Zimmer® Polymer Technology

Polyester Continuous Process

 Polyester polycondensation plant

Introduction
Since 1962 continuous polycondensation plants for the pro-
duction of polyethylene terephthalate (PET) has been build
with Zimmer® proprietary technology; total built capacity is
nearly nine million tons/year.

This success, which is currently increasing, results from a

fast innovation cycle supported by
■ Several plant start-ups per year incorporating improve-

ments from ongoing R&D and operational experience

■ Proprietary design for key equipment

■ Close contacts to clients and markets.

Continuous technology is used for big plant capacities and

technological reasons e.g. direct spinning of the polymer
melt into fibers/filaments. The economic advantage
increases with higher capacities.

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Process principles
For continuous production PTA (pure terephthalic acid), The vacuum generating system is operated with EG from
MTA (medium purified terephthalic acid) or DMT (dimethyl the process. The pre-polycondensation product is dis-
terephthalate) can be used as raw materials together with charged into the final polycondensation reactor.
EG (ethylene glycol). The polycondensation takes place under increased tempera-
The main process steps are the raw material preparation, ture and increased vacuum. As part of a patented, glycol
the esterification/transesterification, the pre-polycondensa- management and vacuum system, an EG driven jet is used
tion and the polycondensation. The PTA is mixed with EG to facilitate raw material recovery and contribute to environ-
and catalyst solution in a paste and fed into the esterifica- mental protection. The polyester melt obtained in the reac-
tion system. The esterification takes place under light over- tor is processed either directly into fibers/filaments or into
pressure by splitting off water. When DMT is used, the DMT chips.
melt and catalyst are pumped with EG into the transesterifi-
cation system, where the reaction takes place under atmos-
pheric pressure by splitting off methanol. The materials split
off are rectified in a direct connected stand-alone column
system for raw material recovery compatible with the envi-
ronment.
In the final part of the vertical cascade compact reactor the
pre-polycondensation reaction is performed under vacuum.

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 additive
catalyst chips
systems

PTA raw material esterification poly- additive

EG preparation pre-polycondensation condensation systems

vacuum direct
system spinning

Polyester continuous technology

Key features of Zimmer® two reactor

technology
Two reactor process In addition:
■ Optimized residence times, facilitating capacities up to ■ Low raw material consumption

1500 tons/day ■ Low DEG-formation

■ Low product temperature profile ■ Bright colour (L-value)

■ Low temperature difference between product and heat ■ Low yellowness (b-value)

transfer medium ■ Low oligomer content

■ Low catalyst contents ■ Low acetaldehyde content

■ Optimized process cascading resulting in more efficient ■ Reduced reformation of acetaldehyde in further

conversion of raw materials and greater product homo- processing

geneity ■ Very narrow residence time distribution

■ Low energy consumption ■ Very uniform product with excellent rheological

■ Less space requirement behavior

■ Highest plant availability

■ Excellent operating economics

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Plant design
Esterification/Pre-polycondensation Vacuum systems
■ One vertical cascade reactor for smooth reaction The vacuum generating system consists of jet pumps driven
progress up to 1500 t/d plant capacity by process EG and a liquid ring pump with associated EG
circulation systems for cooling. This EG-jet system is very
Final polycondensation reactor reliable so it is used as a common vacuum generating sys-
■ Specially designed and patented horizontal Disc Ring tem for both pre-polycondensation and final polycondensa-
Reactor (DRR) with single shaft sealing operating as a tion steps. All split off glycol from the process is recycled in
multistage cascade system, guaranteeing narrow reten- this closed circulation system. This results in significantly
tion time spectrum and high uniformity of the product reduced water consumption and waste water treatment as
■ Low entrainment, high vacuum integrity and low main- well as elimination of gaseous emissions when compared to
tenance requirements steam-jet systems.
■ Low inlet temperature required; mild temperature

increase occurs in the last third of the reactor Avoidance of oxygen intrusion
■ Low jacket and wall temperature can be maintained by Nitrogen blanketing of the process prevents oxidation
heat input from product shearing rather than by heat degradation of the product.
transfer The integrity of the nitrogen blanketing is achieved by
■ Thermal stress to polymer is minimized proven design features (ex: reduced number of flanges and
■ For higher viscosities a special double drive disc ring seals), resulting in higher quality product and greater plant
reactor (DD-DRR) featuring the same advantages as the availability.
single drive reactor is used.

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Supplementary technology
availability
Product formulas b) Solid state polycondensation for specialities
Proven formulas and additive packages designed to meet In order increase viscosity to high values and removing
specific polymer characteristics for textiles, bi-oriented films, volatiles a solid state polycondensation is available at
packaging, bottles and engineering plastics are available. capacities up to 1000 tons/day.

a) Delustering and additive systems c) Dealdehydisation (DAH)

■ Suspension and post-polycondensation masterbatch DAH technology removes volatiles as acetaldehydes
delustering systems of feed material with high IV. Capacities up to 1000
■ In-line and masterbatch additive systems for film tons/day in one line are available.
grades and special additives as liquid or solid

Plant capacities Tons/day Applications

Medium viscosities Vertical cascade 90 – 1500 Textile filaments, staple fibers, BCF
0.50 – 0.66 IV reactor and disc carpet yarns, feed materials for solid
ring reactor state polycondensation for specialities
High viscosities Vertical cascade reactor < 1000 Industrial yarns,
0.66 – 0.96 IV and double drive disc engineering plastics
ring reactor
DAH tower < 1000 Packaging & bottles
Very high viscosities Vertical cascade reactor < 100 Tire cord, rigid engineering plastics
0.90 – 1.00 IV and disc ring reactor and
self cleaning reactor
Products Polymer melt or chips

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 Polyester disc ring reactor

Summary
Polyester markets ask for several requirements to select an In particular, the advantage of continuous PET polyconden-
appropriate technology and engineering package. Those sation process is mainly given by very smooth and moderate
requirements include: operational conditions, providing easy handling of the plant
■ Minimum investment and operating costs per unit of and stable operation. The reliability and high technical stan-
capacity (economies of scale) dard of the operating equipment has been proven in many
■ High capacities with optimum operational flexibility plants and the process with its key units, the Zimmer® reac-
■ Consistent and market-leading polyester product tors and the total internal recycling, is recognized by impor-
quality tant PET producers as being the best polycondensation
■ Environmental compatibility technology yet available.
■ Optimum engineering execution with fastest time-to-

market
■ High reliability, up-times >3 years

Therefore, the Zimmer® polyester production processes

combine a sophisticated and proven process philosophy
with innovative technologies and strong capabilities in plant
engineering.

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Lurgi is a leading technology company operating worldwide
in the fields of process engineering and plant contracting.
The strength of Lurgi lies in innovative technologies of the
future focusing on customized solutions for growth markets.
The technological leadership is based on proprietary tech-
nologies and exclusively licenced technologies in the areas
gas-to-petrochemical products via synthesis gas or methanol
and synthetic fuels, petrochemical, refinery technology and
polymer industry as well as renewable resources/food.

Lurgi is a member of the Air Liquide Group

4010e/08.08/5

Lurgi GmbH
Lurgiallee 5 · 60439 Frankfurt am Main · Germany
Phone: +49 (0)69 5808-0 · Fax: +49 (0)69 5808-3888
E-mail: [email protected] · Internet: www.lurgi.com