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Uhde Inventa-Fischer to build large scale PET resin plant in Russia

Feb. 19, 2007 - At the end of September 2006 Uhde Inventa-Fischer has been awarded a contract by the Russian company Alco-Naphtha LLC for a large-scale PET resin plant. The new PET resin plant, which will have a capacity of 240,000 tonnes per year, will be located at Alco-Naphtha’s site in Kaliningrad. It will be the biggest single-line polyester plant in all Europe.

Uhde Inventa-Fischer’s scope of supply and services includes the licence, the basic and detail engineering, supply of all equipment and supervision of the erection and commissioning activities. Uhde Inventa-Fischer announced this contract already in October 2006, referring to a project in Eastern Europe.

Uhde Inventa-Fischer joins forces with its Russian sister company OAO Uhde in Dzerzhinsk to provide Alco-Naphtha with important services locally. Alco-Naphtha has chosen OAO Uhde to supply the permit engineering in accordance with Russian statutory regulations and the outside-battery-limit engineering for the plant site near the city of Kaliningrad.

The new plant will use Uhde Inventa-Fischer’s proprietary 2-Reactor (2R) technology and Melt-To-Resin (MTR®) process to produce high-quality PET resin grades for Russia and other markets which can be processed into PET bottles and containers for carbonated soft drinks (CSD), beer, water, juice, sport drinks, ready-to-drink (RTD) tea etc.

The 2R technology simplifies the polycondensation process and the plant layout compared to conventional multiple reactor technologies, which results in appreciable reductions of investment and operating costs. The first reactor is an innovative tower reactor, the so-called ESPREE® reactor, that replaces the first three reactors of a typical conventional polycondensation plant. The ESPREE® reactor comprises of several reaction sections and has a total height of up to 30 m. It uses, besides other new features, a liquid film flow on the inner surfaces of vertical tubes to produce the pre-polymer. Since there is intense mixing caused by physical phenomena within the different reaction sections, agitators and the associated seal systems are avoided. The advantages are lower energy and maintenance costs, higher raw material yield and superior quality.

The new plant in Kaliningrad will be the first plant in Eastern Europe based on the MTR® process that is said to be the most advanced process for PET resin production not only in view of the outstanding product quality, but also due to its higher efficiency.

The MTR® process offers a cost-effective alternative to conventional production processes because it eliminates expensive solid state postcondensation (SSP). The required high-molecular PET material for bottle production up to an intrinsic viscosity of 0.85 dl/g is obtained on the direct way of polycondensation in the melt phase by means of a special high-viscosity finisher, the so-called DISCAGE® MV reactor that has a lot of benefits due to its unique design. The high mechanical stability of the horizontal cage-type agitator allows polycondensation at low temperature and forced transport of the polyester melt from inlet to outlet.

Overall, the 2R-MTR® technology allows to cut the cost of converting the raw materials purified terephthalic acid (PTA) and ethylene glycol (EG) into PET resin by remarkable 28% compared to conventional polycondensation technologies.

This new contract marks another milestone in Uhde Inventa-Fischer’s activities in Eastern Europe following the successful start-up of the PET resin plant of the Russian company Senege New Polymers Plant Ltd. near Moscow and execution of a contract for a polyester plant for the Belorussian company OAO Mogilevkhimvolokno in Mogilev. Both of these two production plants are also based on Uhde Inventa-Fischer’s proprietary 2-Reactor technology.