Project Synopsis

Develop an FEL-2 level process design for a compounding line in the production of a specialty polymer.

Project Summary

Process Engineering Associates, LLC (PROCESS) was contracted by the client, a US chemical manufacturing concern, to develop an FEL-2 level process design for a Polymer Compounding Line.  The project scope covered these Inside Battery Limits (ISBL) facilities for transforming polymer base resins to their final, formulated, and pelleted form:

  • Polymer Base Resin and Additive Handling and Mixing
  • Extrusion and Pelleting
  • Final Product Classifying and Packaging (Bagging and Bulk Loading)
  • Extruder Vent Handling and Dust Collection.

The client provided the desired final product formulations and example process design information for a similar plant already in operation.  The process development work included applying this basic process information to prepare the following FEL-2 deliverables:

  • Process Flow Diagrams (PFDs)
  • Material Balances – Summarize the flows of Polymer base resins and additives to the Extruder on both an hourly average and batchwise basis, and the expected flows around the Extruder Vent Handling system
  • Equipment List – Identify all major equipment items and their anticipated performance requirements
  • Equipment Arrangement Drawings – Present how the major equipment items can be laid out within the existing building based on typical vendor data (vertical stackup and plan-view layout)
  • Piping and Instrumentation Diagrams (P&IDs)
  • Equipment Datasheets – Detail performance requirements, operating conditions, and material properties for major equipment items including loss in weight feeders, hoppers, conveying systems, pelletizers, etc.

Industry Type

Polymer Production  

Utilized Skills

  • Process design
  • Polymer processing equipment design and layout
  • Process dust collection system design.

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