-style perforated baffles that enable a larger contact area
to condense the vapors. However, some of the EG vapors is left uncondensed and
is condensed in a different condenser and collected in a different vessel.
26
5.9 FILTER
The DRR material is introduced into a filter, where more contaminants are
eliminated. This particular filter is a candle-type filter. The filter is 40 microns in
size and has 74 candles. Due to the DRR material's high viscosity and smaller
micron size, the filter can be readily clogged, and it is then sent to the filter
cleaning area.
5.10 CUTTER
The filter material is then split into two parts. One passes through the die head to
three cutters, and the other passes to another three cutters. 19 sensors in the die
head alarm when any hazardous or unhealthy conditions exist; in this case, the
product from the cutter is discarded as garbage. There are three types of water
used:
1) CONVEYING WATER: It is used in the cutter to prevent from high temperature.
2) OVER FLOW WATER: It is used to convey the laces or spaghetti.
3) SPRAY WATER: It is used to maintain the temperature during conveying.
5.11 DRYER
After being sliced, the chips are fed into the dryer, where air is drawn in with the
aid of a blower to remove the water content from them.
5.12 VIBRO SCREENING

In this portion, oversize and undersized chips are sorted, and the remaining ones
are subsequently delivered to the amorphous silos with the assistance of conveying
air. The different sizes of chips can be sorted using vibrating screens.
27
CHAPTER 6
MATERIAL AND ENERGY BALANCE
Note: The data using in calculations are provided by NOVTEX PVT LTD.
6.1 Paste composition:

For 900 tons per day:
900 tons 1day 1000 kg
Day 24 hr 1 ton
= 37500 kg/hr.
6.2 Ratio of raw materials:

• Ethylene Glycol:
For 333 kg per ton

333 kg 900 tons 1 day = 12487.5 kg/hr
1 day 24 Hr
• Di-ethylene Glycol:
For 4 kg per ton

4 kg 900 tons 1 day = 150 kg/hr
1 day 24 hr
• Catalyst (Antimony Triacetate):
0.160 kg 900 tons 1 day = 22.87 kg/hr

1 day 24 hr
• Blue tonner (Pigment):
0.00075 kg 900 tons 1 day = 0.02 kg/hr

1 Day 24 hr
• Red tonner (Cobalt Acetate):
0.066 kg 900 tons 1 day = 2.36 kg/hr

1 Day 24 hr
28
• Iso-phthalic Acid:
18.8 kg 900 tons 1 day = 705 kg/hr

1 Day 24 hr
• Phosphoric Acid:
0.075 kg 900 tons 1 day =2.81 kg/hr

1 Day 24 Hr
6.3 MOLAR FLOWRATES

Terephthalic Acid:
32204÷166 = 194 kmol/hr
Ethylene Glycol:
12487.5÷62 = 201.45 kmol/hr
Iso-phthalic Acid:
705÷60 = 11.75 kmol/hr
Diethylene Glycol:
150÷106 = 1.41 kmol/hr
Catalyst:
22.87÷298 = 0.0767 kmol/hr
Red tonner:
2.36÷177.02 = 0.0133 kmol/hr
Phosphoric Acid:
2.81÷97 = 0.028 kmol/hr
For water:
o TPA contains 0.002 fraction of water
o EG contains 0.0005 fraction of water
So that,
29
(194×0.002) + (201.41×0.0005) + (3.88) + (1.007) = 4.89 kmol/hr
6.4 ESTERIFICATION-1
o (92% of conversion)
TPA + MEG BHET + 2H2O
Basis: 189.75 kmol/hr of TPA

• Molar flowrate of unreacted TPA:
(194)(1-0.92) = 15.52 kmol/hr
• Molar flowrates of unreacted EG:
(201.41)(1-0.92) = 16.11 kmol/hr
• Molar flowrate of BHET:
(194)(0.92)(1) = 178.48 kmol/hr
• Molar flowrate of water:
(194×0.92×2)+(4.84) = 361.75 kmol/hr
6.5 Esterification-2
• Molar flowrate of unreacted TPA:
(15.52)(1-0.92) = 1.24 kmol/hr
• Molar flowrate of unreacted EG:
(16.11)(1-0.92) = 1.28 kmol/hr
• Molar flowrate of BHET:
(15.52×0.97×2) + (178.47) = 193.53 kmol/hr
• Molar flowrate of water:
(15.52×0.97×2) = 30.10 kmol/hr
6.6 PREPOLYMERIZATION-1
o (97.5% of conversion)
o The degree of polymerization: n= 40
30
• Molar flowrate of PET:
(193.53×0.975×1/40) = 4.71 kmol/hr
• Molar flowrate of EG:
(193.53×0.975)(40-1÷40) = 183.97 kmol/hr
• Molar flowrate of unreacted BHET:
(193.53)(1-0.975) = 4.83 kmol/hr
6.7 PREPOLYMERIZATION-2
o The degree of polymerization: n= 150
Molar flowrate of PET:

(4.83) (0.99) (1/150) + (4.83) = 4.86 kmol/hr
Molar flowrate of EG:
(4.83) (0.99) (150-1/150) + (5.74) = 10.41 kmol/hr
Molar flowrate of unreacted BHET:
(4.83)(1-0.99) = 0.0483 kmol/hr
6.8 DISK RING REACTOR

o Degree of polymerization: n= 180
Molar flowrate of PET:

(0.0483)(0.99)(1/180) = 0.000265 kmol/hr
31
RAW MATERIAL FLOW RATE(Kg/hr) MOLAR FLOW RATE
(Kmol/hr)
PURIFIED 32204 32204÷166 = 194

TEREPHTHALIC ACID
ETHYLENE GLYCOL For 333 kg/ton 12487.5÷62 = 201.45

(333×900) ÷24 = 12487.5
DI-ETHYLENE GLYCOL For 4 kg/ton 150÷106 = 1.41
(4×900) ÷24 = 150
ANTIMONY For 0.61 kg/ton 22.87÷298 = 0.0767

TRIACETATE
0.610×900) ÷24 = 22.87
BLUE TONNER For 0.00075 kg/ton. -

(0.00075×900) ÷24 = 0.02
RED TONNER For 0.066 kg/ton 2.36÷177.02 = 0.0133

(COBALT ACETATE) (0.066×900) ÷24 = 2.36
ISO-PHTHALIC ACID For 18.8kg/ton 705÷60 = 11.75

(18.8×900) ÷24 = 705
PHOSPHORIC ACID For 0.075 kg/ton 2.81÷97 = 0.028

(0.075×900) ÷24 = 2.8
TABLE 6.1: RAW MATERIAL QAUANTITY
32
ESTERIFICATION I:
COMPONENT INLET (kg/hr) OUTLET(Kg/hr)
PTA 33204 2576.32
MEG 12487.42 998.82
WATER 88.02 6511.5
BHET - 45376.75
PET - -
TABLE 6.2: ESRER-1 MATERIAL BALANCE
ESTERIFICATION 2:
COMPONENT INLET(Kg/hr) OUTLET(Kg/hr)
PTA 2576.32 205.84
MEG 998.82 79.36
WATER - 541.8
BHET 45376.75 49203.06
TABLE 6.3: ESTER-2 MATERIAL BALANCE
PREPOLY I:
PREPOLY II:
TABLE 6.4: PP-1 MATERIAL BALANCE
33
PREPOLY II:
TABLE 6.5: PP-2 MATERIAL BALANCE
DISK RING REACTOR:
COMPONENT INLET(Kg/hr) OUTLET(Kg/hr)
BHET 12.27 0.067
PET 37394.48 37505.08
TABLE 6.6: DRR MATERIAL BALANCE
34
6.8 ENERGY BALANCE
ESTER -1
Heat duty = (mass flow rate) * (heat capacity) * (temperature difference)
Mass flow rate = 1.10E+03 lb/hr

Heat capacity = 48 btu/lb F
Inlet temperature = 140 F
Outlet temperature = 464 F
Heat duty = 17143125.12 Btu/hr
Enthalpy balance:
Enthalpy in = -2.79E+08 Btu/hr

Enthalpy out = -2.85E+08 Btu/hr
ESTER-2

Heat capacity = 50 btu/lb F
Inlet temperature = 464 F
Heat duty = 4563576. Btu/hr
Enthalpy balance:

35
DISTILLATION COULMN (TOP)

Heat capacity = 10.3 btu/lb F
Inlet temperature = 334.51 F
Outlet temperature = 386.51 F
Heat duty = 5.21×105 Btu/hr
Enthalpy balance:
DISTILLATION COULMN (BOTTOM)

Heat capacity = 10.3 btu/lb F
Inlet temperature = 334.51 F
Heat duty = 2.05×105 Btu/hr
Enthalpy balance:
36
CHAPTER 7
BLOCK FLOW DIAGRAM OF PET
37
CHAPTER 8
PROCESS FLOW DIAGRAM OF PET
FIGURE 8.1: PASTE PREPARATION TANK
The raw materials from storage silos are sent to the pate vessel though pumps and
conveyors which are purified terephthalic acid (PTA), mono-ethylene glycol
(MEG), isophthalic acid (IPA), blue and red tonner and catalyst. The Coriolis force
is the force that acts upon a particle accelerating radially outward in a rotating
system. This force acts perpendicular to the direction of motion of the particle and
is directly proportional to acceleration. Mass flow rate is independent of process
variables including bulk density, friction coefficient, and moisture content of the
particles. In the paste vessel, no reaction is taking place this phase is only for the
mixing of raw material. Once the paste is formed, this paste is then sent to the
esterification reactor where the reaction occurs.
38
FIGURE 8.2: ESTERIFICATIONS REACTORS.
The paste coming from the paste vessel into the esterification reactor. There are
two esterification reactors in which the reaction between PTA and MEG takes
place. The two reactors are operating at the temperatures of 255-2700C and 270-
2800C respectively. The required temperature is achieved by the circulation of
HTM through the jackets of the reactors. The two reactors have and operating
pressure of 1.5-2 bars. Each of them is given a suitable residence time to achieve
the maximum conversion which is about 92%. The product formed from these two
reactors is BHET (bis hydoxy ethyl terephthalate). During the esterification
reaction some amounts of EG are left unreacted and form vapors, these vapors are
then sent to the distillation column where it separates the water and EG vapors,
condensed EG is treated and then sent to the paste vessel again.
39
FIGURE 8.3: PRE-POLYMERIZER -1 AND PRE-POLYMERIZER-2
The BHET formed in the esterification-2 reactor is sent to the pre

polycondensation reactors where they polymerize to form PET. The temperature
of the two reactors is maintained at 2770C and 2800C respectively. Vacuum is
created by using liquid ring vacuum pump with a pressure of 100-120 mbar and
15-17 mbar respectively. Both reactors are given proper residence time to achieve
maximum conversion, this residence time helps to lift the intrinsic viscosity from
0.13 to 0.3 dl/g.
40
FIGURE 8.4: DISC RING REACTOR AND CUTTER
The material from pre-polycondensation 2 is then sent to the DRR, which has
single shaft driven by double motors. HTM is circulated in the jackets of DRR to
prevent the material from sticking to the walls with a temperature of 2830C. this
helps in building the IV to 0.6 dl/g. this material then sent to the candle type filter
of 40 microns to remove any impurities, then cutter which is surrounded by water
lines to prevent high temperature, then sent to the dryer and finally to the vibro
screening to separate different sized chips.
41
CHAPTER 9
PIPING & INSTRUMENTATION DIAGRAM
P&IDs are schematic representations of the functional connections between pipe,

instrumentation, and system equipment used in the automation or instrumentation
fields. Typically, engineers who are creating a manufacturing process for a
physical plant design them.
Field technicians, engineers, and operators use P&IDs to comprehend the process
and how the instrumentation is connected better. They can be helpful in educating
employees and contractors.
FIGURE 9.2: ESTER-1 AND ESTER-2(P&ID)
FIGURE 9.2: DISTILLATION COLUMN (P&ID)
42
CHAPTER 10
HAZOP STUDY
HAZOP is a methodical qualitative approach to studying process variations in
order to discover process dangers and prospective operating issues. A HAZOP is
used to examine every step of a process to identify potential deviations from the
design's objective as well as their potential causes and effects. This is
accomplished methodically by using appropriate cue words. This is a methodical,
in-depth review strategy for batch and continuous plants that can be used to find
dangers in both new and old processes.
A Hazard and Operability Study, often known as HAZOP, is a methodical

methodology to find potential dangers in a work process. This method divides the
procedure into parts and examines each step's potential pitfalls by taking into
account any variations in the work parameters. To have an impact on the design,
the HAZOP research should ideally be conducted as early as possible in the design
phase.
Typically, after the detailed design is finished, the HAZOP is conducted as a last
check.
• PARAMETERS:
An element in a set, usually a number or other quantifiable quantity that

characterizes a system or establishes the parameters under which it operates.
• GUIDEWORDS:
A succinct phrase used to conjure up variations on the design or process' original

aim. NO, MORE, LESS, AS WELL AS, PART OF, OTHER THAN, and
REVERSE are the most often used guidewords.
• DEVIATIONS:
A deviation is a way in which the process conditions may depart from their
design/process intent.
43
• POSSIBLE CAUSES:
The potential causes of the discrepancy. It is possible to find multiple explanations

for a single deviation.
• CONSEQUENCES:
If the deviation occurs, the outcomes that follow. Process dangers and operability
issues, such as plant shutdown or decreased product quality, can both be
consequences.
• ACTION REQUIRED:
Action to be taken to eliminate the consequence.
HAZOP GUIDE WORDS:
44
10.1 SLURRY PREPARATION TANK (11-TA01):
PARAMETER GUIDED DEVIATION POSSIBLE CONSEQUENCES ACTION
WORD CAUSE REQUIRED
FLOW NO No flow Malfunctionin Agitator will be Low level alarm

g of rotary of broken as no must be installed.
PTA silo. product will be
there in tank.
Flow controller
Malfunctionin must be installed
g of flow on MEG line and
transmitter of must interlock it
MEG. with LAL.
MORE High flow Malfunctionin Inadequate mixing Level alarm high

g of rotary of of raw materials. LAH must be
PTA silo. installed in order
to maintain level
Malfunctionin Load on agitator of tank.
g of flow will be increased
transmitter of and it can trip Interlocking of
MEG. motor of agitator.
LAH with motor
of rotary and
flow controller
of MEG
TEMPERA MORE High Temp. High agitator Decrease in Agitator speed

TURE speed. viscosity of slurry must be
from desire range. maintained.
Surrounding
Temperature
(Hot weather). Cooling jacket
must be installed
in slurry tank
cooling purpose.
45
FIGURE 10.3: PASTE PREPARATION TANK TA-1101
46
10.2 ESTER-1 (12-R01):
WORD CAUSE REQUIRED
PRESSURE MORE High High If EG vapors goes Pressure gauge

pressure quantity of to further reactors must be
water and instead of installed.
EG vapors in distillation column it
reactor. will cause formation
of acetaldehyde. PSV must be
installed on
reactor to
release excess
pressure.
NO No pressure No vapors of The conversion will Pressure gauge
EG and decrease as pressure must be
water is maintained at installed.
certain level for
reaction.
Acid
value/Unreacted
TPA quantity will
increase
causing clogging in
lines
FLOW MORE High flow at Increase rpm Load on agitator Level alarm
inlet. of pump. will be increase. high should be
install and
interlock it
Conversion rate with Pump
High level of
will decrease. (trip pump as
slurry tank.
level reaches
high.
LESS Low flow Malfunctioning Residence time Routine

from outlet. of control valve will be increased maintenance
at outlet. causing loss in of control
production. valve.
47
TEMPERAT LESS Low Leakage in No reaction. Proper
URE temperature e lines of insulation of
of reactor HTM. HTM lines.
Conversion rate
will decrease
MORE High High Degradation of Temperature

temperature temperature of monomers. controller
HTM. must be
installed in
Loss of
order to
oligomers with
maintain
vapors
temperature of
reactor.
48
10.3 DISTILLATION COLUMN:
PARAMETER GUIDED POSSIBLE CONSEQUENCES ACTION
WORD DEVIATION CAUSE REQUIRED
FLOW NO NO FLOW Pipe blockage Column dry out. Installation
No operation of Flow
indicator on
No vapors vapors line.
generation in
Proper line
Ester-1
maintenance
.
LESS Less flow Clogging in Change in Installation
vapors line. concentration of Flow
of distillate and indicator on
Low vapors vapors line.
condensate.
generation in
Ester reactors. Proper line
maintenance
MORE High flow Malfunctionin Flooding in column Installation of

g of valve High-level
alarm
Temperature
decrease
TEMPERATU High Low flow Inadequate Installation of

RE MOR temperature at inlet. separation. temperature
E controller.
High EG concentration
temperature of will be higher at
vapors stream top.
from Ester
reactors.
LESS Low High flow Inadequate Installation of
temperature. from separation. temperature
inlet. controller.
Water
concentration will
be higher at
bottom.
PRESSURE HIGH High pressure Vapor Inadequate Installation of
pressure separation. Pressure
increases due gauge.
to high
amount of Entrainment in
vapors distillation column.
generated.
49
LESS Low pressure Malfunctionin Reactor Rupture. Proper
maintenance of
-g of pressure
Pressure
controller controller.
FIURE 10.3: DISTILLATION COLUMN C-101
50
10.4 PRE-POLYMER REACTOR 1 (14-R01)
WORD CAUSE REQUIRED
PRESSURE MORE High No emission of Vacuum of PP-1 EG vapors

pressure EG vapors will break causing must be
decrease in IV taken off
continuously
Ejector system PSV
is not working installation
properly on top of
reactor.
Pressure
controller on
vapors line
of EG
LESS Low pressure Malfunctioning Reactor Rupture. Proper
maintenance
of pressure
of Pressure
controller controller.
FIGURE 10.3: PRE-POLYMERIZER I (14-R01)
51
10.5 PRE-POLY FILTERS (16-F01):
PARAMETER GUIDED DEVIATION POSSIBLE ACTION

WORD CAUSE CONSEQUENCES REQUIRED
PRESSUR MORE High Filter medium Pressure at the Increase SET

pressure
E choked. discharge of the Value of the
filter increased. circulating
HTM.
Filters are not Pre-Polymer Pump
perfectly RPM abruptly
heated. increase. Pre- Change-over
Polymer Pump
to stand-by
tripped.
filter.
NO No pressure Pressure gauge Damage the Install PSV

failure. discharge line of inlet line of the
the Pre Polymer Pre- Polymer
pump. filter.
Pre-Polymer
Pump tripped.
DRR temperature Install pressure
increased. indicator at the
Control Valve discharge of
malfunctioned. Level of Pre- the filter.
Polymer reactor
increased.
FLOW MORE High flow at Due to high Nominal choking Schedule

inlet. level of Pre cause high maintenance in
pressure order to avoid
Poly 2
difference. massive
reactor. choking of pre
polymer filters.
Control
valve at
discharge of
PrePoly filter
not work
efficiently.
52
10.6 SCRAPPER CONDENSER (15-E01):

WORD CAUSE REQUIRED
PRESSURE MORE High EG vapors Observed high Break vacuum
Temperature formed due peak of of the
to very temperature in condenser up to
fine scrapper the desired
vacuum and condenser. value.
axial
agitation in
pre-poly
reactors.
Un-efficient Flashing of
heat EG showering
transfer in lines.
cooler.
LESS Low Inefficient Do not achieve Decrease the

Temperature supply of desired IV level of EG to
HTM to (Intrinsic the condenser.
the Viscosity)
consumer. required for
particular pre-
poly reactor.
Make a fine
vacuum in pre-
poly reactors.
Efficiently and
effectively
manage
HTM
circulation.
53
CHAPTER 11
LINE SIZING
11.1 MIXER TO ESTER-1:

DATA:
QUANTITY UNIT
Liquid Flow rate
10671.54 BPD
Temperature
600.5 R
Inlet pressure
97.5 psi
specific gravity
1.27
Viscosity
30 cp
Length of the Pipe
100 ft
Dia of the pipe
6 inch
CHARTS USED:
54
FORMULAE USED:
REYNOLD NUMBER: R =
PRESSURE DROP:
Liquid velocity:
CALCULATIONS:
R = 6935.54
PRESSURE DROP = 0.98 psi/100ft
LIQUID VELOCITY =3.55 ft/s
11.2 ESTER-1 TO ESTER -2:

DATA:
QUANTIT UNI
Y T
Liquid Flow rate= 10496.1 BPD
Temperature= 959 R
Inlet pressure= 14.7 Psi
specific gravity= 1.14
viscosity= 30 Cp
Dia of the pipe= 6 Inch
55
FORMULAE USED:
REYNOLD NUMBER: R = 92.1 S.G QL
VISCOSIT * DIA
PRESSURE DROP: 11.5e−d55 L Ql2
Liquid velocity: 0.012 L Ql2 ft/sec
CALCULATIONS:
R = 6122.3
LIQUID VELOCITY = 3.49 ft/s
11.3 ESTER-2 TO PP-1:

DATA:
QUANTITY UNIT
Temperature= 986.17 R
Inlet pressure= 21.75 psi
viscosity= 40 cp
Length of the Pipe= 100 ft
Dia of the pipe= 6 inch
56
FORMULAE USED:
REYNOLD NUMBER: R =
PRESSURE DROP:
Liquid velocity:
CALCULATIONS:
R = 4343.06
11.4 PP-1 TO PP-2:

DATA:
QUANTITY UNIT
Temperature= 995.5 R
Inlet pressure= 21.7 psi
viscosity= 40 cp
57
Length of the Pipe= 100 ft
Dia of the pipe= 7 inch
FORMULAE USED:
REYNOLD NUMBER: R =
PRESSURE DROP:
Liquid velocity:
CALCULATIONS:
R = 2637
58
11.5 PP-2 TO DRR:
DATA:
QUANTITY UNIT
Temperature= 1022 R
Inlet pressure= 21.75 Psi
viscosity= 50 Cp
Length of the Pipe= 100 Ft
Dia of the pipe= 7 Inch
FORMULAE USED:
REYNOLD NUMBER: R =
PRESSURE DROP:
Liquid velocity:
CALCULATIONS:
R = 3246
LIQUID VELOCITY = 2.47 ft/sec
59
CHAPTER 12
EQUIPEMENT DESIGN
12.1 ESTERIFICATION –I:
Reactor Specification Sheet
Project Title: PRODUCTION OF PET
Item # R-1201
Description Reactor
Column:
DIAMETER (m) 3.4
CROSS SECTIONAL AREA

0.6
(m2)
L/D RATIO ASUMMED 5
LENGTH (m) 17
HEIGHT (m) 9.6
VOLUME (m3) 132
RESIDENCE TIME (h-1) 3.8
60
12.2ESTERIFICATION –II:

R-1301
Item #
Reactor
Description
Column:
DIAMETER (m) 3.4
CROSS SECTIONAL AREA (m2) 20.1
L/D RATIO ASUMMED 5
LENGTH (m) 14.2
HEIGHT (m) 9.3
VOLUME (m3) 101.89
12.3 PRE POLYMERIZER I:

Item # R-1401
Description Reactor
Column:
DIAMETER (m) 4.815
L/D RATIO ASUMMED 4
LENGTH (m) 19.56
HEIGHT (m) 10
VOLUME (m3) 132.35

61
12.4PRE POLYMERIZER II:

Item # R-1501
Description Reactor
Column:
DIAMETER (m) 4.35
L/D RATIO ASUMMED 2
LENGTH (m) 8.7
HEIGHT (m) 2.175
VOLUME (m3) 172.30
12.5 DISC RING REACTOR:

Item # R-1601
Description Reactor
Column:
DIAMETER (m) 4.50
CROSS SECTIONAL AREA (m2) 50
L/D RATIO ASUMMED 2
LENGTH (m) 9
HEIGHT (m) 2.25
VOLUME (m3) 190.75
RESIDENCE TIME (h-1) 5
62
12.6SLURRY PUMP:
PUMP SPECIFICATION SHEET

Item # P-101
Description Pump
FLUID FLOW AND PROPERTY SPECS.
FLOW (M3/hr) 28
TEMPERATURE (°C) 60
DENSITY (kg/m3) 1272.55
VISCOSITY (cP) 30
VAPOR PRESSURE (Bara) 1.00
SUCTION SIDE
SUCTION VESSEL PRESSURE (BarA) 1.5

MIN LIQUID LEVEL ABOVE PUMP
CENTER LINE 10
(mt)
LINE LENGTH (mt) 10
SUCTION LINE (ID) (in) 10
LINE LOSS (Bar) 0.000
OTHER LOSS (Inst, str, equip etc) 0.0

MINIMUM SUCTION PRESSURE
2.75
(BarA)
NPSHA (mt) 14.0
85%NPSH / NPSHA -1 (mt) 11.9
NPSHA (mt) 11.9
DISCHARGE SIDE
TERMINAL PRESSURE (BarA) 28.5
63
MAX STATIC HT ABOVE PUMP CENTER
10
LINE (mt)
PUMP CALCULATION
CALCULATED DIFFERENCE PRESSURE

25.7
(Bar)
CALCULATED DIFFERENCE HEAD (m) 206
CALCUATED HYDRAULIC POWER (kW) 24.3
LINE LENGTH (mt) 10
DIS LINE (ID) (in) 8
DIS PRESS REQD. (BarA) 28.5
64
12.5 DISTILLATION COLUMN C-101:
Distillation Column Specification Sheet
Project Title:
Date:
PRODUCTION OF PET
Item # C-101
Description Distillation Column SKETCH
Column:
Internal Diameter (ft) 5.206
Wall Thickness (in) .375
Tray Thickness (mm) 10
Column height (m) 13.4
Tray Type Sieve
No Of Trays 22
Tray Passes Single
No of Holes (Active) 16560

13.4 m
Feed Tray 3
Material Of
CS
Construction
Fluid:
Phase(V.L.V/L) V/L
Feed Temperature (K) 553
Overhead Temperature
383
(K) 5.23 m
Bottom Temperature
438
(K)
65
CHAPTER 13
MATERIAL OF CONSTRUCTION
The following qualities should be taken into account when choosing a construction
material:
1. Mechanical properties
a) Strength-tensile strength
b) Stiffness-elastic modulus (Young's modulus)
c) Toughness-fracture resistance
d) Hardness-wear resistance
e) Fatigue resistance
f) Creep resistance
2. The effect of high and low temperatures on the mechanical properties
3. Corrosion resistance
4. Any special properties required; such as, thermal conductivity, electrical resistance,
magnetic properties
5. Ease of fabrication-forming, welding, casting (see Table 10.1)
6. Availability in standard sizes-plates, sections, tubes
7. Cost
66
13.1 MECHANICAL PROPERTIES:
Table 12.1 Mechanical strength properties of metals and alloys (at room
temperature)
EFFECT OF TEMPERATURE ON THE MECHANICAL PROPERTIES:
Metals' tensile strength and elastic modulus decrease as temperature rises. For
instance, the Young's modulus of mild steel (low carbon steel, C 0.25%) is 200,000
N/mm2 at 25°C and decreases to 150,000
N/mm2 at 500°C. The tensile strength of mild steel is 450 N/mm2 at 25°C and
decreases to 210 at 500°C. If the material is exposed to severe strains at high
temperatures, creep resistance will be critical.
CORROSION RESISTANCE:
There are numerous ways in which corrosion-causing circumstances might develop.
It is convenient to divide corrosion into the following categories for this quick
discussion on the selection of materials:
• General wastage of material-uniform corrosion.

• Galvanic corrosion-dissimilar metals in contact.
• Fitting-localized attack.
• Inter-granular corrosion.
• Stress corrosion.
67
• Erosion-corrosion.
• Corrosion fatigue.
• High temperature oxidation.
• Hydrogen embrittlement.
Selection for corrosion resistance:
• The process environment to which the material will be subjected must be

thoroughly understood in order to choose the appropriate construction material. In
addition to the primary corrosive compounds present, the following things need to be
taken into account:
• Mechanical characteristics and corrosion rate are influenced by temperature.

• Pressure.
• pH.
• Presence of trace impurities-stress corrosion.
• The amount of aeration-differential oxidation cells.
• Stream velocity and agitation-erosion-corrosion.
• Heat-transfer rates-differential temperatures.
13.2 COMMONLY USED MATERIALS OF CONSTRUCTION:
1. Iron And Steel:
The most popular type of steel used in engineering is low carbon steel, or mild steel. It
is affordable, accessible in a variety of conventional shapes and sizes, and is simple to
work with and weld. It is ductile and has strong tensile strength. Except in certain
situations like strong sulfuric acid and caustic alkalis, carbon steels and iron are not
corrosion resistant. With the exception of chlorinated solvents, they can be used with
most organic solvents, however they may discolor if corrosion products are present.
2. Stainless Steel
The corrosion-resistant materials most frequently utilised in the chemical sector are
stainless steels. Chromium concentration must be over 12% in order to confer
68
corrosion resistance, and the more chromium an alloy has, the more resistant it is to
corrosion under oxidising circumstances. To increase corrosion resistance in non-
oxidizing conditions, nickel is used.
TYPES OF STAINLESS STEEL:
There is a large selection of stainless steels available, each with a composition

designed to provide the exact qualities needed for a certain application. According to
their microstructure, they can be grouped into three major classes:
1. Ferritic: 13-20 per cent Cr, < 0.1 per cent C, with no nickel
2. Austenitic: 18-20 per cent Cr, > 7 per cent Ni
3. Martensitic: 12-10 per cent Cr, 0.2 to 0.4 per cent C, up to 2 per cent Ni.
Table 12.2. Commonly used grades of austenitic stainless steel
69
3. Nickel:
Nickel is workable and has good mechanical characteristics. The majority of

applications prefer its alloys over the pure metal (>99 percent), which is not typically
employed in chemical plants. The major application is for machinery handling caustic
alkalis at temperatures more than 70 °C, the maximum temperature at which carbon
steel can be employed. Nickel doesn't break due to corrosion.
4. Copper And Copper Alloys
Chemical equipment seldom ever uses pure copper. It has a long history of use in the
food business, especially in brewing. Small-bore pipes and tubes are frequently made
of copper because it is a comparatively soft metal that can be worked quite easily.
Brasses, which are alloyed with zinc, and bronzes, which are alloyed with tin, are the
two principal copper alloys. The silicon bronzes and the aluminum bronzes are some
further so-called bronzes.
5. Aluminum And Its Alloys:
Although pure aluminum lacks mechanical strength, it is more corrosion resistant than
its alloys. The Duralumin (Dural) family of aluminum-copper alloys, which have a
typical composition of 4% Cu and 0.54% Mg and a tensile strength comparable to mild
steel, are the primary structural alloys utilized. To combine the corrosion resistance of
the pure metal with the strength of the alloy, the pure metal can be utilized as a cladding
on dual plates. The development of a thin oxide film is what gives aluminum its
resistance to corrosion (as with the stainless steels). Because of this, it is best used in
highly oxidizing environments.
6. Lead:
Lead was once a common building material for chemical plants, but not anymore. Due
to its high cost, competing materials, particularly plastics, have mostly taken its place.
It is a ductile, soft substance that is typically utilized in the shape of pipes or sheets (as
linings). It is well tolerant of acids, especially sulfuric.
70
7. Titanium:
Due to its resistance to chloride solutions, such as sea water and wet chlorine, titanium
is now utilized rather frequently in the chemical industry. Dry chlorine attacks it
quickly, but even a tiny amount of moisture, like 0.01 percent, will stop the attack.
Similar to stainless steels, titanium also depends on the development of an oxide
coating for resistance.
15.3 Our Suggested Material of Construction.
Purified Terephthalic Acid (PTA) is highly corrosive and it can cause severe corrosion
(erosion corrosion). There for we will suggest a strong corrosion resistant material of
construction for the plant. Austenitic stainless steel is the most effective material
which is highly corrosion resistant among all the types of material. It is durable,
formable and weld able. It does not become brittle at cryogenic temperature and it is
non-magnetic as well. Type 304 has nickel amount of 8-11% and is less expensive
among all the types of austenitic stainless steel.
Since stainless steel and austenitic stainless steel in particular is expensive because
the nickel content is very high. Considering the cost of material, we will suggest:
71
MATERIAL OF
EQUIPMENT REASON
CONSTRUCTION
PTA is highly corrosive and since it is

Austenitic stainless steel, type our main raw material and in high
PASTE VESSEL
304 amount. Austenitic stainless steel is the
best choice.
PTA is in ESTER-1 as well, Austenitic
Austenitic stainless steel, type stainless steel is suitable material of
ESTER-1
304 construction in order to protect our
valuable equipment.
High quantity of PTA does consume in
Ester1, but still there is fair amount of
Austenitic stainless steel, type
ESTER-2 PTA that can corrode our equipment. So
304
Austenitic stainless steel should be
material of construction for Ester-2
In distillation column we have MEG and
DISTILLATION COULMN water. Mild steel is very cheap source of
Mild Steel
construction and also there is no threat
of corrosion.
In PP-1 BHET is converted into PTA
with formation of MEG, PTA is almost
consumed with some tiny amount of
PP-1 Mild Steel
unreacted PTA left. There is no real
threat of corrosion, so we can use mild
steel as it the cheapest source.
Again, mild steel will be a good option
PP-2 Mild Steel because of its cost and there is no
corrosive material in reactor.
The main purpose of DRR is to give
residence time and presence of no
DRR Mild Steel corrosive material makes Mild steel the
best choice for DRR.
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CHAPTER 14
PLANT LAYOUT
14.1 INTRODUCTION:
To ensure affordable construction and effective operation of the finished plant, plant
layout and construction design must be taken into account early in the design process.
The fundamental details and safety arguments for the plant structure chosen for the
newly proposed PET facility are provided in this portion of the study. In general, the
layout depicts the fundamental organization of the primary industrial site, supporting
structures, and a few significant safety considerations. The chosen plant layout could,
however, have an impact on the finished plant's ability to operate safely, so any
necessary modifications or extensions must be approved. The structure of a plant
frequently represents a compromise between a variety of criteria, such as the
requirement to maintain transportation distances between storage and production
facilities to a minimum in order to minimize costs and dangers. The site's geographical
restrictions. Interaction with on-site infrastructures, such as current roads, drainage
systems, and utility routes. Interaction with nearby plants. The requirement for plant
maintenance and operability. The requirement to situate hazardous material facilities
as far away from site borders and nearby residents as possible. The requirement to
make emergency services accessible. The requirement to offer staff on-site emergency
escape routes.
However, in terms of safety considerations, the most crucial plant layout elements are
those to: Prevent, limit, or mitigate escalation of neighboring occurrences. Make sure
the occupied buildings on site are safe. Limit unauthorized personnel's access.
14.2 PLANT LAYOUT CONSIDERATION FACTORS:

The factor to design plant layout for the PET has been reduced to multiple factors, as
listed below, based on the previously mentioned considerations. Thus, to ensure that
the final design for plant layout is complied with all the factors that has been discussed
earlier.
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1. COST:
By using the shortest stretch of connecting pipe between pieces of equipment,

building costs can be kept to a minimum. Using the least amount of structural steel
work also lowers the cost. The most crucial element is to have a setup for the greatest
operating and upkeep.
2. OPERATION:
Valve, sample point, and instrument equipment are examples of regularly used
equipment. They are close to the control room and have practical placements and
heights to make the operator's job easier.
Additionally, enough headroom and working space are given for simple equipment
access.
14.3 SITE LAYOUT:

We will have a short introduction of all the areas of plant and purpose behind choosing
it.
1. Administration Building:
To guarantee that staff members can reach the assembly point more quickly in an
emergency, the administration building is located next to the parking area that also
serves as a staff assembly location. The administration building is situated distant from
the process area according to the plant's layout in order to safeguard employees and
visitors from any potential risks.
2. Canteen And Mosque:
The canteen is situated across from the administrative building for convenient access
by staff and guests, and far from the process area to prevent food contamination and
guarantee public safety. The placement is so well-chosen that it prevents the food
supply from being exposed to the work area while still allowing them to enter and exit
74
with ease. Employees can worship during lunch in the mosque that is adjacent to the
canteen.
3. Training Room:
Training room is also located with main administration building. This room can be
used as a waiting room as well for visitors. Interviews can be conducted as well in
training room.
4. Poly Condensation Unit:
Poly condensation unit is main process building of industry. Control room of this unit
is located in the unit for easy control of process.
5. SSP Unit:
SSP unit is another main process building of industry. Control room of this unit is
located in the unit for easy control of process.
6. Raw Material Storage:
Just after main gate, on right side storage of raw material warehouse is located. Main
solid raw material will be stored there.
7. Safety Section:
In this section we have safety department, first aid clinic for any kind of emergency,
fire station in middle of plant for easy access to all areas of plant and then maintenance
department which has to see the plant as well as utilities. This safety section is
sandwiched between both solid and liquid raw materials storage and just in front of
both main process units.
8. Liquid Raw Material Storage:
Our liquid raw materials required tanks for storage. This area is for decanting and
storage of liquid raw materials.
75
9. Utilities Section:
This section will supply cooling water, high pressure steam and nitrogen to the main
process unit. Its placement is ideal for providing the most cost-effective pipe run to
and from the process unit.
10. Laboratory:
After the product is produced, the purity of the PET is evaluated to see if it satisfies
the requirements. All of the results will be delivered to the control room, where any
necessary changes to the controls will be made.
11. Power Supply:
The power supply is in use to provide electricity to the entire facility including the
administrative area.
It was situated in the center of the factory and close to the processing area.
12. Waste Treatment Plants:
To remove the contamination from the water, the waste stream from the separation
area will enter the waste treatment facility. In order to avoid waste release from
contaminating the product and people in the process area, the treatment facility is
situated distant from separating units.
13. Product Storage:
Product is stored here and delivered from here.
14. Loading Area:
Loading area is where the trucks deliver the chemicals used in running of the plant and
also load the products that are going to be distributed locally. Thus, it is directly
located to the storage.
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15. Future Expansion:
For future expansion there are areas which are left in case management wants increase
in production. This expansion area is in both main process units, in utilities section, in
product storage area and also big area with in plant after waste water treatment plant.
77
FIGURE 13.1: PLANT LAYOUT
78
EQUIPEMENT LAYOUT
69
80
81
CHAPTER 15
ACETALDEHYDE FORMATION DURING

PET MANUFACTURING
15.1 Introduction:
Poly Ethylene Terephthalate (PET) bottles are commonly used for storing beverages,
particularly mineral water. In order for these bottles to be suitable for this purpose,
they must have a neutral odor and taste. However, during the production of these
bottles, a chemical called Acetaldehyde is released, which can become trapped in the
bottle's walls and slowly be released into the beverage. This chemical can give the
beverage an undesirable taste and smell, so it is important to measure its concentration
in PET bottles that will be used for food and beverage storage. Acetaldehyde is a
colorless liquid with a strong odor and is used in the production of a variety of
products, such as acetic acid, perfumes, drugs, and flavoring agents. Prolonged
exposure to Acetaldehyde can be harmful and it is found in plants and fruits.
Additionally, it is produced during the metabolism of ethanol through the action of
enzymes called alcohol dehydrogenase.
15.2 Acetaldehyde in Our Daily Life:
Acetaldehyde is an unwanted chemical found in some food and beverages,

particularly alcoholic beverages, and can also be produced by yeast or bacteria
fermentation in certain foods. Additionally, it can be found in food packaging
materials, such as polyethylene terephthalate (PET) bottles, which are commonly used
for mineral water and other beverages. When PET is exposed to heat and other external
factors, it can degrade and release acetaldehyde into the bottle's contents. This
chemical can give the beverage an undesirable fruity flavor, and can be detected in
low concentrations in mineral water. The European Commission has set a limit for the
amount of acetaldehyde that can migrate from PET into bottled water, and techniques
to minimize its production in the manufacturing process have been developed to
adhere to this limit. The amount of acetaldehyde in mineral water is usually harmless
and can only be detected by the consumer when the concentration exceeds a certain
level.
82
15.3 Mechanism of Acetaldehyde Production:
During the production of PET resin, a byproduct called acetaldehyde (AA) is formed
during the polymerization stage. This stage takes place in the melt phase and the
amount of AA produced can vary depending on the temperatures and residence time
used in the process. The amorphous grain obtained may have AA ranges between 50-
100 ppm. However, through a process called solid state polymerization, the
temperature of the amorphous chips is raised to their glass transition temperature,
which causes the AA to separate from the chain and attach to other chains, resulting
in the formation of straight PET chains. Additionally, the AA is removed from the
grain through Nitrogen purging. In the molding process of PET, the melting
temperature is controlled to minimize the generation of
AA and the use of raw materials DEG and IPA also helps to minimize AA levels. The
resulting PET resin for packaging can have AA levels as low as 3-4 ppm and even
lower depending on the desired specifications of the manufacturer. The resin is often
used in the injection blow molding process, where it is re-melted and can generate
small amounts of AA due to the low melting point.
15.4 Test for Acetaldehyde Concentrations:

During the production of PET resin, a small amount of acetaldehyde (AA) is formed
as a byproduct. This can occur during the polymerization stage, as well as during the
molding process. Factors that can contribute to the formation of AA include high
83
temperatures, high pressures, extruder speeds, and long barrel residence times. The
type and formulation of the resin, as well as the type of equipment and processing
conditions, can also affect the levels of AA. However, AA levels in finished products
are typically low, as most of the AA generated in the melt phase polymerization is
removed during the solid-state polycondensation process. The ASTM F2013 test is
used to measure the content of AA in PET. To minimize the formation of AA during
the injection molding process, it is important to maintain optimum processing
conditions, such as using low temperatures and storing and drying the PET granules
under a nitrogen atmosphere. Research has shown that the molecular weight and
molecular weight distribution of the PET have an impact on the formation of AA, and
that limiting contact with air before processing can help to reduce AA levels.
84
CHAPTER 16: SAFETY ISSUES AND
HAZARDS ANALYSIS
Safety is the most important element in a plant. Lack of safety awareness will lead to
potential accidents and near misses at the workplace which results in loss of
production, time, property and life. Hence, safety regulations and obligations are
established in order to ensure the health and welfare of employees and public by
introducing a systematic approach that covers a proactive identification, evaluation
and mitigation of chemical release which occurs due to failures and problems in
processes, procedures and equipment.
Industrial hazard includes fire and explosion, mechanical and electrical hazards from
moving machinery, biological hazards such as allergic reactions to chemicals, physical
hazards for instance falling and tripping as well as ergonomically hazards due to
carrying heavy loads. Hazards include any human activity or process that has the
potential to negatively impact the environment or result in property damage, injury, or
other health effects. Even though the negative effects of hazards, especially natural
hazards, are frequently impossible to completely avoid, there are numerous ways to
significantly reduce their scope or severity.
16.1 IDENTIFICATION OF MATERIAL AND CHEMICAL

HAZARDS
The substances or chemicals used in this process could be hazardous to both the
environment and the persons involved. Therefore, it is crucial to determine the
potential risks associated with each chemical. The substances used in a Polyethylene
Terephthalate (PET) plant are mentioned in Table 1 below.
85
PURIFIED TEREPHTHALIC ACID (PTA):
Type Chemicals/Materials
Purified Terephthalic Acid (PTA)

Feed Ethylene Glycol
Intermediate Bis(2-hydroxyethyl) terephthalate

Product (BHET)
Products Polyethylene Terephthalate (PET)
Byproducts Water
Catalyst Metal Catalyst
Table 16.1 List of Chemicals/Materials Involved
PTA typically exists as a white, crystalline powder with a faintly acidic smell. The
eyes, skin, and respiratory system are only slightly irritated by it. The substance causes
mild gastrointestinal discomfort and could be dangerous if eaten in excessive amounts.
By ingesting the material or inhaling its aerosol, the substance can enter the body. At
20°C, evaporation is low; nevertheless, when dispersed, a nuisance-causing
concentration of airborne particles can be quickly obtained.
Table 2 below provides a review of the many exposures and hazards this chemical can
produce.
86
Types of Acute First Aid/ Fire
Hazard/ Hazard s/ Prevention Fighting
Exposure Symptoms
Water spray, foam,
Fire Combustible No open flames powder, carbon
dioxide
Finely Prevent In case of fire: keep
dispersed deposition of dust; drums, etc., cool by
spraying with water.
Particles form closed system,
Explosion explosive dust explosion-
mixtures in proof equipment
air. and lighting.
Local exhaust or Fresh air, rest

Inhalation Cough breathing
protection
Remove
contaminated clothes.
Rinse skin with
Skin Redness Protective gloves
plenty of water or
shower.
First rinse with plenty

of water for several
minutes (remove
Eyes Redness Safety goggles contact lenses if
easily possible), then
take to a doctor.
Rinse mouth
Do not eat, drink,
or smoke during
Ingestion work. Wash hands
before eating.
Table 16.2 Summary of types of hazard/exposure from Purified Terephthalic Acid
87
ETHYLENE GLYCOL:
The most common form of ethylene glycol is an odorless, colorless, viscous,

hygroscopic liquid. Both inhalation and skin contact with the drug might result in
absorption into the body. At 20°C, the evaporation of this material will take a while
before a dangerous pollution of the air is attained.
Table 3 below provides a review of the many exposures and hazards this chemical can
produce.
Types of Acute Hazards/ Prevention First Aid/ Fire

Hazard/ Symptoms Fighting
Exposure
Fire Combustible No open flames Powder, alcohol
resistant foam,
water, spray,
carbon dioxide.
Inhalation Cough. Ventilation Fresh air, rest.

Dizziness. Artificial
respiration may
Headache. be needed.
Refer for
medical
attention.
Skin Dry skin Protective Remove
gloves contaminated
clothes. Rinse
skin with plenty
of water or
shower.
88
Eyes Redness. Pain Safety goggles First rinse with
plenty of water
for several
minutes
(remove contact
lenses if easily
possible), then
take to a doctor.
Ingestion Abdominal pain. Do not eat, Rinse mouth.
Dullness. drink, or smoke Induce vomiting
during work.
Nausea. Refer for
Unconsciousness medical
Vomiting. attention. If no
medical
personnel are
available and
the patient is
conscious,
ingestion of
alcoholic
beverage may
prevent kidney
failure.
Table 16.3 Summary of types of hazard/exposure from Ethylene Glycol
BIS (2-HYDROXYETHYL) TEREPHTHALATE (BHET):
The ester of PTA and EG is called bis(2-hydroxyethyl) terephthalate (BHET), and it

is typically found in solid form as a white crystalline powder. Any chemical exposure
should be kept to a minimum. Abrasion to the skin or eyes may cause inflammation.
If inhaled or consumed, it might be dangerous. When handling this product, industrial
hygiene procedures must be followed, and the appropriate personal protection
equipment must be used. Table 4 below provides a review of the many exposures and
hazards this chemical can produce.
89
Types of
Acute Hazards/ Prevention First Aid/ Fire
Hazard/
Symptoms Fighting
Exposure
Fire Combustible at No open SMALL FIRE: Use

high temperature flames DRY chemical powder.
LARGE FIRE: Use

water spray, fog or
foam. DO NOT use
water jet.
Inhalation Cough. Ventilation If the victim is not
Dizziness. breathing, perform
mouth-to-mouth
Headache. resuscitation. Loosen
tight clothing. If
breathing is difficult,
oxygen can be
administered. Seek
medical attention if
respiration problems do
not improve.
Skin Dry skin Protective In case of contact,
gloves immediately flush skin
with plenty of water.
Remove contaminated
clothing and shoes.
Eyes Redness. Pain Safety Check for and remove

goggles any contact lenses. In
case of contact,
immediately flush eyes
with plenty of water.
Table 16.4 Summary of types of hazard/exposure from BHET.
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POLYETHYLENE TEREPHTHALATE (PET):
PET is the most widely used thermoplastic polymer resin in the polyester family and
is utilized in garment fibers, food storage containers, and liquid storage containers. It
is originally created as a thick, viscous mass, which is subsequently cooled and
thinned to create polymer chips. Its hues range from milky white to black, or they
could be translucent. This product shouldn't produce any exceptional emergency
hazards under typical usage circumstances. The dry resin poses a risk of irritating
dust. Resin may release gas and vapor that are strong irritants when heated above
383oF (195oC). Inhalation, skin and eye absorption, and absorption via the skin are
the main exposure pathways. Table 5 provides a review of the various risks and
exposures this chemical can produce.
Types of Acute Hazards/ Prevention First Aid/ Fire

Hazard/ Symptoms Fighting
Exposure
Fire Combustible No open Class A or Class B fire
flames extinguishers or water
fog.
Inhalation Irritation of the Ventilation Remove to fresh air.

upper respiratory Drink water to clear
tract, coughing, throat, and blow nose
and congestion to remove dust.
may occur.
Skin Molten resin will Leather or If contact with molten

cause thermal cotton gloves resin occurs the
burns. should be worn affected area should be
to prevent skin flushed with plenty of
contact and water.
irritation.
Eyes Temporary Wear safety Flush eyes with large
irritation (itching) glasses with amounts of water for 5-
or redness may side shields. 15 minutes. If irritation
occur. develops, or persists,
seek medical attention.
Table 16.5 Summary of types of hazard/exposure from Polyethylene Terephthalate

(PET)
91
The table below lists the summary of the potential hazards posed by all the materials or chemicals used and produced in this plant. Also refer
to Appendix for the MSDS for each chemical and feed properties table.
Auto- ignition
Fire and
Flash Point Oral
Explosion
Chemicals Temp Risk Exposure Reactivity Health Effect
(LD50)
>6400 mg/kg (rat) Harmful by
inhalation, in contact
Purified 496 ºC > 300 ºC with skin and if Combustible Reactive with Carcinogenic
Terephthalic swallowed. Irritating at high strong oxidizing
to eyes, respiratory temperature agents.
Acid 3200 mg/kg system and skin.
(mouse)
(PTA)
92
Ethylene 399 ºC 127 ºC Harmful by Combustible Reactive with Repeated exposure
Glycol inhalation, in contact at high strong oxidizing may produce general
5840 mg/kg with skin and if temperature agents, strong deterioration of
swallowed. Irritating acids, strong health by an
(rat) to eyes, respiratory alkalis (bases), accumulation in one
system and skin. and heat. or many human
organs.
Table 16.6 Hazard Identification for chemicals involved
NA Combustible at Repeated or
high prolonged exposure
Bis(2hydroxyethyl) temperature Reactive with to this is not
oxidizing
terephthalate NA >200 ºC Compound
NA agents, alkalis
aggravate known to
(bases)
medical existing
(BHET) conditions.
Polyethylene Not a skin irritant, NA NA Fumes irritating to
but is a mild eye the eyes, nose and
Terephthalate 375 ºC NA NA throat may be
irritant. produced at
(PET) temperatures above
Low ingestion & about 235°C.
inhalation hazard
93
Strong acids
and bases can
cause rapid
Water NA NA > 90ml/kg NA Non-flammable NA
heating.
Reaction with
sodium metal
can result in
explosion.
94
There are different routes for producing a chemical substance. Every method has a
different process flow. Hence, chemicals used such as feed, catalysts and utilities are
different for different processes.
Each method should be analyzed to determine which route is less hazardous.
Inventories are amount of raw materials and finished products at a given time. By reducing
inventories, whether it is the raw material (feed) or final product, accidents such as major
explosion and leakage can be reduced.
An approach to use hazardous materials under less hazardous conditions should be

considered. Appropriate design and operating conditions such as temperature and pressure
are needed to ensure a safe process. Using a lower possible temperature and pressure can
prevent serious accidents such as major explosion as well as minimizing utility
consumption.
A facility should be situated in an area with low production and distribution costs, secure
living circumstances for plant employees, and a friendly local environment. When
choosing a location, factors including the accessibility of raw materials, the availability
of sufficient land, transportation options, and the distance to the nearest hospital and fire
station should be taken into account. Transportation of feed or products within the plant
must be done safely and the piping systems
16.2 OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) 1994:
OSHA 1994 defines the general duties of employers and self-employed persons in relation
to safety and health at work. The regulations under this Act are as below:
• Regulations from 1995 known as OSH (Employers' Safety and Health General Policy
Statements)
• Regulations from 1996 known as OSH (Control of Industrial Major Accident Hazards)
• OSH Regulations (Safety and Health Committee) 1996-SHC
• CPL's 1997 OSH (Classification, Packaging, and Labeling of Hazardous Chemicals)
Regulations
• The 1997 OSH (Safety and Health Officer) Regulations
95
• The OSH (Use and Standards of Exposure to Chemicals Hazardous to Health) Regulations
of 2000
• Regulations from 2004 known as OSH (Notification of Accident, Dangerous Occurrence,

Occupational Poisoning, and Occupational Disease)
16.3 ENVIRONMENTAL QUALITY ACT (EQA) 1974:

EQA 1974 focuses on public health and safety while primarily addressing pollution issues
brought on by industrial discharge and emissions into the land, water, and atmosphere.
The Department of Environment primarily regulates the laws under this Act (DOE). The
department is the principal agency in charge of enforcing regulations and programs for
pollution control.
Environmental Impact Assessment reports must be completed prior to the start of any
industry in order to provide information on the industry and its effects on the environment.
Before a license can be issued, the EIA report must be submitted to the state's Department
of Environment for approval.
The following laws pertain to the process plant industry:
• Regulations for Environmental Quality (Clean Air) from 1978

• Regulations for Environmental Quality (Licensing), 1977
• Regulations governing environmental quality (sewage and industrial effluents) from 1979
• Regulations for Environmental Quality (Prescribed Activities) from 1986
• Environmental Quality (Prescribed Activities) Order (EIA) 1987
• 1987's Environmental Quality (Prescribed Activities) (Environmental Impact
Assessment) Order
• Regulations for Environmental Quality (Scheduled Wastes) from 1989

• Order from 1989 governing Environmental Quality (Prescribed Premises) (Scheduled
Treatment and Disposal Facilities)
The manufacture of plastics accounted for 14% of the nation's total harmful discharges
into the air. Sulfur oxides, nitrous oxides, methanol, ethylene oxide, and volatile organic
compounds are among the main emissions from the manufacturing of plastics.
96
The pollution caused by the production of plastic resin is less obvious but nonetheless
highly harmful. Although the refining process employs techniques to reduce waste,
point-source air emissions are still high due to the inherent challenges of handling
significant quantities of pressured gases.
Numerous chemical additions that offer plastic products desired performance

characteristics also have detrimental impacts on the environment and people's health, in
addition to posing safety issues during production. Direct poisoning is one of these
impacts. These substances are utilized in barrier resins, flame retardants, colorants,
plasticizers, antioxidants, and colorants. Many of these additives may be combined with
one type of resin, complicating the chemical composition. To overcome these effects
which may be harmful for our environment, industries should analyze the manufacturing
process critically and list down the all possible ways through which these emissions can
be minimized.
The most important factor is to reduce the energy usage and to minimize it if possible,
also by minimizing the use of water. A lot of water is used during manufacturing such as
cooling, washing and cleaning, this used water can be treated and used again to minimize
the excess usage of water.
Some machines and the parts that make them up use fossil fuels, which are among the
main causes of climate change. You will ultimately save money by switching to renewable
energy-powered equipment, and you will also be able to significantly lower your carbon
emissions.
Some materials are well known for their dependency on fossil fuels, such as the majority
of plastics. You can further reduce your energy needs and switch to renewable sources by
examining the raw materials you use and the goods you produce.
Utilizing multi-tasking equipment is a crucial strategy for reducing energy consumption

and, consequently, carbon emissions. These devices integrate many processes. By
completing many procedures at once, you can drastically cut down on setup and
manufacturing time.
97
The quantity of energy needed to create materials or things will be reduced by using fewer
equipment for a single project, which has the added benefit of lowering energy prices and
carbon emissions. Additionally, it means that you will need fewer component parts for
various devices. Fewer machines allow you to boost production output efficiency and
make better use of your industrial space.
Effective maintenance is one of the finest strategies to prolong the life of our
manufacturing equipment. Depending on the machinery, equipment maintenance will
vary, but in general, maintenance is simple. Although it's crucial to set up procedures for
skilled experts to frequently inspect your equipment, there are things you can do on your
own as well.
It is crucial to keep your equipment clean and free of debris because doing otherwise can
significantly reduce its efficiency.
The key to lowering factory pollution is the efficient handling of trash at the end of the
production process. Waste treatment is the process of altering the hazardous industrial
waste's qualities to make it less dangerous. Physical, chemical, or biological changes may
occur. Physical procedures have the potential to alter the waste's size or shape. Contrarily,
biological treatments use organisms to break down waste components into simpler
organic matter and biomass whereas chemical treatments use chemicals to change the
content of the waste. Manufacturers can lower the volume and toxicity of their waste
before disposal by treating it in this way before it leaves the plant.
Leakages are among the most prevalent issues with manufacturing equipment that waste
energy. Leak checks are advised in addition to routine equipment inspections, which are
necessary for general maintenance. This will enable you to find any leaks and address
them before they do more damage.
Long-term leak prevention can be achieved by using the proper sort of seal on your
cylinder parts.
For all businesses to be sustainable and reduce carbon emissions, the UK must reach its
net-zero goal by 2050. The manufacturing industry has a significant impact because it is
one of the main producers of greenhouse gases in the United Kingdom. You can lower
your emissions to support crucial environmental issues by taking action regarding the
98
equipment and component parts your manufacturing facility utilities, including how and
where you get them, how you use them, and how you maintain them.
99
CHAPTER 17
COSTING
FORMULAE USED:
Purchase cost: (bare cost from graph# 6.5 & 6.6) × (material factor) × (pressure factor)
Fixed Cost: (purchase cost) × (cost index 2021)

(Cost index 1998)
EQUIPMENT PURCHASE FIXED

COST($) COST($)
ESTER-1 80000 9.25E+07
ESTER-2 80000 9.25E+07
PP-1 75000 9.30E+07
PP-2 30000 3.72E+07
DRR 30000 3.72E+06
DC 110000 1.45E+08
TOTAL 405000 4.64E+08
FIXED CAPITAL COST: 4.64×108 $
WORKING CAPITAL COST = 2.37×107 $
TOTAL INVESTMENT = 4.87×108 $
VARIABLE COST:
100
RAW MATERIALS:
TOTAL DAYS/YEAR: 347
FLOW RATE
PRICE/TON TONS/DAY $/YEAR
PTA 680 772 182161120
MEG 750 290 75472500
TOTAL 257633620
UTILITIES:
UTILITIES CONSUMPTION PER DAY
Name Unit Product/Ton $/ton

Electrical Power kWh 83 1.9
Cooling Water m3 0.5 0.005
Chilled Water m3 75 6
Industrial Water m3 1 0.06
Denim Water m3 0.12 0.18
LP Stream kg 24 216
Instrument Air Nm3 25 0.06
Nitrogen Nm3 48 4.3
Heat Value Kcal 582000 873000
$873,228.51
MISCELLANEOUS= 1.16E+06 $
TOTAL VARIABLE COST= 259666995.5 $
101
FIXED COST $
Maintenance cost 4.64×1006
operating labor 32200
Plant overhead 16100
Laboratory 9660
Capital charges 2.32×1007
Insurance 4.64×1006
TOTAL FIXED COST 3.25×1007
102
Annual operating cost = total variable cost+ total fixed cost = 2.92E+08 $
Net income = gross income-annual operating cost= 9.82e+07 $
ROI = net income/ total investment*100
ROI =20.2
Payback time = 100/ROI
Payback time = 4.96 years
102
103
REFERENCES
1. Chanda M., R. S. (1994). Industrial Polymers, Specialty Polymers, and their
Applications. USA: CRC Press.
2. Ethylene Glycol (EG) Pricing and Information. (n.d.). Retrieved August 13, 2010, from
http://www.icis.com/V2/chemicals/9075765/ethylene-glycol-mono/pricing.html
3. ICIS Pricing Polyethylene Terephthalate (Asia Pacific). (2010, February 12). Retrieved
August 13, 2010, from http://www.icispricing.com/il_shared/Samples/SubPage217.asp.
4. J.I., K. (1998). Concise Encyclopedia of Polymer Science and Engineering. USA: Wiley
and Sons.
5. Meyers, R. A. (2005). Handbook of Petrochemicals Production Processes. USA:

McGraw-
Hill.
6. Niaz H., F. M. (2009, January). Process Plan of Continuous Melt-Phase Polyethylene

Terephthalate (PET) Production Plant. Retrieved August 9, 2010, from
http://www.scribd.com/doc/21182843/Final-Project-Report-Plastic-Bottle-Manufacture
7. Production of Polyethylene Terephthalate. (2010, February). Retrieved August 2010,

from http://www.scribd.com/doc/28631275/PET-Production-Technical-Report
8. Purified Terephthalic Acid (PTA) Prices and Pricing Information. (n.d.). Retrieved
August 13, 2010, from http://www.icis.com/V2/chemicals/9076460/terephthalic-
acid/pricing.html
9. Reimann, R. (2005). Patent No. US 6,864,345 B2. United States of America.

10. Schork F. J., D. P. (1993). Control of Polymerization Reactors. New York, USA: Marcel
Dekker.
11. Stephen M. M., J. F. UOP SINCO Solid-State Polymerization Process for the Production
of PET Resin and Technical Fibers. Illinois, USA: UOP LLC.Thomas S., Y. W. Advances
in Polymer Processing. USA: Woodhead.
12. Ullman's Encyclopedia of Industrial Chemistry (5 ed., Vol. 28). (1997). New York, USA:
Wiley VCH.
104
13. Max S. Peters, K. D. T., Ronald E West, Plant Design and Economics for Chemical
Engineering. Mc Graw Hill: 2003; Vol. 5.pg 30,31
14. [1] G. Haack, J. Ewender, Sensory thresholds and analytical determination of
acetaldehyde in mineral water for the quality control of PET bottles, 2nd international
Symposium of Food Packaging, Vienna, 2000
15. [2] J. Ewender, R. Franz, A. Mauer, F. Welle, Determination of the Migration of

Acetaldehyde from PET Bottles into Non-carbonated and Carbonated Mineral Water,
Deutsche LebensmittelRundschau, 2003, 99(6), 215-221
16. [3] Mahesh VS, Tharpa K, Gadigone NS, Al-Farhood BF, Al-Mutairi FH, Kumar A.
Mechanism of acetaldehyde formation in polyethylene terephthalate resin—A new insight.
Polym Eng Sci. 2020;1–5
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acetaldehyde in polyethylene terephthalate bottle polymer using an automated static
headspace sampling device and a capillary GC with a flame ionization detector accessed.
105

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DESIGN 900 TONS/DAY PET

MANUFACTURING PLANT AND STUDY

HAFIZA WAJIHA NAZ B1833015

MUHAMMAD AAMIR B1833024

UZAIR AHMED QURESHI B1833048

WAQAS AHMED B1833050

DEPARTMENT OF CHEMICAL ENGINEERING

HAFIZA WAJIHA NAZ B1833015

MUHAMMAD AAMIR B1833024

UZAIR AHMED QURESHI B1833048

WAQAS AHMED B1833050

Project supervisor (internal) Project supervisor

FIGURE 4.1: Pert Chart

FIGURE 7.1: Block flow diagram

FIGURE 8.1: Process flow diagram

FIGURE 8.2: Process flow diagram of esterification reactors.

FIGURE 8.3: Process flow diagram of PP-1 & PP-2

FIGURE 8.4: Process flow diagram of DRR and cutter

FIGURE 9.1: P&ID of mixing vessel

FIGURE 9.2: P&ID of Ester-1 and Ester-2

FIGURE 9.3: P&ID of distillation column

PET Polyethylene Terephthalate

BOPET Bi-axial Polyethylene Terephthalate

PTA Purified Terephthalic Acid

Sb2O3 Antimony Triacetate

IPA Iso-Phthalic Acid

BHET Bis-Hydroxy Ethyl Terephthalate

H3PO4 Phosphoric Acid

DRR Disk Ring Reactor

SSP Solid State Polymerization

g/dL Gram per deciliters

lb/hr Pounds per hour

1.1 PROJECT BACKGROUND:

1.2 PROBLEM STATEMENT:

Polyester is a type of polymer that belongs to the family of thermoplastic polymers

One of the most well-known applications of polyester is in the production of

2.2 POLYETHYLENE TEREPHTHALATE (PET)

PET, also known as polyethylene terephthalate, is a thermoplastic polyester resin

• PET is commonly used in food packaging, including beverage bottles and

• A wide range of goods and beverages, such as wine, salad dressing,

It is entirely flammable and leaves little residue.

CHEMICAL STABILITY: includes strong

HYDROLYTIC STABILITY: Decent resistance

RECYCLABILITY: De-polymerization enables

TABLE: 2.1 Properties of PET.

3.1 AVAILABLE TECHNOLOGIES:

4) China Textile Industrial Engineering Institute (CTIEI)

Objective Developed for the production of bottle-grade

3) Lower production cost: decreased pressure drop

Types of Catalyst Antimony Trioxide, Sb2O3

Conversion Rate Approx. = 99 % - 99.5%

Unit Operations 1) Pre-crystallizer (Fluid-bed-type HX) Operating

3.2.1 Zimmer technology:

3.2.2 The pet production process:

It is a five-reactor technology having two staged esterification reactor, two staged

3.2.3 ADVANTAGES OVER OTHER TECHNOLOGIES:

• Low temperature requirements:

• Higher viscosity lift

• Lower process temperature

• Lower thermal stress and product degradation

• Exceptional availability and reliability

FIGURE 4.1: PERT CHART

1. PROJECT OVERVIEW AND LITERATURE REVIEW: