Polymers 1 Department is the core of GRS production, enabling the manufacture of the innovative GRS emulsion polymers. Equipped with 4 synthesis reactors (14,000 liters each) plus a 2,500-liter pilot reactor, it is used by GRS both for production of QualiFloc series “water-in-oil” emulsion polymers and for synthesis of other solution polymers and resins.
The pilot 2,500-liter reactor, with its most advanced utilities, has proven invaluable importance in the manufacture of experimental, high-technology, synthesis products while providing the chemical insight required for industrial scale-up operations.
Polymers 1 Department provides GRS with a throughput of about 6,000 t/year.
Polymers 2 Department consists of four innovative synthesis reactors which can work under extreme process conditions. The first 4,500-liter is a ceramic reactor, it is used to manufacture aggressive synthetic products under controlled conditions.
This reactor, equipped with the most advanced control systems, ensures operating temperatures above 200°C and enables working under pressurized and absolute vacuum conditions. Electronic meters ensure perfect conduction of chemical reaction.
The second 14,000-liter, reactor is used to manufacture the innovative “Brine Dispersions” water-suspended polymers and water-soluble polymers solvent based. This reactor, equipped with next-generation electronic control systems guarantees the synthesis of high-quality products through optimal control of process parameters.
Recently the department Polymers 2 has been implemented with other two advanced chemical reactors with capacity of 23,000 liters each. The new reactors and their utilities are totally managed through an advanced DCS (Distributed Control System) that is assuring high-quality process and manufactured chemicals.
A control room monitors the whole Department through computer-aided systems.
Polymers 2 Department’s throughput is about 10,000 t/year.
Reactors technical data
|Reactor name||Capacity [m3]||Max temperature [°C]||Max pressure [Bar]||material||Condenser type||Electronic controllers and record||Stirring speed||Filtering||Other|
|R1||10||130||0.9||INOX AISI 316||70 - 120||AZO 185 µm|
|R2||15||130||0.9||INOX AISI 316||Reflux and condensate recovery||T - P - ΔT||70 - 120||AZO 185 µm|
|R3||15||130||0.9||INOX AISI 316||T - P - ΔT||70 - 120||AZO 185 µm|
|R4||15||130||0.9||INOX AISI 316||T - P - ΔT||70 - 120||AZO 185 µm|
|R5||2.5||220||4.0||INOX AISI 316||Reflux and condensate recovery||T - P - ΔT||from 0 to 150 (inverter)||AZO 185 µm||4 automated feedig lines for catalyst|
|R6||5||200||6.0||GLASS LINED||Reflux and condensate recovery||T - P - ΔT||from 0 to 150 (inverter)||AZO 185 µm||2 automated feedig lines for catalyst|
|R7||15||200||6.0||INOX AISI 316||Reflux and condensate recovery||T - P - ΔT||from 0 to 150 (inverter)||AZO 185 µm||4 automated feedig lines for catalyst|
|R8||24||120||0.5||AISI 316 L||None||T – P - ∆T||5 – 100||AZO 185 μ||4 automated feeding lines for chemicals|
|R9||24||120||0.5||AISI 316 L||Reflux and condensate recovery||T – P - ∆T||5 – 100||AZO 185 μ||2 automated feeding lines for chemicals|
Fuel combustion additives
In this department GRS is manufacturing additives for thick fuel oils and coals, which are then sold all over the world.
These additives enhance the combustion process while minimizing the environmental impact and improving the thermal efficiency.
The plant consists of two rough slurry homogenisation vessels and three (steel ball) micronisation mills and has an average annual throughput of 4,500 tonnes of finished product. It is then sold in various packages or in bulk, according to the customer’s needs.