POLYESTER RESIN.docx

Pilot Plant Requirements (100–200 tons/year): the one Units with volume 1 m³ Reactor Batch reactors (chemically resistant, capable of 250°C & vacuum conditions). Mixing system for high-viscosity media

Industrial Reactor Options:

Polymer resin pilot system

Pilot Plant Requirements (100–200 tons/year): the one Units with volume 1 m³ Reactor Batch reactors (chemically resistant, capable of 250°C & vacuum conditions). Mixing system for high-viscosity media.

Cooling conveyor belt & granulation system for "pale chips." Must replicate full-scale production to ensure product compliance.

Lab Scale reactor the volume 5Lwith Filling column vertical condenser, horizontal condenser, and Thermostats, and head mixer, and vacuum pump.

1. Reactor Material

The reactors are made of AISI 316 stainless steel.

2. Process Material and Viscosity
The final product is polyester resin. The resin viscosity ranges from 2000 to 6000 cP at 200°C.

3. Feeding Materials and Bulk Density  
The materials to be fed into the system are: 

3.1 Neopentyl glycol (NPG) 

Specific gravity~1.06 g/cm³ at 20 °C

Bulk density ~660–690 kg/m³ ( at 20^оС )

3.2 Ethylene glyco

Density ~1.11 g/cm³ at 20 °C

3.3 Terephthalic acid (PTA)

Density: ~1.5 g/cm³ (solid)

Bulk density: ~1.12 g/cm³ ≈ 1120 kg/m³ (powder)

3.3 Isophthalic acid (PIA)

Density: ~1.526 g/cm³ (solid)

Bulk density: 800–1100 kg/m³ (powder)

3.4 Adipic acid

Density: ~1.36 g/cm³

Bulk density: ~700 kg/m³

4. P&ID and Instrumentation Diagram Description 

Solvent-free polyester resin production process 

Solvent-free polyester resin is an environmentally friendly resin without volatile organic solvent (VOC) in the production process, mainly through the following steps:

4.1 Raw material selection 

4.1.1 Polyol: such as ethylene glycol, propylene glycol, neopentyl glycol, etc

4.1.2 Polyacid：: such as phthalic anhydride (PA), interphthalic acid (IPA), adipic acid, etc. 

4.1.3 Catalyst：: such as tetrabutyl titanate, zinc acetate, etc

4. 1.4 Additives: such as antioxidants, UV stabilizer, etc.

4.2 Esterification reaction

4.2.1 Polyols and polyacids are added to the reactor in proportion.

4.2.2 Esterification is performed by heating to 180–220 °C under nitrogen protection.

4.2.3 The water generated during the reaction is discharged through a fractionation column or a vacuum system.

4.2.4 The reaction progress is monitored by detecting acid value (AV) and hydroxyl value (OHV) until the target value is reached. 

4.3 ondensation polymerization

4.3.1 After esterification, the temperature is raised to 220–250 °C for condensation reaction.

4.3.2 Molecular weight is increased by removing residual water and small molecule byproducts under reduced pressure (vacuum).

4.3.3 The reaction endpoint is controlled to ensure molecular weight and viscosity requirements.

5. Working Space Dimensions, Shape, and Layout Requirements Installation layout: the reactor system is expected to be two-level, with an upper platform for access and maintenance. 

6. Automation Level
At this stage, we are inclined toward implementing a PLC-based control system for the pilot polyester resin unit.

6.1 A human-machine interface (HMI) for operator interaction (setpoints, alarms, visualization)

6.2  Automation of key parameters (temperature, pressure, vacuum, mixing speed)

6.3 Manual or semi-automatic handling of raw material feeding and product discharge.