UFLEX LIMITED

Practice School 1

IMROVE BATCH REACTOR OF TEMPERATURE CONTROL

Submitted to: Submitted By:Dr. NEHA SHARMA SANA PERWEEN

UFLEX LIMITED

• UFLEX Limited is India’s largest and fastest-growing flexible packaging company.

• Headquartered in NOIDA, the Company has manufacturing facilities in India and Dubai. It has offices in UAE, Europe & North America as well, and has significant market presence in more than 85 countries.

Batch Reactor Temperature Control

Fast heat up or cooldown to a new set point withoutoscillation and with minimum over-shoot.

hold temperature within a certain band around the set point,preferably without oscillation.

Proper mixing of temperature during reaction.

BATCH REACTOR

FORMATION OF POLYOL

When excess diol react with acid in the presence of specific catalyst form the polyester polyol.

FLOW DIAGRAM OF POLYOL REACTOR

P-COD 1152SP

CHARGING TIME 2hr

REFLEX TIME 1hr

THERMOPAK SETTING 250-280

REACTOR TEMP FROM CHARGING TO REFLEX 180-154

REACTOR TEMP FROM REFLEX TO 1ST SAMPLE OF ACID VALUE 154-195

COLUMN TEMP FROM REFLEX TO 1ST SAMPLE OF ACID VALUE 75-148

QC PARAMETER OF ACID VALUE >1

WATER VACCUM TIME 0.3hr

MAX WATER VACCUM ACHIEVED 0-620mmhg

OIL AND BOOSTER PUMP TIME 0.1hr

MAX VACCUM ACHIEVED 700

FINAL QC PARAMETER av-0.97,oh-36.76

R-42 ADD AT TEMP 72

REACTOR RPM @37TEMP MAINTAINED AT 82-87 82-87@37 RPM

REFLEX CONTINUOUS/BREAK continuous

1ST PART NCO FREE 5.3hr

QC PARAMETER VISCOSITY 3270

2ND PART NCO FREE 4.45hr

QC PARAMETER VISCOSITY 4460

FINAL RESULT 4780

ACTUAL DATA OF1152SP PRODUCT

DATE 23-May-16 28-May-16 7-Jun-16 8-Jun-16

POLYOL CODE 1152SP-23 1152SP-28 1152SP-16 1152SP-8

TOTAL POLYOL RM 4668.12 4668.12 4668.12 4668.12

1ST DRT 174.1 185.1 177 188

2ND DRT 494 483 491.1 470

TOTAL DRT 668.1 668.1 668.1 658.12

POLYOL PRODUCTION 4000 4000 4000 4010

%YIELD OF POLYOL 85.68% 85.68% 0.8568 85.90%

TOTAL TIME TAKEN BY POLYOL 19:00 19:30 19:30 18:30

POLYOL VISCOSITY 690cps 846cps 740cps 660cps

POLYOL ACID VALUE >1 0.89 0.93 0.88

POLYOL OH VALUE 36.97 33.67 34.9 37.4

TOTAL PU RM 6304.46 6264.902 6262.632 6495.608

PU PRODUCTION 6298 6237 6231.6 6469

%YIELD OF PU 99.89% 99.55% 99.82% 99.59%

TOTAL TIME TAKEN BY PU 17:30 20:00 17:00 22:00

PU SOLID CONTENT 65.98% 65.95% 66.12% 65.17%

PU VISCOSITY 4740 5090 4390 4320

PRODUCTION DATA OF 1152SP PRODUCT

TIME

REACTOR TEMP 23-

MAY

REACTOR TEMP 28-

MAY

REACTOR TEMP 7-

JUNE

REACTOR TEMP 8-

JUNE

00:00 124 179 140 186

00:30 70 77 74 74

01:00 92 68 84 96

01:30 110 150 117 130

02:00 145 142 158 161

02:30 158 160 167 176

03:00 173 173 184 190

03:30 187 187 193 198

04:00 193 198 199 200

04:30 200 201 203 201

05:00 202 201 205 205

05:30 203 205 176 179

06:00 196 192 196 193

06:30 199 196 199 200

07:00 196 197 199 201

07:30 199 196 199 202

08:00 199 197 198 201

08:30 199 197 198 201

09:00 199 196 198 201

POLYOL REACTOR TEMPERATURE

09:30 199 196 198 201

10:00 199 196 198 201

10:30 198 195 198 201

11:00 199 196 198 201

11:30 198 196 198 201

12:00 199 197 198 202

12:30 199 197 198 202

13:00 199 197 199 202

13:30 199 197 199 202

14:00 199 197 198 202

14:30 199 198 199 202

15:00 199 198 199 203

15:30 199 198 200 203

16:00 200 198 200 203

16:30 200 199 200 203

17:00 200 198 200 201

17:30 200 198 200 198

18:00 188 198 196 197

18:30 186 199 195 195

19:00 172 197

19:30 188

20:00 188

TIME

REACTOR TEMP 23-

MAY

REACTOR TEMP 28-

MAY REACTOR TEMP 7-JUNE REACTOR TEMP 8-JUNE

0

50

100

150

200

2500

:00

0:3

0

1:0

0

1:30

2:0

0

2:3

0

3:0

0

3:30

4:0

0

4:3

0

5:0

0

5:30

6:0

0

6:3

0

7:0

0

7:30

8:0

0

8:3

0

9:0

0

9:3

0

10:0

0

10:3

0

11:0

0

11:3

0

12:0

0

12:3

0

13:0

0

13:3

0

14:0

0

14:3

0

15:0

0

15:3

0

16:0

0

16:3

0

17:0

0

17:3

0

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19:0

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19:3

0

20

:00

TE

MP

ER

AT

UR

E(D

eg

ree

Ce

lciu

s)

Time(min)

POLYOL REACTOR TEMPERATURE

REACTOR TEMP 23-MAY REACTOR TEMP 28-MAY REACTOR TEMP 7-JUNE REACTOR TEMP 8-JUNE

POLYURETHANE REACTOR

polyurethanes are made from the reaction between an isocyanate and a polyol.

The first step of this reaction results in the chemical linking of the two molecules leaving a reactive alcohol (OH) on one side and a reactive isocyanate (NCO) on the other These groups react further with other monomers to form a larger, longer molecule.

FLOW DIAGRAM OF POLYURETHANE REACTOR

POLYUREATHANE REACTOR TEMPERATURE

TIME PU TEMP 23-MAY PU TEMP 28-MAY PU TEMP 7-JUNE PU TEMP 8-JUNE

00:00 37 20 40 30

00:30 139 130 137 145

01:00 124 120 120 120

01:30 106 106 106 105

02:00 92 190 90 96

02:30 78 86 80 89

03:00 59 70 57 77

03:30 72 55 65 78

04:00 78 65 80 81

04:30 84 80 85 82

05:00 86 82 85 84

05:30 87 83 86 85

06:00 86 83 87 85

06:30 86 83 90 84

07:00 86 84 89 85

07:30 87 86 89 86

08:00 85 87 88 85

08:30 86 87 88 85

09:00 86 88 89 85

09:30 85 88 87 85

10:00 85 88 87 85

11:00 86 88 89 84

11:30 86 87 91 84

12:00 86 87 88 84

12:30 86 86 58 85

13:00 59 86 57 85

13:30 55 72 58 85

14:00 50 63 57 85

14:30 50 59 57 85

15:00 50 57 52 85

15:30 50 56 52 85

16:00 50 56 52 85

16:30 49 54 52 85

17:00 49 54 51 58

17:30 49 55 63

18:00 56 53

18:30 56 51

19:00 56 52

19:30 55 53

20:00 52 52

20:30 53

21:00 53

21:30 52

22:00 51

10:30 86 87 87 85

TIME PU TEMP 23-MAY PU TEMP 28-MAY PU TEMP 7-JUNE PU TEMP 8-JUNE

0

20

40

60

80

100

120

140

160

180

200

TE

MP

ER

AT

UR

E(D

eg

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Time(min)

POLYURETHANE REACTOR TEMPERATURE

PU TEMP 23-MAY PU TEMP 28-MAY PU TEMP 7-JUNE PU TEMP 8-JUNE

PROBLEM IDENTIFIED

Oscillatory tuning of the reactor temperature controller. Oscillatory tuning of the jacket temperature controller. Excessive dead zone in the jacket split range logic; and

Control valve setup problems. Power cut off is main problem. Excess amount of acid input .

THANK YOU