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INTRODUCTION

APU is part of finishing area, where


in this section PE powder will be
added with some additives, and will
change the form from powder to
pellet at the end of this unit
Powder / pellet is transferred using
pneumatic conveying system
The Advantage of Pneumatic
Conveying

No dust release to environment


Minimum maintenance
High operational efficiency
Extra cooling, drying, etc, can be
realized easily
Disadvantage

Limited by capability of blower


(distance, pressure drop, capacity)
Could damage the material because
contact with conveying line
ADDITIVE
and PELLETIZING UNIT

CONSIST :

POWDER CONVEYING SYSTEM

PELLET CONVEYING SYSTEM


EQUIPMENT
F800 : Virgin Powder Surge Silo Cyclo Filter
H800: Virgin Powder Surge Silo
V801 : Rotary below F800
V800: Rotary below H800

F810 : Virgin Powder Surge Silo Cyclo Filter


H810 : Extruder Virgin Powder Feed hopper
V811 : Rotary below F810
F811 : Virgin Powder Feed hopper Cyclo Filter
V812 : Rotary below F811
DIVERTER VALVE

Diverter valve 3V830 accessible


from DCS
Powder from PU can be sent to one of
two silos :
3H810 Via F810
3H800 via F800
F800
Virgin Powder Surge Silo Cyclo Filter

Separate powder and transport air,


powder falls down into H800, air passes
through the bag filter before back to C460
Bag filter cleaned by NM and dust drops
with main powder flow into H800 via V801
Feed :
from PU by pneumatic conveying 3V460 via
V830
H800
Virgin Powder Surge Silo

Capacity : 120 - 160 T ( depend on


bulk density of powder )
Bottom : introduced NL ( FI800 )
H800
VIRGIN POWDER SURGE SILO

Used to accommodate grade changes


product when reactor start up
The content H800 emptied using
Fitted with variable speed rotary valves
V800, so feed rate to H810 can be
controlled
F810
Virgin Powder Bin Bag Filter

Separate powder and transport air,


powder falls down into H810, air passes
through the bag filter before back to C460
Bag filter cleaned by NM and dust drops
with main powder flow into H810 via V811
Feed :
from PU via V830 ( as normal feeding )
F811

Separate powder and transport air,


powder falls down into 3H810, air passes
through the bag filter before back to C460
Bag filter cleaned by NM and dust drops
with main powder flow into H810 via V811
Feed :
from 3H800
H810
VIRGIN POWDER BIN
Main route in normal operation,
Main supply to Main Feeder of 3/4 W810
Supply powder to Master Batch 3/4 M825A/ B
H810 is supported on load cells ( WI810 )
Fitted a high-high level alarm ( LAHH810 ) which
stop the feed inlet
Feeding to extruder

 NORMAL FEEDING
3V460 – 3V830 – 3F810 – 3H810

 CONSEQUTIVE FEEDING
3V460 – 3V830 - 3F800 – 3H800 – 3F811 – 3H810

 TWIN FEEDING
(3V460 – 3V830 – 3F810 – 3H810 ) +
small (3H800 – 3F811 – 3H810)
Feeding to extruder ( cont… )

1. Normal feeding :
Powder directly transferred to H-
810 from D-460
Done when the powder from reactor
already achieved in prime limit
Feeding to extruder ( cont… )

2. Consecutive feeding :
Powder from D-460 transferred to H-800 first and
then to H-810.
Done with the purpose to extrude powder with
FIFO principle.
Powder in H-800 usually has very far difference on
quality compare to fresh powder from D460, so it
could not be mixed with fresh powder to get prime
Example :
Fail of current quality ( PU ), H800 prime quality.
Too fast grade change ( PU reach on Prime ) while H800 old
product
Feeding to extruder ( cont… )

3. Twin Feeding :
Powder from D-460 transferred to
H810 and mixed with powder from H-
800 which has close quality , even the
quality not in blending limit, as long as
it could be mixed and the result is in
prime limit.
Purpose to emptying powder in H800
MASTER BATCH
M825A-B

PE and additive powder are mix in


M825A/B Powder Master Batch
Blenders to give a homogeneous
mixture
Operate under nitrogen with cooling
water on jacket to avoid low melting
point additives sticking to the wall
MASTER BATCH FILLING

Fill Master batch by sequence


Empty blender filled with PE powder using
W821(screw feeder) to V820
Additive added manually via W820A/B Master
Batch Additive Feeder
Filling M/B which has very different formula,
must be flushed first using powder
Master Batch to Extruder

Blended material ( PE powder + additive )


transferred to extruder via W830A/B Powder
Master Batch Weigh Feeder under automatic
DCS control
Ratio flow
MASTER BATCH EQUIPMENT

M825A/B : Powder Master Batch Blender


Mixing Screw and Orbital Arm.
( As arm rotates in the vessel it also rotates itself )
W820A/B : Master Batch Additive Feeder
W-821 : Master batch blender screw feeder
V820 : Diverter valve to M825A/B
F825 : Filter above M825
Cooling Water Jacket
WEIGH FEEDER

W830A/B : Powder Master Batch Weigh


feeder (Mass flow)
W810 : Virgin Powder Weigh feeder
Using spinning dish
W855 : Rerun Pellets feeder
FEEDER

Flow into H840 Extruder Feed


Hopper from H810 is via W810 , this
system required to control feed rate
Have local controller facilities,
required for test purpose /
calibration.
Set point driven from local
Rerun H-855

Pellet Feeding from H-855


Purpose : To re-extrude the unacceptable pellet
to be prime limit pellet by mixing with fresh
powder prime ( Facility to rerun off
specification product )
Pellet that has quality in unacceptable limit but
still in the same grade can be re-extruded via
H-855 then to W855 Rerun Pellets Feeder, as
long as the black spec level not more than the
blending limit and the result still in prime limit
Rerun H-855 ( cont… )

H855 can be filled from transition silo


by C103 or direct from extruder
LAH8552 = + 8 Tones
LALL8553
EQUIPMENT

TYPE : PNEUMATIC CONVEYING


Auxiliaries : Suction / Discharge filters, coolers,
dehumidifiers, dampers

BLOWER ;
Positive displacement type, deliver big quantities with
low diff. Pressure.
Pressure drop depending pipe length
EQUIPMENT ( cont… )

ROTARY FEEDER
Primary function is to deliver pellets into transfer line

DIVERTER
Designed to convey / direct the pellets to desired
destination
Normally one entry, two exits
Two position :
‘through’ – in and outlet, same
‘divert’ - in and outlet, not same line
EQUIPMENT ( cont… )

ELUTRIATOR ( Classifier )
To separate the pellets from dust, fines and streamers
Dust ( lighter than pellets ) is carried away with air
flow to the top of elutriator

CYCLONE
To separate the dust and air conveying
H850Homo Silo
PELLET SURGE HOPPER
H850

Palletized product in pellet surge hopper H850 is


transferred to
Rerun Pellets Bin H855 – start up ( high black spec, deform,
over/under size )
Transition Silo 6H102 – blending limit ( not accepted range )
Homogenization Silo 6H101A/B – prime product

Pellet pneumatic conveying system use 6C101A/B


3H850 to SILO
EQUIPMENT
6S101-3A/B : 6C101A/B Suction Filter
6E101-3 : Pellets Conveying Air Dehumidifier
6S131-3 : Mist Separator
6T101 -3 : Brine Tank
6P102-3A/B : Brine Pump
6C107-3 : Brine Chiller
6C101-3A/B: Dried Pellets Conveying Blower
6E111-3A : Pellets Conveying Air Cooler
6F101-3 : Dried Pellets Conveying Blower
discharge Filter
4H850 to SILO
EQUIPMENT

6S101-3A/B : 6C101A/B Suction Filter


6E101-3 : Pellets Conveying Air Dehumidifier
6S131-3 : Mist Separator
Unused
6T101 -3 : Brine Tank
6P102-3A/B : Brine Pump Before that use for
6C107-3 : Brine Chiller All blower
6C101-4 : Dried Pellets Conveying Blower
6E111-4 : Pellets Conveying Air Cooler
6F101-4 : Dried Pellets Conveying Blower
discharge Filter
LINE UP

Normal Transfer (Same train)


H850 to H855
6V102 - H855
H850 to 6H101A ( Homo Silo A )
6V102 - 6V109 - 6V113-6V103A-H101 A
H850 to 6H101B ( Homo Silo B )
6V102 - 6V109 - 6V113-6V103B-H101B
H850 to 6H102 ( Transition Silo )
6V102 - 6V109 - 6V113-6V103B-H101B
Cross Transfer (Others train)
3H850 to 6H101-4A ( Homo Silo A )
6V102-3  6V109-3  6V113-3 6V103-4AH101-4A

3H850 to 6H101-4B ( Homo Silo B )


6V102-3  6V109-3  6V113-3 6V103-4BH101-4B

3H850 to 6H102-4 ( Transition Silo )


6V102-3  6V109-3  6V113-3 6V103-4BH101-4B
HOMOGENISATION SILO
6H101A/B
In normal operation, product from H850 will be
transferred / collected into homogenization silo
Not only used for storage of pellets, also for
homogenizing the content
Blending pellets is carried out by recycled pellets, using
6C102
Pellets that collected at bottom are re-conveyed to the
top
HOMOGENISATION SILO
( cont… )

Homogenizing is recommended because


reactor output slight vary, it guarantees
the customer to receive quality
polyethylene with same specification
Homogenized pellets from homogenization
silo transferred to Bagging Silo 6H103A/B
using 6C104
HOMOGENISATION SILO
EQUIPMENT

6S102: 6C102 Suction Filter


6E102: Pellet Conveying Air Dehumidifier
6S132: Mist Separator
6C102:Final Pellet Conveying Blower
6E112: Final Pellet Conveying Blower
Discharge Cooler
6F102: Final Pellet Conveying Blowe
Discharge filter
LINE UP

Homogenize pellets in homo silo A


6V105A – 6V106A – 6V104A – 6H101A
Homogenize pellets in homo silo B
6V105B – 6V106B – 6V104B – 6H101B
TRANSITION SILO
6H102
Transition Silo will be used principally during
grade change
Off specification pellets in transition silo are
recycled back to rerun pellets bin H855 for re-
compounding if required, using C103
Blending limit product ( out of accepted range )
will be collect for mixing / blending with other
product to get prime product
TRANSITION SILO
EQUIPMENT

6S103: 6C103 Suction Filter


6E103: Pellet Conveying Air Dehumidifier
6S133: Mist Separator
6C103: Final Pellet Conveying Blower
6E113: Final Pellet Conveying Blower
Discharge Cooler
6S123: Pellets Conveying Inline Filter
LINE UP

Transfer pellets from transition silo to H855 Rerun Pellets Bin


6C103 – 6V108 – H855

Transfer pellets from Transition Silo to Homo Silo A


6V114 – 6V108 – 6V104A- 6H101A
Transfer pellets from Transition Silo to Homo Silo B
6V114 – 6V108 – 6V104B- 6H101B

6C103 – 6V108 – 6V104B – Homo silo B


Transition silo To Bagging Silo

Transition silo to H-103(same Train)


6V114-36V108-36V115-36V112-3
6V114-36V110-36V111-36H103-3A/B

Transition silo to H-103(Other Train)


6V114-36V108-36V115-36V112-4
6V112-4
6V114-46V110-46V111-46H103-4A/B
BAGGING SILO
6H103A/B
Homogenized pellets from homogenization silo
transferred to Bagging Silo 6H103A/B using 6C104
via classifier 6H104, where pellets are de-dusted
Can receive homogenized pellets from other train
Product pellets in bagging silo are fed to bagging
machine package 6W110 by gravity flow
BAGGING SILO
EQUIPMENT

6S104 : 6C104 Suction Filter


6E104 : Pellet Conveying Air Dehumidifier
6S134 : Mist Separator
6C104 : Final Pellet Conveying Blower
6E114 : Final Pellet Conveying Blower
Discharge Cooler
6F104 : Final Pellet Conveying Blower
Filter
BAGGING SILO
EQUIPMENT ( cont… )

6C106 : Fan for Elutriator (vacuum)


6S114 : Elutriator
6V110 : Elutriator Discharge Rotary valve
6V111 : Elutriator Discharge Diverter valve
6S115 : Dust Collector
6H104-3 : Dust collection hopper
TRANSFER CONVEYING

 LINE UP

 Transfer pellets from Homo silo A to Bagging silo


6C104 – 6V105A-6V106A– 6V115-6V112-6H104 – 6V111 –
Bagging silo A/B

 Transfer pellets from Homo silo B to Bagging silo


6C104 – 6V105B-6V106B– 6V115-6V112-6H104 – 6V111 –
Bagging silo A/B
Cross transfer Train 34

 LINE UP

 Transfer pellets from Homo silo 3A to Bagging silo


4A/B
6C104-3 – 6V105-3A-6V106-3A– 6V115-3
6V112-46H104-46V111-4 Bagging silo A/B

 Transfer pellets from Homo silo 3B to Bagging silo


4A/B
6C104-3 – 6V105-3B-6V106-3B– 6V115-3
6V112-46H104-46V111-4 Bagging silo A/B
Cross transfer Train 43

 LINE UP

 Transfer pellets from Homo silo 4A to Bagging silo


3A/B
6C104-4 – 6V105-4A-6V106-4A–6V115-4 
6V112-36H104-36V111-3 Bagging silo A/B

 Transfer pellets from Homo silo 4B to Bagging silo


3A/B
6C104-4 – 6V105-4B-6V106-4B– 6V115-4
6V112-36H104-36V111-3 Bagging silo A/B
Detainting
Detainting

To remove odour (during Organoleptic


grade)
Introduce hot air via C105 and Do
blending during 12 hours
SILO WASHING
Purpose ;
To avoid an excessive accumulation dust or
streamer generation deposit in the silo
To avoid product contamination each other
Grade Change
6P101 : Silo Cleaning Pump
Desalinated water, flow : top silo to bottom
of silo (low point)
SILO DRYING

6S105 : 6C105 Suction Filter


6C105 : Silo Drying Blower
Steam Low : To heat up air
Hot air flow : from bottom to top of
silo

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