Week 2:

This week i followed the induction program to various plants in POY.
In the process, i learnt many things about processes,maintenance and work culture of the company.

1. NG 3 (next generation 3 plant) :This plant produces the PET chips which are used in preparing resin for plastic bottles that are used to store cold drinks and mineral water.

Inputs:
PTA Purified Terapthallic acid
IPA Isopthallic acid
MEG mono ethylene Glycol
Additives:
DEG Di ethylene Glycol
Antimony trioxide
Toner: cobalt acetate in Phosphoric acid.
Outputs:
PET chips
There are 2 main sections:
Melt
SSP (solid state polymerization)

2. Utility:
Polyster utilities

In house:

Dow vapour Generation
(Heat transfer Media)

Cooling Water
POY-CT
PTA 1- CT
NG 3 –CT

Chilled Water

Chillers (refrigeration machines)
Chilled water – pumps

Air handling units (Air Conditioning)
Quench
Comfort

Compressor house

Air Compressors
i. LP air compressors
ii. HP air compressors

Instrument Air (2 Instrument air Driers)

NG3 Dow heater (Liquid)

CP 10/11 utilities
Dow vapour Generation
Cooling Water
Chilled Water
Air handling units
Compressors
TEG
Used for
§ Cleaning Pack Parts
§ Cleaning Spinnerettes
§ Cleaning Candle filters


Effluent/ Sewage collection and Disposal
- Collect and pump effluents to ETP.


From Phase I

1. Steam
HP
LP CPP
MP
2. Nitrogen
3. MEG (ASU)
4. Water – CPP
Filter Water – (CT Make Ups)
Service Water
Drinking water
De-Mineralized water

Chemicals
1. Virgin EG
2. TEG
3. Furnace oil
4. DEG

Fuel used
1. CPP Natural gas
2. Cracker gas
3. Bio gas – (from ETP)
4. PVG – (from MEG)

Dow Dowtherm : Eutectic mix of 73.5 Diphenyl oxide and Di phenyl


POY Process

The POY plant has been setup in RIL Hazira Complex with technology licensed from Dupont. The capacity of the plant when the upcoming expansions are completed will be 405 KTA. There are five Continuous polymerization units which are producing POY. ( CP-1, CP-2, CP-4, CP-5, ( 90TPD each ) and CP-9 ( 155 TPD). The upcoming unit CP-10 is of 600 TPD capacity.


Traditionally Polyester melt ( which is fed to Spinning machines) is produced through two different chemical processing route : DMT route and PTA route. At present all technology suppliers and producers prefer the PTA route because of the Safety, lower conversion cost, lower energy consumption pattern.

Polyester melt is used to produce various types of the products like POY, PFY, FDY, PSF and PET for various end-uses. The polymerization process is similar in each case.

The CP is consists of two main sections:
1. Esterification Section
2. Polycondensation Section

besides I also visited the Spinning section,winding section and the Lag area sections.
whose functions are self explanatory.

I was also untroduces to varioous maintenance procedures carried out by mechanical and electrical departments.maintenance is a 3-fold procedure pro-active (predictive) ,preventive (prevent maintenance requirement) and reactive (React to the problems).
Unplanned shutdowns are budgeted zero.