The document is an industrial training presentation on Thermax heater operation and maintenance at Dhunseri Petrochem Limited in Haldia, West Bengal. It provides information about the company, which manufactures PET resin using German technology. It describes the raw materials and two-step process used. It then details some key equipment used - the bucket elevator, hot water pump, plate heat exchanger, Cyclomax, and bag filter. Finally, it discusses maintenance of the Thermax heater and its components to ensure efficiency and prevent breakdowns.

1. INDUSTRIAL TRAINING PRESENTATION
ON
THERMAX HEATER OPERATION & maintenance
COMPILED BY-
RISHABH SINGH
[ ME,4TH YR ]
At
Dhunseri Petrochem Limited,
Haldia ,
West Bengal

2. CONTENTS OF
PRESENTATION

3. ABOUT THE COMPANY
 Dhunseri Petrochem Limited started in 2003 at Haldia, West Bengal
 Its an export oriented unit of Bottle Grade Pet Resin, ASPET
 The plant uses world class German technology known as ZIMMER
 Currently its the second largest domestic PET Resin manufacturer
having a capacity of 200,000 TPA (Tones Per Annum)
 The leading producer is Reliance Industries Limited ( 290,000 TPA)
Brands of
DHUNSERI
Group

4. Raw Materials Used :
• PTA ( Purified Therepthalic Acid )
• MEG ( Methyl Ethylene Glycol )
• IPA
• Catalyst (Antimony Tri Acetate )
• Blue Toner
• Red Toner
• RHB 2
• P - Additives
Final Product : PET (Poly Ethylene Therepthalene)

5. PROCESS ENGINEERING
In processing there are the following two steps:
 Continuous Polycondensation (CP)
 Solid State Polycondensation (SSP)

6. Continuous
Polycondensation(CP)
PTA Tilting
Station
PP-1
DRR
PP-2
Paste Pre-
paration
Vessel
ES-2
Amorpho
us
Chips
Silo
ES-1
PTA
Storage
Silo
Dryer
Blue
Toner
P-Additive
cutter
Gear Pump
Polymer Filter
Distribution Valve
Mess
Paste Pump
(Screw type)
Product
Transfer
Pump
MEG Feed
Pump
Towards SSP
Area
PTA
Day
Silo
IP
A
Gear Pump

7. Solid State
Polycondensation(SSP)

8. THERMAX HEATER
RELATED EQUIPMENTS
The following are some of the Thermax Heater related
equipment's which were installed in the company :
• Bucket elevator
• Hot water pump
• Plate heat exchanger
• Cyclomax
• Bag filter

9. Bucket Elevator
• Bucket elevator are the most
used systems for vertical
transport of bulk, dry, wet and
even liquid materials.
• Designed with various options
of height, speed and
constructive details depending
on the type of material to be
transported.
• They are constructed by pieces
or units to allow to define
efficiently the need of height.

10. Hot Water Pump
 Its a complete unit consisting of
pump, motor, pressure tank &
electronic controller.
 Has corrosion resistant materials,
built in thermal overload, anti-
cycling feature, etc.
 The presence of relief valve does
not allow the pressure to increase
limit of 70 PSI

11. Plate Heat Exchanger
Working principle : channels
are formed between plates &
corner ports so that two media
flow through alternate
channel & thus heat is
transferred and complete
counter flow is created for
highest possible efficiency.
Applications : general
heating and cooling duties.
Heating by means of steam.

12. Cyclomax
 Dust laden gas
enters the upper
cylinder
tangentially &
moves down in
conical paths.
 Centrifugal force
developed results
movement of dust
particles radially
outward.
 Proper
consideration of
various factors
ensure a high
collection
efficiency,
enhanced product
and very low
emission levels.

13. Bag Filter
It is an apparatus used to separate dust
from dust laden air by filtering through
fabric filter.
Features:
 Quick dust blow off by compressed
air
 Constant operation by minimum
fluctuation of pressure loss
 Easy exchange of bag
 Good for high density gas
application
 High efficiency of 99.9%
 Low pressure drop about 80-200
mm Ag
 Can collect fine particles down to
0.1m
 Easy maintenance

14. Maintenance of Thermax Heater
Maintenance of Thermax Heater means maintaining of its parts
regularly. Thermax heater maintenance is mainly done by taking care
of its parts and its components like bucket elevator, Cyclomax, bag
filter, coal and sand conveying system, plate heat exchanger, furnace,
coal handling system, etc.
Maintenance may be of following types :
 Preventive Maintenance
 Breakdown Maintenance
 Predictive Maintenance
Following are some of the maintenance common to various
Thermax Heater related equipment's :
 Regular maintenance of bearings used in various devices
 Maintaining the buckets (choked or not)
 Regularly scrubber the bag and check bag quality
 Check oiling and greasing of adjacent gear box
 Check the tension of belt drives.

15. Conclusion
 The 4 weeks summer training at Dhunseri Petrochem
Limited, Haldia turned out to be a wonderful industrial
experience which not only provided me with the opportunity
to be aware of the different process of manufacturing pet
resin and its maintenance, but also provided me the
opportunity to interact with the experienced personnel’s in
industry on various issues.
 Basically I came across the project ‘Thermax Heater
Operation & Maintenance’, the efficiency can be increased by
providing least heat loss to the surroundings, and use of more
fine, pulverised coal to the furnace and breakdown can be
eliminated by daily maintenance.
 I also found an opportunity to go through various types of
machines, instruments and types of water treatment process
used for production of pet resin at the automated controlled
plant.

16. Thank you and have a nice
day!