MTR Melt-To-Resin Technology For the cost-efficient, energy saving production of high-quality PET

Transcription

1 MTR Melt-To-Resin Technology For the cost-efficient, energy saving production of high-quality PET Uhde Inventa-Fischer

2 2 Polyester Technology For all your packaging needs Production of bottle-grade chips using MTR technology Uhde Inventa-Fischer s Melt-To-Resin (MTR ) technology for the production of bottle-grade PET chips is a continuous polycondensation process that obviates the need for the solid-state polycondensation process step. MTR technology uses the established resin formulation to produce PET chips for all packaging applications. Seals of approval have been awarded by all major brand owners. The MTR process offers benefits to both PET producers and PET converters. And, of course, Uhde Inventa-Fischer s MTR process is backed by more than 50 years experience in developing, engineering and designing leading polymerisation processes. Technical innovation 1965: First 5-reactor continuous polycondensation (CP) plant based on PTA 1988: First 4-reactor CP plant 2001: First 600 t/d single-line plant for bottle-grade and textile-grade PET 2002: First 2-reactor CP plant 2005: First PET Direct-Film-Casting (MTF ) CP plant 2007: First CP plant based on Melt-To-Resin (MTR ) technology Melt-To-Resin (MTR ) production plant: above as-design and below as-built Commercial experience Long-standing experience in PET processes More than 150 PET plants supplied worldwide Patent coverage on technology and equipment Reference Plants Customer Location Capacity Special Features OCTAL Petrochemicals Oman 2 x 140,000 t/year 2-reactor process, Melt-To-Resin (MTR ) technology, Melt-To-Sheet (MTS) technology OCTAL Petrochemicals Oman 2 x 250,000 t/year of bottle-grade PET 2-reactor process, Melt-To-Resin (MTR ) technology JSC Alco-Naphtha Russia 240,000 t/year of bottle-grade PET 2-reactor process, Melt-To-Resin (MTR ) technology, first plant in Europe to use Uhde Inventa-Fischer s proprietary MTR technology Indorama AlphaPet Inc. USA 2 x 216,000 t/year of bottle-grade PET 2-reactor process, Melt-To-Resin (MTR ) technology, retrofit of Uhde Inventa-Fischer s Flakes-To-Resin (FTR ) recycling technology DAK Americas USA 200,000 t/year of bottle-grade PET 2-reactor process, Melt-To-Resin (MTR ) technology

3 MTR Melt-To-Resin Our technical innovation is your competitive advantage 3 Economy of the CP plant The MTR process stands out for its cost savings in energy, capital investment and operation, leading to a total 40% reduction in conversion costs compared to the conventional route with an SSP stage. The combination of highly efficient reactors and MTR technology also leads to savings in raw materials. Costs and yield are drastically improved by omitting the solid- stating process. Advantages of the CP plant Major savings are gained through a reduction in electrical and heating energy No nitrogen circuit with booster blowers, nitrogen purification and heaters Use of latent heat ESPREE reactor does not require agitators Process steam is generated as a by-product during esterification Approximate 40% reduction in conversion costs compared to the conventional route with an SSP stage Reduction in plant carbon footprint as well as building costs and erection costs Quality features of the resin produced The MTR process provides the mild reaction conditions during the chemical processes of esterification and polycondensation that are required for high-quality PET resin made of PTA/MEG and co-monomers. There is no make- good left to further production steps. The specific properties of the melt are key to the quality of the final MTR product. The MTR chips have the following characteristics: Reduced energy consumption for preforming Reduced raw materials consumption Adjustment of carboxyl end groups according to downstream requirements Excellent hot-fill properties High bottle strength Narrow molecular weight distribution Long cleaning intervals for preform cavities Low downstream regeneration of acetaldehyde (AA) Bright colour Low bottle wall thicknesses possible Low i.v. drop on extrusion No core-shell viscosity deviation

4 4 MTR Melt-To-Resin High-quality PET bottle resin in a single step MTR Melt-To-Resin The MTR process is commercially well proven, demonstrates utmost energy efficiency and cuts raw materials and operating costs. Nine lines with a total capacity of almost 2,000,000 tonnes per year will be in operation by the end of The characteristic components of the MTR technology are: 1. ESPREE reactor, heart of Uhde Inventa-Fischer`s 2-reactor concept 2. DISCAGE reactor, in which the required viscosity can almost be achieved even during the melt phase and at low shear stress 3. Die face granulation to keep pellets at a high temperature 4. MTR Conditioning silo to remove acetaldehyde using the inherent heat which significantly reduces energy consumption MTR route PTA / PIA + EG MTR polycondensation High-viscosity PET bottle resin Advantages Conventional route PTA / PIA + EG Conventional polycondensation Precursor pellet with low viscosity Solid-state postcondensation High-viscosity PET bottle resin Innovative, patented design highlights such as the advanced ESPREE and DISCAGE reactors as well as the improved polymer line design, high-efficiency filtration, die face hot cut, AA conditioning and extremely gentle process conditions accord the MTR process the following outstanding features: PTA/PIA EG Paste Mixer ESPREE Reactor MV Discage Finisher Uhde Inventa-Fischer`s patented Melt-To-Resin (MTR ) technology Hot Cutting air MTR Conditioning BG chips Fewer preform and bottle faults Reduced crystallinity of resin, compared to SSP resin Reduced heat input for preform extrusion Reduced AA regeneration Increased extrusion speed No highly crystalline spots or failure AA (acetaldehyde) content below 1 ppm No scavenger required Stoichiometric material yield No losses of EG or oligomer Clean process Less dust formation Higher raw material yield

5 5 DISCAGE & ESPREE 2 highlights of the MTR technology ESPREE reactor The innovative ESPREE reactor is an energy-efficient and cost-efficient tower reactor that replaces the first three reactors of typical conventional polycondensation plants as it combines all relevant reaction sections within a single reactor. One of the technical highlights of the ESPREE is the liquid film that flows down the inner surface of its vertical tubes to produce the prepolymer. ESPREE reactor features Minimised hold-up and reaction time Autogenous stirring / no mechanical agitators Pre-polycondensation: high film surface vs. volume ratio Co-current flow of vapour & liquid Liquid flow from top to bottom Compact design Advantages Low energy and maintenance costs High raw material yield Excellent colour values Short reaction time at low temperature Fast, optimised esterification and polycondensation Lowest AA generation rate compared with other processes Hold-up time of only three hours from raw material to polymer Low side-product generation due to large heat exchanger surfaces and low wall temperatures Minimal oligomer formation and losses Vacuum generated by steam from reaction Total recycling of EG DISCAGE reactor The DISCAGE reactor is the finishing reactor for the continuous polyester processes and is suitable for the production of PET, Co-PET, PET-G, PBT, PBS, PEN and other polymers. The reactor generates the surface needed for devolatilisation and polymer chain build-up, while at the same time creating a perfectly homogeneous polymer with minimal polydispersity. The DISCAGE reactor has a shaftless design, thus avoiding the disadvantages associated with melt adhering to a central shaft. With this unique design, the agitation elements that generate the surface (uniquely shaped punched discs and spoked rings) are designed as a mechanically stable, rigid cage which is constantly moved and dipped through the melt. The position and shape of the spoke wheels assisted by stripping elements propel the polymer from inlet to outlet. DISCAGE reactor features Largest possible surface renewal of the polymer during residence Continuous viscosity build-up and optimum molecular distribution No dead spots and comparatively short residence time Optimum heating, low temperature difference between polymer and reactor wall Avoidance of polymer oxidation, all-welded closures Easy, quick maintenance and long maintenance intervals Advantages Bending of the cage stirrer < 2 mm at a length of 10 m, for example minimum gap towards the reactor wall guarantees maximum efficiency Low bending moments on the outer bearings and seals as no central shaft is used Long-life bearings and seal tightness, easily accessible, no bellows Stiffness of the construction increases with reactor diameters

6 6 MTS Melt-To-Sheet & MTF Melt-To-Film Direct melt supply technologies MTS Melt-To-Sheet Melt-To-Sheet is a variation of the Melt-To-Resin MTR process. Unlike the conventional extrusion process, MTS supplies the PET melt directly to the sheet-casting machines. This eliminates the following conventional process steps: chip-cutting and storage, transportation, crystallisation, drying and extrusion. Significant energy and conversion cost savings can be achieved through MTS. The resulting PET sheet is highly uniform, has very high clarity and is free from impurities. MTF Melt-To-Film The Melt-To-Film (MTF ) process enables multilayer packaging film to be generated directly from the melt. Back integration eliminates complete sections of the process compared to the conventional film process. In-line modification of the polymer melt through proprietary Melt Conditioning (MC) provides a fully integrated production process and unique product flexibility as well as the lowest waste figures and consequently the lowest production costs in today's production of PET film. Economy The Melt-To-Film (MTF ) process is suitable for plant configurations of 100 to 300 t/d, but it can also be used for large polyester complexes of between 500 and 1,000 t/d, thus offering new product flexibility as well as the following advantages: Production cost savings of up to 30% Elimination of cost-intensive production steps such as chip production / storage / transport as well as crystallisation, drying and extrusion Conversion cost savings as well as savings in marketing and transport of the PET chips to the film manufacturer add to the profit usually obtained from a conventionally designed PET film plant.

7 FTR Flakes-To-Resin Fully integrated high-quality PET recycling process 7 FTR Flakes-To-Resin PET Recycling Volatile prices for PTA and EG as well as widespread PET collection and sorting systems make PET recycling a very attractive option. Furthermore, consumer attention is becoming increasingly focused on green products, which is making PET products with recycled content increasingly popular. Uhde Inventa-Fischer offers a cost-effective process for the recycling of post-consumer (PCR) PET bottle flakes into rpet resin. The FTR recycling technology is based on post-consumer flakes which are filtered and i.v.-adapted before being introduced as a melt side-stream back into the prepolymer of the continuous polymerisation process. The blend is finished in the DISCAGE reactor like a virgin melt and passes through the further MTR process without any additional treatment. Any contarmination which may have been entrained with the flakes from misuse of the bottles is eliminated during the melt- phase reaction in a high vacuum. The FTR technology has passed a challenge test with excellent results and has received the approval of the FDA for PCR contents of up to 50%. The final product is a top-quality raw material for either bottle-to- bottle or packaging applications. There is no down-grading of the valuable polymer. Advantages Recycling technology for food-grade PET packaging Cleaning efficiency has been tested successfully in a challenge test FTR is approved by the US Food and Drug Administration (FDA) for food-contact applications FTR can be integrated into PET production plants Up to 50% recycling material without an adverse effect on product quality Two-step process Elimination of impurities Rebuild to virgin-like PET bottle resin Post consumer flakes Melting Water vapor Flake Processing Glycol Partial depolymerisation Fine filtration Impurities Pre-polymer MTR polycondensation Contaminants Glycol High-viscosity PET bottle resin

8 Uhde Inventa-Fischer GmbH Holzhauser Strasse Berlin Germany Phone Fax Uhde Inventa-Fischer AG Via Innovativa Domat/Ems Switzerland Phone Fax scher.com info@uhde-inventa-fi scher.com