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8/15/2019 Anas Final Internship Report.pdf
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September 11, 2014
INTERNSHIPREPORT
IBRAHIM FIBRES
LIMITED38KM, Faisalabad Sheikhupura Road,
Faisalabad
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SUBMITTED TO
Mr. Raza Ali Alvi
(Manager Training & Development)
SUBMITTED BY
Anas Bin AshrafBS Chemical Engineering, Third Year
National University of Sciences and Technology
(NUST), Islamabad
Zaid Ashraf RanaBS Chemical Engineering, Graduate
National University of Sciences and Technology
(NUST), Islamabad
Imran RasheedBS Chemical Engineering, Final Year
University of The Punjab (PU), Lahore
Amina MehmoodBS Chemical Engineering, Final Year
National University of Sciences and Technology
(NUST), Islamabad
Aqsa KhalidBS Polymer Engineering, Final Year
University of Engineering and Technology
(UET), Lahore
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“ In The Name of Allah; The Most Beneficent, and The Most Merciful ”
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“ Knock, And He'll open the door
Vanish, And He'll make you shine like the sun
Fall, And He'll raise you to the heavens
Become nothing, And He'll turn you into everything.”
( Rumi )
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Table of ContentsAcknoledgments………………………………………………………………………………………10
Preface…….................................................................................................................... ............11
Safety Precautions…..……………………………………… ..……………………………………….12
Company Profile……………………………………………………………………………………….13
Polymer Section………………………………………………………………………………………..17
Product (PET) Introduction......................................................................................................... 18
Process Summary for PET Production ....................................................................................... 18
Mass Balance for PET Process ................................................................................................... 20
What is PTA? ................................................................................................................................ 21
PTA Uses ....................................................................................................................................... 22
PTA Section Division .................................................................................................................... 22
Storage and Handling ............................................................................................................. 22
Charging of PTA ........................................................................................................................ 23
Conveying of PTA ..................................................................................................................... 23
Process Flow Diagram ................................................................................................................ 25
Main Equipment Used ................................................................................................................ 25
Filter .................................................................................................................................. 25
Compressor ................................................................................................................... 26
Cooler ............................................................................................................................. 26
Rotary Feeder ............................................................................................................... 26
Equipment Interlocks .................................................................................................................. 27
Ethylene Glycol ........................................................................................................................... 27
Process Description .................................................................................................................... 27
MEG Sampling............................................................................................................................. 28
MEG Unloading and pumping to Process line ....................................................................... 28
MEG Uses ..................................................................................................................................... 29
Process Flow Diagram ................................................................................................................ 29Equipment Interlocks .................................................................................................................. 30
EGR……………………………………………………………………………………………………….29
Process Description .................................................................................................................... 30
Main Equipment Used ................................................................................................................ 31
Kettle type Evaporator ............................................................................................... 31
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Distillation Column ....................................................................................................... 32
Equipment Interlocks .................................................................................................................. 32
Process Flow Diagram ................................................................................................................ 33
HTM……………………………………………………………………………………………………….33
Process Description .................................................................................................................... 34
BCO Cycle ................................................................................................................................... 36
HTM Cycle .................................................................................................................................... 36
Process Flow Diagram ................................................................................................................ 37
Main Equipment Used ................................................................................................................ 37
Furnace .......................................................................................................................... 37
Conduction ...................................................................................................... 38
Convection ...................................................................................................... 38
Radiation ........................................................................................................... 38
Stack ................................................................................................................................ 38
Pre-Heater (HFO).......................................................................................................... 38
Atomizer ......................................................................................................................... 38
Blower .............................................................................................................................. 39
Economizer .................................................................................................................... 39
Damper .......................................................................................................................... 39
Equipment Interlocks .................................................................................................................. 39
TDO……………………………………………………………………………………………………….40
Process Description .................................................................................................................... 40
Process Flow Diagram ................................................................................................................ 41
TDO Uses ...................................................................................................................................... 42
Catalyst Systems……………………………………………………………………………………….42
Process Description .................................................................................................................... 42
Process Flow Diagram ................................................................................................................ 43
Paste Preparation……………………………………………………………………………………..44
Process Description .................................................................................................................... 44
Process Flow Diagram ................................................................................................................ 45
Main Equipment Used ................................................................................................................ 46
Shank System ................................................................................................................ 46
Paste Mixer ..................................................................................................................... 46
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Esterfication……………………………………………………………………………………………..46
Process Description .................................................................................................................... 46
Temperature and Pressure ........................................................................................................ 47
Residence Time ........................................................................................................................... 47
Acid Number ............................................................................................................................... 47
Process Flow Diagram ................................................................................................................ 48
ES-1 ................................................................................................................................... 48
ES-2 ................................................................................................................................... 49
Polycondensation……………………………………………………………………………………..50
Process Description .................................................................................................................... 50
Process Flow Diagram ................................................................................................................ 52
PP-1 and PP-2 ................................................................................................................ 52
DRR ................................................................................................................................... 52
Main Equipment Used ................................................................................................................ 53
Scrapper Condenser .................................................................................................. 53
Ejector System ............................................................................................................... 53
Vacuum Pump ............................................................................................................. 53
Fume Arrestor ................................................................................................................ 53
MEG Safety .................................................................................................................................. 54
Emergency Overview ................................................................................................. 54
Inhalation ....................................................................................................................... 54
Ingestion ......................................................................................................................... 54
Skin Contact .................................................................................................................. 54
Eye Contact .................................................................................................................. 54
Chronic Exposure ......................................................................................................... 54
Aggravation of Pre-existing Conditions ................................................................. 54
First Aid Measures ......................................................................................................... 55
Inhalation ....................................................................................................................... 55
Ingestion ......................................................................................................................... 55
Skin Contact .................................................................................................................. 55
Eye Contact .................................................................................................................. 55
Note to Physician ......................................................................................................... 55
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PTA Safety .................................................................................................................................... 55
Emergency Overview ................................................................................................. 55
Skin contact .................................................................................................................. 55
Inhalation ....................................................................................................................... 55
Ingestion ......................................................................................................................... 55
Eye contact ................................................................................................................... 56
First Aid Measures ......................................................................................................... 56
Eye ................................................................................................................................... 56
Skin ................................................................................................................................... 56
Inhalation ....................................................................................................................... 56
Ingestion ......................................................................................................................... 56
PET Safety ..................................................................................................................................... 56Emergency Overview ................................................................................................. 56
Inhalation ....................................................................................................................... 56
Skin ................................................................................................................................... 56
Absorption ..................................................................................................................... 56
Ingestion ......................................................................................................................... 57
Eyes .................................................................................................................................. 57
Target Organs ............................................................................................................... 57
Primary Routes of Entry (Exposure) .......................................................................... 57
First Aid Measures ......................................................................................................... 57
Inhalation ....................................................................................................................... 57
Skin ................................................................................................................................... 57
Ingestion ......................................................................................................................... 57
Eyes .................................................................................................................................. 57
Utilities……………………………………………………………………………………………………58
Boiler.…………………………………………………………………………………………………….58
Types ............................................................................................................................................. 58
Components ............................................................................................................................... 59
Process Description .................................................................................................................... 60
Process Flow Diagram ................................................................................................................ 61
Capacities ................................................................................................................................... 62
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Equipment Interlocks .................................................................................................................. 62
Why Nitrogen is Important? ....................................................................................................... 63
Production ..................................................................................................................... 63
Process Description .................................................................................................................... 64
Technical Nitrogen ...................................................................................................... 64
Pure Nitrogen ................................................................................................................ 64
Pressure Swing Adsorption ......................................................................................... 64
Process Flow Diagram ................................................................................................................ 67
Applications ................................................................................................................................ 67
Cooling Towers…………………………………………………………………………………………68
Basics ............................................................................................................................................ 68
Process Description .................................................................................................................... 69
Process Diagram ......................................................................................................................... 70
Water Treatment Plant………………………………………………………………………………..71
Water required: ........................................................................................................................... 71
Equipments .................................................................................................................................. 72
Process Description .................................................................................................................... 73
Process Flow Diagram ................................................................................................................ 74
Chillers……………………………………………………………………………………………………75
Electric Chiller .............................................................................................................................. 75Process Description .................................................................................................................... 77
Compressor Drive...................................................................................................................... 77
Compressor ................................................................................................................................ 77
Condenser .................................................................................................................................. 77
Evaporator .................................................................................................................................. 77
Process Flow Diagram ................................................................................................................ 78
Steam Absorption Chiller ........................................................................................................... 78
Process Description .................................................................................................................... 79
High Temperature Generator (HTG) .................................................................................... 79
Low Temperature Generator (LTG) ..................................................................................... 79
Condenser .................................................................................................................................. 79
Evaporator .................................................................................................................................. 80
Absorber ...................................................................................................................................... 80
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UDY/SPUN TOW ................................................................................................... 97
PSF ......................................................................................................................... 99
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ACKNOWLEDGMENTS
We are thankful to, Almighty Allah for His unlimited blessings and
bounties; for keeping us sane, sound and successful, our Parents for
all their support and trust in us, Ibrahim Fibres Limited for providing
us with this great opportunity which not only give exposure to
industry but also enhanced our technical and professional skills.
Our Instructors Mr. Muhammad Saeed (Area Manager Polymer), Mr.
Haseeb (Deputy Manager Polymer), Mr. Mirza Faqeer (Area
Manager Utilities), Mr. Nouman (Deputy Manager Utilities), Mr. Alam
(Deputy Manager Utilities), Mr. Khalid Ejaz (Senior Deputy Manager
Spinning), Mr. Abaid Ullah (Senior Deputy Manager Textile Lab), Mr.
Jamshaid Yaqub (Senior Assistant Manager Utilities), Mr. Irfan Aziz (HR
Officer), Mr. Salman Qazim (Shift Engineer), Mr. Iftikhar (Shift
Engineer), Mr. Khalid (Shift Engineer), Mr. Bilal (Shift Engineer), Mr.
Zafar Niazi (Shift Engineer), Mr. Umer Mehboob (Shift Engineer), Mr.
Umar Faraz (Shift Engineer), Mr. Ahsan (Shift Engineer), Mr. Hamza
Abbas (Trainee Engineer), Mr. Afnan Amjad (Trainee Engineer) and
Mr. Zain Ul Abideen (Trainee Engineer)
in Ibrahim Fibres Limited for all their guidance and help. We are also
thankful to all the Supervisors, Operators and every Individual who
has helped us even a bit for the completion of this report.
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PREFACE
This report produces a peer based review and learning
outcome about the working and processes of polyester fiber at a
plant. In this report we have tried to mention all those things which we
have learned during our internship. In the first section of this report,
Polymer Section is briefly explained. Basically all the chemicalprocesses needed in the production of polymer melt occur in this
section. Second section of this report is based on Utilities. Utilities are
those things which are necessary to run a plant. e.g. steam, N2 &
compressed air etc. This section is considered as the Heart of the Plant.
Third section of this report deals with Spinning and Fibre line Process.
This section is totally based on physical operations. Spinning is theformation of filaments by the use of spinnerets. Fibre Line is the area
where all of the drawing of fibres is done. Fibres acquire most of their
physical properties in this area. Last section is relevant to testing and
characterization of different materials in the whole plant, Textile Lab.
Safety Precautions about the plant are also discussed in this report.
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SAFETY PRECAUTIONS
In order to avoid the hazards on the plant, company train its employees for the
safe handling and operation of materials and units installed on plant. Even a small
mistake on the plant can cause a serious damage so man, machine & material is
very important.
Personal Protection Equipments (PPEs) must worn in the plant premises.
Smoking is strongly prohibited on all areas of the plant because at different
places different flammable materials are under process and some
leakages may occur and so serious damage can occur.
Over speeding is prohibited on the roads because staff is always crossing
the roads and also tanks with explosive materials are present at different
places and anything hitting them may cause a serious danger.
Mobile phone is not allowed in plant area because electromagnetic waves
may disturb the sensitive control system.
For the training of internees, schedules are issued that means that for every
unit some guide is provided for the specific period of time and we are not
allowed to go in any area according to our desire.
Yellow marks are there on the steps that are odd as compared to other to
prevent injury of workers.
Yellow borders are also provided in front of computer control systems to
prevent the tripping of systems as they are very sensitive.
MSDS (material safety data sheets) are provided with every material for the
safe handling and storage of the materials.
Different water, gas and sand exhaust systems are provided for overcoming
fire.
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COMPANY PROFILE
Ibrahim Fibres Limited Company was established in 1947 in Faisalabad, Pakistan
as a cloth trading business. In 1980, Ibrahim Textile Mills Limited was established
under the form of a manufacturing blended yarn. In 1982 and 1987 two more
companies were established (A.A. Textiles Limited and Zainab Textile Mills Limited).
In order to improve the efficiency and quality of its manufacturing units that
require a continuous uninterrupted supply of electricity, the Ibrahim Group has
established its Power Generation plant and now it is being expanded to cater for
the expansion of its manufacturing units. Power generating capacity of the
project is 31.8 MW based on heavy fuel oil. The plant and machinery of the project
comprises of 6 furnace oil generating sets, each having a capacity to produce
5.3 MW, supplied by Nigata Engineering Company, Japan. All these
manufacturing companies have now been merged into Ibrahim Fibres Limited.
Ibrahim Fibres Limited is incorporated in Pakistan as a public limited company
under the Companies Ordinance, 1984 and is listed on Karachi and Lahore Stock
Exchanges in Pakistan. The principal business of the Company is manufacture and
sale of Polyester Staple Fibre and Yarn. The registered office of the Company islocated at 1-Ahmed Block, New Garden Town, Lahore. The manufacturing units
are located at Faisalabad- Sheikhupura Road, in the Province of Punjab.
Allied Bank Limited
The consortium of Ibrahim Leasing Limited and Ibrahim Group assumed the
control of the Allied bank in August 2004 by injecting Rs 14.2 billion into the capital
of Allied bank for acquiring 325 million additional shares. Today Allied Bank's paid
up Capital & Reserves amount to Rs. 10.5 billion, deposit exceeded Rs. 143 billion
and total assets equal Rs. 170 billion.
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The Allied Bank's story is one of dedication, commitment to professionalism,
adaptation to changing environmental challenges resulting into all round growth
and stability, envied and aspired by many.
Polyester Fibre Project
The Polyester Fibre Project is based on the engineering and technology supplied
by Zimmer AG Germany, who are market leaders in the Polyester Polymer
capacities supplied worldwide representing nearly 30% share in the world market.
The plant is equipped with Provox plus Distributed Control System (DCS) using SRX
process controllers providing a foundation for real time, effeicient and accurate
control and monitoring of the process of entire plant through ComputerIntegrated Manufacturing (CIM).
The Provox plus data provides access to historical process data for monitoring and
analyzing process conditions. Intelligent alarming techniques help enhanced
operator control capability to evaluate changing conditions and to respond
quickly to any process changes. The plant has one to one redundancy starting
from process control units up to all input/output modules enabling smooth and
consistent operation of the plant. The designed capacity of the project,
consumption of raw materials, utilities and quality of finished products are
guaranteed by German supplier.
Polyester Fibre Project IFL-l
Initiated in 1994 and operational since December 1996, Plant I has a capacity to
produce 200 tons/day of PSF in two lines of 100 tons/day each. Based on 24
hours/day operations of the poly condensation and spinning plant and on 20
hours/day operation of fiber lines, the installed annual manufacturing capacity of
the plant 70,000 tons of PSF.
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Polyester Fibre Project IFL-ll
This plant has a single polymer line of 410 tons/day and three spinning and staple
fibre processing lines, each having capacity of 132 tons/day. The installed annual
manufacturing capacity of the plant is 138,600 tons of PSF per annum. The plant
supplier opted to start operations of spinning and staple fibre processing lines one
after other and the commercial production was started in October 2002.
Polyester Fibre Project IFL-lll
The Company has successfully implemented the balancing, modernization and
expansion of Polyester plant with a new project IFL-ll having a production
capacity of 600 tons per day. The commercial production of this plant has been
started in the month of April 2013.
The Polyester Fibre Division of the company produces wide range of the PSF of
different lusters and varieties including semi dull, bright, optical bright, anti pilling,
flame retardant and tri lobal with cut length of 32, 38, 44, 51 and 64 mm and
fineness of 0.8, 1.0, 1.2, 1.5, 1.7, 2.0, 3.0 and 6.0 denier.
The project is the first in Pakistan to start the production of dyed fibre and hollowfibre in siloconised and non-siliconised varieties. Some of the specifications of the
products produced are:
Sr # Parameters Unit Specification Max Tolerance +/-1 Denier d 0.8 0.04
2 Cut lengths mm 38 4 %
3 Tenacity g/d 6.8 0.2
4 Elongation % 21 3
5 Crimp No No./inch 13 16 Crimp Removal % Min 15 -
7 Crimp Stability % Min 60 -
8 Shrinkage % 5.0 1.0
9 Elec.Resistence Ω x 1011 Max 1.0 -
10 Moisture % Max 0.4 -
11 Color L - Min 92 -
12 Color b - Max 3.0 -
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Ibrahim Fibres is situated at the integrated site of Ibrahim Group close to
Faisalabad, where nearly 50% of Pakistan's spinning capacity is located. The site
orientation allows for just in time delivery for over 80% of the customers. The textile
plants of group are also users of polyester staple fibre and this allows in housequality tests.
The group today derives its strength from a unique blend of entrepreneurial
ownership added with unparalleled skill of professionals.
Keeping up with the ever increasing awareness of quality and high standards, the
principle of continually improving the products and production techniques is
followed. A well-trained quality control department is responsible for ensuring that
the quality of all the products of the Company meets the most stringent
international standards. The people in this important activity are supported by
complete and modern chemical and textile laboratories. A further step to
strengthen the manufacturing efficiency, process and products was achieved
when the Company received ISO 9002 Quality Certification for its manufacturing
process.
The Company achieved net sales of Rs. 38,839 million during the year under
review as compared to Rs. 35,853 million during the previous year. The gross profit
earned during the year was Rs. 2,725 million as against Rs. 2,622 million earned
during previous year.
Today, the Group is managed by highly qualified team of professionals with vast
experience in their respective fields. Every department is headed by a
professional, qualified and experienced executive. At present Ibrahim Group has
total employment of 2958 individuals comprising of 1727 skilled persons, 879 semi-
skilled persons, 87 senior technical executives and 265 officers and managerial
staff.
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Product (PET) Introduction
The main product in this process is the Polyethylene terephthalate. However,
water is produced as a polycondensation by-product with no important
economic value.
Polyethylene terephthalate (PET) is a polycondensation polymer. It is most
commonly produced from a reaction of ethylene glycol (EG) with either purified
terephthalic acid (PTA) or dimethyl terephthalate (DMT), using a continuous melt-
phase polymerization process. In many cases, melt phase polymerization is
followed by solid-state polymerization.
This polymer is the most common thermoplastic polyester. It is often called just
“polyester”, which often causes confusion. PET is a hard, stiff, strong, dimensionally
stable material that absorbs very little water. It has good gas barrier properties
and good chemical resistance except to alkalis (which hydrolyze it). Its crystallinity
varies from amorphous to fairly high crystalline. It can be highly transparent and
colorless but thicker sections are usually opaque and off-white.
PET is widely known in the form of thermally stabilized films used for capacitors,
graphics, film base and recording tapes etc. It is also used for fibres for a very wide
range of textile and industrial uses. Other applications include bottles and
electrical components.
Process Summary for PET ProductionIn Ibrahim Fibres Limited, PET is generally produced direct esterification of purified
terephthalic acid (PTA) with EG. The first stage is to produce a mixture of ethylene
glycol ester ofterephthalic acid. This mixture of linear oligomers (mainly bis-
hydroxyethyl terephthalate BHET) is subjected to a further stage known as
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Mass Balance for PET Process
Following assumptions are made for calculations:
1.
No impurities are present in the reactants
2. 100% conversion of reactants
3.
100% solubility of PTA in EG4.
By-products other than water are neglected
5.
No loss of expensive materials
E/T=1.03/1
Components In (kg/kg PET) Out (kg/kg PET)
MEG 0.33 -
PTA 0.86 -
PET - 1.00
Water - 0.19
Total 1.19 1.19
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E/T = 2/1
Components In (kg/kg PET) Out (kg/kg PET)
MEG 0.64 -
PTA 0.86 -
PET - 1.32
Water - 0.18
Total 1.5 1.5
PTA SECTION
What is PTA?
It is 1, 4-Benzenedicarboxylic Acid with a chemical name of Pure Terephthalic
Acid - C6H4 (COOH) 2. It is commonly produced by the oxidation of p-xylene by
the oxygen in air. Some properties of PTA are listed in the following table:
Color White Crystalline Powder
Auto-ignition Temperature 495oC
Flash Point (Open Cup) 260 oC
Products of Combustion Carbon Oxides (CO, CO2)
Specific Gravity (15 oC) 1.51
Vapor Pressure (25o
C) 0.00158 PaParticle Size 70-160 microns
Impurities Acetic acid, Mo, Cr, Ni, Fe
pH 2.16
Molecular weight, g/mol 166.14
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Melting point, oC 427
PTA (Pure Terephthalic Acid) is the basic raw material for the production of
Polyester. Polyester fibers based on PTA provide easy fabric care, both alone and
in blends with natural and other synthetic fibers. Polyester films are used widely in
audio and video recording tapes, data storage tapes, photographic films, labels
and other sheet material requiring both dimensional stability and toughness.
PTA Uses
1.
PTA, a white solid is a commodity chemical, used principally as aprecursor to the polyester PET, used to make clothing and plastic bottles.
2.
PTA is also used in the pharmaceutical industry as a raw material for
certain drugs.
3.
It is further used as filler in some military smoke grenades.
4.
PTA is also used in the paint as a carrier.
PTA Section Division
The whole PTA section deals with the storage, handling, charging and conveying
of this raw material.
Storage and Handling
PTA is supplied to IFL by the following two companies.
1.
Lotte Pakistan PTA Ltd.2. Siam Mitushi PTA Co. Ltd
Siam Mitushi provide PTA in containers with 22 tons each (container casing weighs
1.2 ton). The container charging crane in PTA section has a capacity to handle a
maximum load of 25 tons.
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Daily consumption of PTA depends on the daily production of polyester plant.
Storage warehouse of PTA section can store a stock of one month.
Charging of PTA
In this process, PTA is charged into Buffer Silos with the help of rotary feeders. The
charging process is of two types:
1.
Bag Charging System
2.
Container Charging System
In Bag Charging system, PTA bags are taken on the top of charging station with
use of hoist system. The bags are then opened on a pan with a vibrating screen
beneath it. A vent pipe is also there to remove extra fine particles. This screen
removes any coarse particles present in the feed. This feed is then transferred to
a rotary feeder equipped with a bag filter to trap any fine particles that may rise
in the feeder. This feed further moves to a buffer silo. This silo opens up in a rotary
feeder. This feeder prepares batch to be moved for compression and finally to a
large storage silo.
The Container Charging system uses large containers to prepare batch for IFL-2
(can also be used for IFL-1). Containers are first loaded on a charging station that
is inclined to an angle of 25-30 degrees. The maximum elevation provided is 45
degrees. The container is opened and PTA is loaded in a rotary feeder after
passing through vibrating screens.
Initial mechanism for both types of charging systems is different while the
remaining steps are essentially same. PTA section has two bag charging systems
(new and old).
Conveying of PTA
In this process PTA is conveyed to the storage silos of second stage with the help
of compressed nitrogen gas. It is then conveyed, from the storage silos, to the
respective plants.
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N2 is separated from air in UTY section. The gas is compressed to ~4.2 barg in Screw
compressors. There are total 8 compressors; 3 for IFL-1, 2 for IFL-2 and 3 for IFL-3.
Each compressor section maintains different outlet pressure, however, the suction
pressure (70-80 mbarg) is same for all the compressor sections. Capacities ofcompressors are listed in the following table:
Compressor Name Capacity Discharge Temp.
1204-K01 13.5 m3/min 165 oC
1204-K02 13.5 m3/min 165 oC
1204-K05 13.5 m3/min 165 oC
1204-K11 29.5 m3/min 135 oC
1204-K12 29.5 m3/min 135 oC
1214-K11 40 m3/min 230 oC
1214-K12 40 m3/min 230 oC
1214-K13 40 m3/min 230 oC
Each compressor has a filter at its inlet and outlet position, except the standby
compressor of IFL-3. A cooler is present at the discharge of each compressor.Temperature of discharged gas depends on the outlet pressure of respective
compressor and that is why outlet temperatures of exit N2 varies for all the three
compressor sections and that is why different water flow rates are maintained in
the coolers to obtain sufficient cooling. After cooling, the gas passes through bag
filters and then through the storage silos to fluidize N2 to different plants.
PTA is not allowed to come in contact with air because if it comes in contact with
10% air, it forms an explosive mixture. That is why N2 is used as a conveying
medium.
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Process Flow Diagram
Main Equipment Used
Filter
There is a bucket type filter where nitrogen is filtered with the polythene type filter
medium that removes all the powdered and undersize particles from the
recovered nitrogen. The purpose of this filter is that no PTA will pass from the
compressor as it can damage the capital property of the compressor.
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Compressor
Here In case of PTA Conveying and Storage we need a compressed inert gas. As
PTA is one of the explosive materials, so for the sake of convenience we have
selected compressed Nitrogen as a driving source of PTA due to its unique
property that it remains inert even at very high temperature. The Compressors are
rotary type screw compressors that compress the nitrogen up to 2.4-3.2 bars
pressure at nearly 250 °C. In screw type compressors the gas is compressed
between the threads of screws that generates very high pressure i-e ranging from
2.4-3.2 bars. The pressure of nitrogen in the conveying and storage lines is nearly
65-80 mbar that is responsible for the fluidization of PTA during the storage and
conveying operations.
Cooler
Compressed nitrogen from compressor contains a high temperature of nearly
250oC, which needs to be cooled to 40-60oC to avoid the auto-ignition with PTA.
For this purpose we cool the temperature of nitrogen to desired range with the
help of Shell and Tube heat Exchanger, where water after passing through the
strainer, installed to remove the suspended solid particles from water, is inserted
into the shell side of cooler where nitrogen is in tube. Both the fluids move in co-
current manner and water is collected into the drain vessel. The cooled nitrogen
is sent to the silos for fluidization of PTA.
Rotary Feeder
Rotary feeder is responsible for the transfer of required PTA at IFL-1, IFL-2 and IFL-
3. Rotary feeder provide the specific mass to a bed of nitrogen depending upon
the capacity of that bed. We have adjusted the Rpm or frequency of Rotary
feeder from the DCR depending upon the requirement of raw material at IFL-1,
IFL-2 and IFL-3 and pressure of nitrogen.
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MEG Sampling
Samples are taken from the tankers before discharging them to IFL main tanks.
Color, viscosity and moisture content is tested. MEG should contain less than 1%
moisture content to pass the quality test.
MEG Unloading and pumping to Process lineUnloading is carried out with the help of a centrifugal pump. A strainer is present
at pump suction and a flow meter (micro meter motion sensor) followed by a filter
at pump discharge. The purpose of strainer (bucket type) and filter is to trap
unwanted objects from the flow. MEG then enters a 3 way valve. The valve directs
it to one of the two MEG storage tanks, 1107-T01, and 1107-T02 for IFL-1. One tankis filled at one time. The total capacity of the tanks is 2000 tons each. Each tank is
equipped with level transmitters which generate the low level alarm and high
level alarm if MEG level in tanks reaches the fixed set-points. The tanks are filled
up to a maximum level of 90%. Level transmitters are used to keep a check on the
level.
MEG is transported with the help of centrifugal pumps at 8-9 bar pressure to
participate in the reaction for the production of polyester. Each pump has a
strainer at its suction, to separate unwanted objects, and each pump has a
recirculation for safety purpose. Some properties of MEG are mentioned in the
following table:
Chemical Formula OH-CH2-CH2-OH
Molecular weight 62.03 g/mol
Boiling Point 197o
CAuto-ignition temperature 398 oC
Flash Point (closed cup) 111 oC
Specific gravity 1.116
Color Colorless
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Odor Odorless
Taste Mild sweet
Purity 99.9%
MEG Uses1.
MEG is primarily used as a raw material in the manufacture of polyester
fibers and fabric industry.
2.
It is also used as an additive to prevent corrosion in liquid cooling systems
for PCs.
3.
One major use of MEG is as a medium for convective heat transfer.
4.
MEG also acts as a Dewatering agent.
Process Flow Diagram
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Equipment Interlocks
Storage Vessels (1107-T01/T02, 1110-T01/T02, 1111-T01/T02) have following
interlocks:
1.
Level Alarm
EGR (Area Code – 3101) Process Description
The EGR unit is basically a recycling plant to enhance the purity of spent ethylene
glycol which is obtained from different plants of poly process plant. Basic
chemical reactions for the preparation of polyester are as follows:
The reaction shows that MEG is obtained as a by-product during the process. This
spent MEG is a contaminated by-product with monomers, aldehydes and
moisture.
The recovery process starts from 3101-V01 Vessel which holds spent glycol from
different parts of process plant. It is transported to a kettle-type evaporator which
maintains a pressure of ~260 mbarg vacuum and temperature of ~167oC. At this
vacuum condition SEG converts to vapor form while it has a boiling point of 197oC
at atmospheric pressure. SEG vapors are added to the 6 th plate of vacuum
distillation column. Top of rectifying section has a temperature of ~60 oC while the
bottom of stripping section has ~160 oC. Temperature is maintained with the help
of hot HTM coils in the bottom of column. ~99.5% pure ethylene glycol is obtained
at the bottom of 3101-C01. 70% level of fluid is maintained in the bottom of
column for the safety of HTM coils. The bottom product, REG, passes through a
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plate and frame cooler (3101-E03); it exchanges heat with cooling water and
then enters to REG storage vessel (3101-V04). Samples of REG are taken to check
the quality. The MEG collected at the bottom is 25% of the total being used at the
plant. This is then forwarded to 1117-T01. The remaining sludge which containsimpurities is collected in the barrels and is sold as fuel.
Top product from 3101-C01, which consists of ~0.5% EG and remaining water
vapors, enters into a partial condensation vessel that is actually a heat exchanger
(3101-E02). Condensate, water, goes to the reflux drum (3101-V02) which supplies
a controlled amount of reflux at the top plate to maintain appropriate
temperature conditions. Also, the reflux is used enhance the purity of top product.
Vapors and any overflow from the partial condenser go to a drain vessel (3101-
V03). Vacuum pump (liquid ring) is attached with partial condenser, evaporator
and reflux drum to maintain vacuum conditions within the whole system. A knock
out drum is attached at the discharge of vacuum pump.
The distillation column is also equipped with temperature sensing elements,
control valves and controllers. The temperature is sensed by the thermocouples
and is converted into current amperes. A set point is given to each controller.
Whenever there is a change in the set point, a signal is generated in the feedback
system which is attached to Distribution Control System (DCS). The DCS responds
to the controller to set the flow rate of HTM to regulate temperature.
Main Equipment Used
Kettle type Evaporator
Kettle type evaporator is special type of evaporator designed especially for the
evaporation under evacuated conditions. It contains a kettle type structure
where heating coils are present.
In this evaporator the SEG (Spent Ethylene Glycol) is heated with the HTM in the
coil at 169 C and 260 mbar pressure. SEG contains MEG, water vapors and
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aldehyde groups. The Boiling Point of MEG is 197 C. Under Vacuum water vapors
and MEG gets boiled at 169 C and collected at the Distillation Column and
sludge is discharged to waste column. It’s necessary to maintain 50% level of this
evaporator to avoid any damage of coils.
Distillation Column
Distillation Column is at 260 mbar pressure. It consists of 16 plates and feed is
provided at the 6th plate. It is bubble and cap type evaporator. The purpose of
bubble and cap is to provide maximum hurdles for the MEG vapors having low
latent heat that they lose their latent heat and condensed at the base. Only
water vapors are at the top of column that are condensed and partly returnedas a reflux and partly stored at the vessel. Reflux has two major benefits:
1.
It gives us maximum purity of MEG.
2.
It utilized the latent heat of MEG vapors and gets evaporated again without
disturbing our economy.
3.
In other words, heat required to evaporate Reflux water (Heat of
Vaporization) =Heat Released by the MEG vapors (Heat of Condensation).
Equipment InterlocksDistillation Column Unit (3101-CO1) have the following interlocks:
1.
Column Differential Pressure
2.
Pressure of Column
3.
Level of SEG storage vessel
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Process Flow Diagram
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HTM Section (Area Code – 3007)
Process DescriptionHTM stands for “Heat Transfer Media”. HTM is used as a source of heat for different
units of plant. Santotherm is used as HTM. HTM is heated in the furnaces. Partially
hydrogenated terephenyl (HTM) liquid circulates in coils where the combusted
natural gas or BC oil heats it in furnace. The trade name of HTM (Santotherm) is
“Therminol 66.” Therminol 66 fluid is designed for use in non-pressurized/low-
pressure, indirect heating systems. It delivers efficient, dependable, uniform
process heat with no need for high pressures. The high boiling point of Therminol
66 helps reduce thevolatility and fluid leakage problems associated with other
fluids. Some properties of HTM (Santotherm) are as follows:
Color Clear, Pale yellow liquid
Maximum moisture content 150 ppm
Flash point 184oC
Fire point 212 oC
Auto-ignition temperature 374 oC
Specific gravity 1.012
Density at 25 oC 1005 kg/m3
Optimum use range 0-345 oC
Dowtherm is another heating media which is used in vapor form. It is used to heat
reaction vessels (ES-1, ES-2, PP-1, PP-2, DRR etc.) by staying in the jacket of these
vessels. It has a low boiling point. Santotherm is used to exchange heat with this
heating media to convert it into vapor state. Some of its properties are listed as
follows:
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Freezing point 2.3oC
Boiling point 243 oC
For heating of HTM, three furnaces are used. In IFL-1, there are two furnaces. One
of them is in operation while the other furnace is at standby position. The most
important thing is the flow in and out of furnace.
There are steam lines (25 bar, 6 bar) coming from boiler house to HTM area to
different places such as
1.
Pre heaters (Steam heaters)
2.
BC oil vessel
3.
HTM drain and make up vessel in HTM area
4.
Economizer
LPG gas (Liquefied petroleum gas) is used to provide initial spark for ignition and
BC oil or Natural gas is used as a fuel.
Air for combustion comes to the intake of the fan from atmosphere and
stoichiometric requirement of air for furnace is 20 % excess air for burning. Processused for sending air by fan to top of furnace is actually known as Force and Draft
Mechanism.
Discharge from FD fan goes to economizer having shell and tube arrangement.
The air freshly enters into the economizer at 49 oC approximately. it is in the shell
side and in tube side there are flue gases at ~330 oC. There is shell and tube
arrangement in economizer.
The air discharge from economizer at approximately 180 oC because flue gases
coming at 330 oC and they exchange heat with air after exchanging heat gases
retain the temperature of about ~220-225 oC.
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BCO Cycle
From V03 vessel, BCO is pumped towards the furnace with the help of low pressure
pumps. V03 has a heating system in its shell which pre-heats BCO to ~100oC before
being pumped by low pressure pumps which increase its pressure to ~9 barg. Itthan goes to the suction of high pressure pumps which increase the pressure
energy to ~35 barg. The discharge passes through a pre-heater which uses 25 bar
steam as a heating medium. BCO then enters the furnace and it is atomized with
the help of an atomizer.
BC oil which is used for burning and is given a set point of 130oC. For BC oil
transportation from vessel to furnace high pressure pumps (Gear pumps) are
used. The flame of gas burning in furnace is blue while the flame of oil burning is
yellow (Blue flame is stronger than yellow).
It is important to pre-heat the BCO, otherwise, cool BCO will disturb the
temperature profile of the furnace. Thus disturbing the whole process.
HTM CycleHTM is built up in a 3007-V01 vessel. Its level is checked with the help of a Magnetic
Level Indicator. It is then moved to 3007-V02 vessel at 25 m. If the level of 3007-
V01 falls, then barrels of HTM are charged each weighing 230 kg. The level of 3007-
V02 is maintained at 50%. If there are any leakages in the HTM system, then they
are directed to 3007-V04 at 0 m.
HTM is used as two systems. In coils as liquid and in vessel boundaries as vapors.
Santotherm is used in the primary cycle where it is heated in the furnace. This
Santo therm then moves in coils to a secondary cycle where it is used to convert
Dowtherm into vapor state in an evaporator. This Dowtherm is used in the linings
of the vessel to maintain the temperature of the mixture and to make sure efficient
heat transfer throughout.
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Process Flow Diagram
Main Equipment Used
Furnace
Furnace is there to heat the santotherm which is our HTM to a temperature of 325
oC from 292 oC. The Furnace is operated with Heavy Furnace Oil (HFO), after pre-
heating the HFO at pre-heater is sprayed at the top of furnace with the help ofan Atomizer. Atomizer Creates a fine spray of HFO for easy and complete
combustion. Another source of fuel for the Furnace is natural Gas, Natural Gas is
being provided by Utility Department at the required temperature and Pressure.
Air is taken from atmosphere, pre-heated in economizer and then provided to the
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damper with the help of blower and then injected both natural gas and air in a
required ratio to the Furnace. It is then started and the HTM is heated with
Conduction, Convection and Radiation mode of heat transfer.
Conduction
This Mode of heat transfer is effective in those coils which are in direct contact
with the burner.
Convection
This mode is effective when the flue gases moves in bulk due to density and
momentum difference.
Radiation
This mode is effective in the whole body of furnace.
Stack
Stack is for the emission of flue gases after passing through the economizer. Stack
have a variable area to reduce the emissions of solid contents and increase the
kinetic head of gases.
Pre-Heater (HFO)
Pre-Heater is available for HFO which pre-heats the HFO using 6 bar steam
followed by 25 bars steam at two different stages. The Purpose of this pre-heater
to save our fuel for maximum heat economy. This step economizes our process by
providing us maximum efficiency.
Atomizer
Atomizer is a device which is used to convert the jet of any fuel or liquid into fine
spray in order to increase the effective surfaces throughout the reactor or
furnaces.
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Blower
Blower is an instrument that is used to convert pressure head of air to its kinetic
head and increases the flow rate for effective combustion.
Economizer
Economizer is also a pre-heater that uses the flue gases and pre-heat the air
coming from blower before providing to the furnace in order to have the
maximum utilization of waste heat.
Damper
We provide natural gas and warm air to damper that maintains a specific air to
fuel ratio for maximum oxidizing flame. As the reducing flame will cause more
toxic emissions that needs to be processed before emitting into the air.
Ignition Fuel
LPG is the ignition fuel of Furnace in order to have effective start up.
Equipment Interlocks
Furnace Unit (3007-F01/F02) has the following interlocks:
1.
HTM Flow Pressure
2.
Air Inlet Pressure
3.
FD Fan (Blower) Load
4.
Fuel Gas Pressure
5. Ignition Gas Pressure
6.
Fuel Oil Temperature
7.
Fuel Oil Pressure8.
Discharge Pressure Pump Load
9.
Blocking Tightness Control
10.
Flame Eye Intensity
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TDO Section
Process Description TDO or Titanium dioxide is a white powdered solid (mol. wt. 79.9 g/mol). In fiber
making process, it is used as dulling agent in the second stage of esterification
process. It is used to make products of different brightness. For making a semi-dull
product, the concentration of TDO in the solution is 10% and 0.3% by weight of
PET in the final product. On the other hand, a bright product must have 3%
concentration of TDO in solution and 0.03% by weight of PET in the final product.
It also has following advantages for the final product,
1.
TDO provides matt finish to the final product.
2. It increases the durability of the product.
3.
TDO Anatase has high refractive index close to diamond, which causes
glitter-ness.
4.
TDO also gives hardness to the product i.e. on a scale of 0-10, where talc
has zero hardness and diamond has maximum of 10, TDO has hardness of
5.5 – 6.5 Mohs.
A 500 kg bag of TDO is added into 1307-V01 vessel via a hopper assembly. Now,
500 kg of fresh MEG is added to this vessel to make a 50% concentration mixture.
Then the mixture is agitated for 4 hours. This mixture then moves to 1307-V07 where
1610 L of EG are added to reduce the concentration of solute to 20%. It is again
mixed for 1 hour before moving it to centrifuge (1307-A02). The centrifuge
undergoes through three steps during its operation:
1.
Classifying – Fine and oversized particles are classified and this process lasts
for 50 minutes.
2.
Dispersing – Dispersion of Oversized particles with MEG and this step lasts for
~20 minutes.
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3.
Discharging – Discharging of oversized particles by MEG to Pearl Mill and
this step lasts for ~5 minutes.
Undersized particles are separated and moved to 1307-V02 in which 1800L of EG
are added to make the mixture concentration to 10%. Pearl Mill grinds the oversize
particles by using a Muller which has fine particles of Zirconium dioxide of
diameter 0.8 micron. Ground particles form pearl mill are again moved to 1307-
V01 vessel.
Mixture from 1307-V02 is now separated into two lines for making products of
different properties i.e. semi-dull and bright. 1307-V03 is used for making semi-dull
product of 10% TDO concentration. Bright product is made up in 1307-V04 vessel
from where it enters 1307-V05 vessel in which 4363 L of EG are added to reduce
the concentration of TDO up to 3%.
Process Flow Diagram
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The true solution prepared in the 2nd equation contains 3250 Liters of MEG along
with 75 kg of catalyst. This solution is charged into the catalyst feed hopper from
where it moves to the 1402-V01 batch preparation tank. This vessel can be
operated at a maximum of level of 95% and minimum of 35%. Flow counters areattached which send the measured quantity of EG in the catalyst vessel. The
batch in the 1402-V01 is then sent to a filter in which batch is filtered for any
suspended solids. Clear solution is now ready for the paste preparation tank.
Process Flow Diagram
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Paste Preparation Section
Process DescriptionIn this stage all the essential components are mixed in specific amounts. A paste
is formed which is then sent to main reaction vessels. Following ingredients are
added into this vessel:
1.
MEG
2.
PTA
3.
Catalyst
PTA and MEG are charged in a specific mole ratio here we call it E/T ratio.
Normally two moles of MEG require one mole of PTA to react. In the paste
chamber the E/T ratio is set as:
=
= 1.12
Essentially no serious reaction is occurring in the paste preparation chamber that
is why the ratio is set as 1.12. The ratio highly depends on the production rate of
plant. Addition of 0.86 mol of MEG is carried out in the later reaction stages to
meet the required mole ratio.
In the paste preparation vessel mostly Recovered MEG from EGR and Column
MEG are added to run the process economically. However, fresh MEG is also
added to maintain a certain purity level. Fresh MEG is 99.9% pure. Flowmeters
carefully control the flow rates of EG entering the vessel.
PTA is added into the paste preparation vessel from the day silo. A rotary feeder
directs PTA to the Shank System, a motor operated assembly. Shank System is an
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arrangement to carefully control the flow rate of PTA in order to achieve a
specified mole ratio.
The catalyst in the 1402-V01 vessel is directed towards paste tank. The capacity
of the tank is 29m3 and is operated at 90% level. The temperature in this tank is
around 45oC which is way lower than the actual process condition. The paste is
constantly agitated with the help of a fix speed agitator. The paste in the tank is
provided a residence time of 3 hours and is then moved to the first esterification
tank. The density of the final paste is 1.393 g/cm3.
Due to the addition of catalyst some amount of product (i-e monomers and
oligomers) start forming in this stage. Thus in later stages reaction completion will
require less time.
Process Flow Diagram
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Main Equipment Used
Shank System
Shank System contains an inclined plate that rotates at a specific speed to
maintain mole ratio between PTA and MEG. It is situated at the base of Rotary
Feeder of Day Silo.
Paste Mixer
Paste mixer receives the raw material from shank system and it has three lines of
MEG. First is fresh MEG, 2nd is REG and 3 rd is recovered MEG. We have maintained
the mole ratio of PTA and MEG is 1:1.12 at the paste mixer. Agitator is present at
the top of paste mixer in order to mix the catalyst and raw material for a specific
time.
Esterification (ES-I and ES-II)
Process DescriptionTwo reactions are involved in the preparation of polyester from raw materials. The
first one is esterification, which takes place in ES-I and ES-II, and the second is
polycondensation which takes place in PP-I, PP-II and DRR.
The main reaction takes place in a large esterification reactor 1424-R01 (ES-I)
which has a capacity of 50m3. It is a Continuous Stirred-Tank Reactor (CSTR) which
is maintained at a level of 55%. The tank is heated internally with the help of 9
spiral Santo therm coils. An external jacket contains Dow therm vapors which do
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Process Flow Diagram
ES-1
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ES-2
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Polycondensation
Process DescriptionThe second reaction of polycondensation takes place in following three reactors:
1.
PP1
2.
PP2
3.
DRR
In these reactors, monomers and oligomers undergo condensation
polymerization with elimination of MEG. Value of degree of polymerization that is
achieved in these stages is ~104. The produced monomer has two functional
groups; carboxl group (COOH) and hydroxyl group (OH). It goes through step-
growth polymerization, where the growth of the molecules occurs through the
reaction of the two functional groups
PP1 is the first reactor of this operation. It does not contain any stirrer. The reactor
is operated at 256oC and 0.12 bar vacuum pressure. Residence time in PP1 is ~1
hour. The EG vapors that evaporate from the top are captured in a scrapper
condenser. This system consists of a liquid EG shower at the top which is used to
condense the vapor. Vapors and liquid are in direct contact with each other. At
the bottom, a scrapper shaft is attached which scraps any solids that may deposit
in the condenser walls. The level of the tank is measured with the help of capacitor
type level indicator. This consists of a 2 rods, one has reference current passing
through it whereas the second rod senses current from the tank. The change in
the current with respect to the reference rod is calibrated as the level indication.
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The product from PP1 is conveyed to PP2 via HTM jacketed lines. PP2 is equipped
with an agitator which continuously cuts the viscous solution and generates new
surfaces. Residence time in PP2 is ~0.85 hour and it operates at ~273oC and 0.02
bar vacuum pressure. Moisture content of the tank is ~10%. Rate of evaporationfrom this reactor is higher because it operates at high temperature and low
pressure. Vapors are, partially, condensed in the scrapper condenser. The level of
the solution in the PP-2 is measured by not only capacitor system but also a
radioactive level measuring system. Radioactive system uses radioactive Cobalt-
60 at the bottom of the tank. A detector is installed at the top which measures
the radioactive intensity. When the level of the tank rises, the intensity at the top
reduces. This reduction in intensity is calibrated against the level measurement.One of the main reasons to use radioactive elements for level measurement is
that the fluid in PP2 becomes highly viscous and other sensors can’t measure the
level accurately.
DRR (Disc Ring Reactor) is a horizontal reactor whose primary purpose is to
achieve a specific value of intrinsic viscosity (0.6). There is a shaft across the length
of DRR which continuously cuts the material with the help of rings. The material is
exposed to high temperature (~280oC) and very low pressure.
EG and moisture evaporates from DRR and pass through a scrapper condenser.
Uncondensed vapors passes through a jet system. The jet system entertains the
vapors from PP2 and DRR. Vapors after passing through the jet system (I, II & III)
undergo sudden expansion which produces vacuum and condenses the vapors.
Uncondensed vapors from the jet system passes through a vacuum system which
uses vacuum pumps. Here maximum portion of vapors is condensed,uncondensed part is vented into the atmosphere. That part mainly contains
aldehydes and ketones due to which it is not condensed.
Product from DRR is filtered through candle filters which have stainless steel
candles and it is then transported to spinning section via gear pumps.
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Process Flow Diagram
PP-1 and PP-2
DRR
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Main Equipment Used
Scrapper Condenser
Scrapper Condenser is used to condense the vapors of MEG and water at the
top of PP-1,PP-2 and DRR.It contain inclined plates and hurdles for vapors so that
they lose their latent heat .Vapor condensate is treated as SEG and the remaining
is sent to Ejector System.
Ejector System
In this system vapors are compressed in the form of jet and then expanded in a
vessel that cause two fruitful effects.
1.
It condensed the maximum vapors.
2.
It generates the vacuum in the lines.
Vacuum Pump
Vacuum Pump generates vacuum by ejecting the gases present in the line with
its suction power and after condensing them in its casing discharge into the vent.
Fume Arrestor
Fume Arrestor is present at the top of every storage vessel which contains the
flame-able liquids. it catches the fumes present at the different temperature of
vessel and reduce the internal vapor pressure that act as a safety for the system.
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Materials Safety Guide
MEG Safety
Emergency Overview Warning! Harmful or fatal if swallowed. Harmful if inhaled or absorbed through
skin. May cause allergic skin reaction. May Cause irritation to skin, eyes, and
respiratory tract. Affects Central nervous system.
InhalationVapor inhalation is generally not a problem unless heated or misted. Exposure to
vapors over an extended time period has caused throat irritation and headache.
May cause nausea, vomiting, dizziness and drowsiness. Pulmonary edema and
central nervous system depression may also develop. When heated or misted, hasproduced rapid, involuntary eye movement and coma.
IngestionInitial symptoms in massive dosage parallel alcohol intoxication, progressing to
CNS depression, vomiting, headache, rapid respiratory and heart rate, lowered
blood pressure, stupor, collapse, and unconsciousness with convulsions. Death
from respiratory arrest or cardiovascular collapse may follow. Lethal dose in
humans: 100 ml (3-4 ounces).
Skin Contact
Minor skin irritation and penetration may occur.
Eye ContactSplashes may cause irritation, pain, eye damage.
Chronic ExposureRepeated small exposures by any route can cause severe kidney problems. Brain
damage may also occur. Skin allergy can develop. May damage the developing
fetus.
Aggravation of Pre-existing ConditionsPersons with pre-existing skin disorders, eye problems, or impaired liver, kidney, or
respiratory function may be more susceptible to the effects of this substance.
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First Aid Measures
InhalationRemove to fresh air. If not breathing, give artificial respiration. If breathing is
difficult, give oxygen. Call a physician.
IngestionInduce vomiting immediately as directed by medical personnel. Never give
anything by mouth to an unconscious person. Get medical attention.
Skin ContactRemove any contaminated clothing. Wash skin with soap and water for at least
15 minutes. Get medical attention if irritation develops or persists.
Eye ContactImmediately flush eyes with plenty of water for at least 15 minutes, lifting lower
and upper eyelids occasionally. Get medical attention immediately.
Note to PhysicianGive sodium bicarbonate intravenously to treat acidosis. Urinalysis may show low
specific gravity, proteinuria, pyuria, cylindruria, hematuria, calcium oxide, and
hippuric acid crystals. Ethanol can be used in antidotal treatment but monitor
blood glucose when administering ethanol because it can cause hypoglycemia.
Consider infusion of a diuretic such as mannitol to help prevent or control brain
edema and hemodialysis to remove ethylene glycol from circulation.
PTA Safety
Emergency OverviewThis product has been evaluated and does not require any hazard warning on
the label under OSHA criteria. Handling and/or processing of this material may
generate airborne fibers and particles which can cause mechanical irritation of
the eyes, skin, nose and throat.
Skin contactNo significant health hazards identified.
Inhalation No significant health hazards identified.
Ingestion No significant health hazards identified.
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Eye contactNo significant health hazards identified. Particles or fibers may cause slight
discomfort similar to getting dust in the eye.
First Aid Measures
Eye Flush eyes with plenty of water.
Skin Wash exposed skin with soap and water.
Inhalation If adverse effects occur, remove to uncontaminated area. Get medical
attention.
Ingestion If a large amount is swallowed, get medical attention.
PET Safety
Emergency OverviewProduct form varies: chips, dice noodles or lace. Colors vary: milky white to black;
several levels of translucence or luster. Under normal conditions of use, this
product is not expected to create and unusual emergency hazards.
Polyesters can burn if exposed to flame. Molten polymer generates small amountsof volatile degradation products (off-gases), one of which is acetaldehyde.
Acetaldehyde vapors form explosive mixtures with air that can spontaneously
ignite (auto-ignite) at temperatures above 347ºF (175ºC).Combustion products
may include compounds of carbon, hydrogen, and oxygen; exact composition
depends on conditions of combustion.
In the event of fire, use normal firefighting procedures to prevent inhalation of
smoke and gases.
InhalationIrritation of the upper respiratory tract, coughing, and congestion may occur.
SkinMolten resin will cause thermal burns.
AbsorptionNot applicable
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Boiler (Area Code-3910)
Boilers are pressure vessels designed to heat water or produce steam, which can
then be used to provide water heating to a building. In most commercial building
heating applications, the heating source in the boiler is a natural gas fired burner.
The basic consumption of steam is in the fiber draw line, heavy furnace oil
& polymerization section.
TypesBoilers are classified into different types based on their working pressure and
temperature, fuel type, size and capacity, and whether they condense the water
vapor in the combustion gases.
Two primary types of boilers include:
1.
Fire Tube Boilers
2.
Water Tube Boiler
Both types of boilers are used in IFL.
Fire tube boilers
Fire tube boilers consist of a series of straight tubes that are housed inside a water-
filled outer shell. The tubes are arranged so that hot combustion gases flow
through the tubes. As the hot gases flow through the tubes, they heat the water
surrounding the tubes. The water is confined by the outer shell of boiler. To avoid
the need for a thick outer shell fire tube boilers are used for lower pressure
applications.
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Condenser
A condenser ensures that all steam is condensed before being pumped back into
the deaerator and on into the boiler.
Damper
A damper is used to make the mixture of air and fuel i.e. to set the air to fuel ratio.
Economizer
An economizer is a heat exchanger that is placed in the exhaust from a boiler.
Fuel
The source of heat for a boiler is combustion of any of several fuels. In IFL two
sources are used:
1.
Natural gas (mostly used)
2.
Furnace oil (stand by)
Process DescriptionThe steam condensate (70%) returning from the plant comes to the condensate
vessel (VO2), after that condensed steam is sent to the vessel (VO3) where two
condensers are used to condense the steam of VO1, VO2 and VO3. Then by using
low pressure pumps (PO4, PO5) condensate is sent to the boiler feed water tank
where a deaerator is also attached to remove the air from the steam
condensate. In this vessel chemicals are added to condensate.
1.
Hydrazine - for removal of free oxygen
2.
phosphate – anti corrosion agent
After the feed water tank the condensate is pumped by boiler feed pumps (PO1,
PO2 and PO3) to the boiler. The condensate along with 30% de-mineralized waterenter the boiler on the shell side and converts to the vapors form by heat transfer
from the fire entering from the tube side. The level of water in Boiler is 2/3 of total
volume of boiler. The steam from the boiler then enters the super-heater at 25-
bar pressure and the steam from the super-heater exits at about 250°C. The
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steam at 25 bar pressure is then divided in to 3 different pressures by steam
header;
1.
25-bar
2.
10-bar3.
6-bar
Process Flow Diagram
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Nitrogen Generation (Area Code – 4400)
Why Nitrogen is Important?Nitrogen is a chemical element with symbol N and atomic number 7. At room
temperature, it is a gas of diatomic molecules and is colorless and odorless.
Nitrogen is a common element in the universe, estimated at about seventh in total
abundance in our galaxy and the Solar System. On Earth, the element is primarily
found as the gas molecule; it forms about 78% of Earth's atmosphere. The element
nitrogen was discovered as a separable component of air,
by Scottish physician Daniel Rutherford, in 1772.
Many industrial compounds such as ammonia, nitric acid,
organic nitrates (propellants and explosives), and cyanides, contain nitrogen. The
extremely strong bond in elemental nitrogen dominates nitrogen chemistry,
causing difficulty for both organisms and industry in converting the N2 into
useful compounds, but at the same time causing release of large amounts of
often useful energy when the compounds burn, explode, or decay back into
nitrogen gas.
Production
Nitrogen gas is an industrial gas produced by the fractional distillation of liquid air,
or by mechanical means using gaseous air (i.e., pressurized reverse osmosis
membrane or pressure swing adsorption). Commercial nitrogen is often a
byproduct of air-processing for industrial concentration of oxygen for steelmaking
and other purposes.
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Process DescriptionIn Ibrahim Fibres Limited, nitrogen is separated from air by using Pressure Swing
Adsorption technique. Primarily, nitrogen is classified into two types depending on
its quality and nature of use; Technical Nitrogen and Pure Nitrogen.
Nitrogen Generation Plant Capacity
IFL 1,2 185 Nm3/hr
IFL 3 220 Nm3/hr
Technical Nitrogen
Nitrogen grade which contains less than 2% oxygen. This grade is obtained,
immediately, after the molecular sieves. Technical nitrogen is used to fluidize PTA
for transferring it from one place to another. It is also used in some level indicating
instruments and to transport materials by exerting a specific head.
Pure Nitrogen
Nitrogen grade which contains less than 10 ppm oxygen concentration is called
Pure Nitrogen. Pure nitrogen has limited applications in polyester plant. It is used
in most critical places, such as reactors, which require inert atmosphere and
proper nitrogen blanketing.
Pressure Swing Adsorption
Pressure swing adsorption (PSA) is a technology used to separate some gas
species from a mixture of gases under pressure according to the species'
molecular characteristics and affinity for an adsorbent material. It operates at
near-ambient temperatures and differs significantly from cryogenic distillation
techniques of gas separation. Specific adsorptive materials
(e.g., zeolites, activated carbon, molecular sieves, etc.) are used as a trap,
preferentially adsorbing the target gas species at high pressure. The process then
swings to low pressure to desorb the adsorbed material.
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Pressure swing adsorption processes rely on the fact that under high pressure,
gases tend to be attracted to solid surfaces, or "adsorbed". The higher the
pressure, the more gas is adsorbed; when the pressure is reduced, the gas is
released, or desorbed. PSA processes can be used to separate gases in a mixturebecause different gases tend to be attracted to different solid surfaces more or
less strongly. If a gas mixture such as air, for example, is passed under pressure
through a vessel containing an adsorbent bed of zeolite that
attracts oxygen more strongly than it does nitrogen, part or all of the oxygen will
stay in the bed, and the gas coming out of the vessel will be enriched in nitrogen.
When the bed reaches the end of its capacity to adsorb oxygen, it can be
regenerated by reducing the pressure, thereby releasing the adsorbed oxygen. Itis then ready for another cycle of producing nitrogen enriched air. Using two
adsorbent vessels allows near-continuous production of the target gas. It also
permits so-called pressure equalization, where the gas leaving the vessel being
depressurized is used to partially pressurize the second vessel. This results in
significant energy savings, and is common industrial practice.
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The process starts with the compression of air (till 8 bar) in double-stage rotary
screw type PD compressors. Compressed air has a temperature of 33-34oC. It
passes through dryers which use chilling effect, thus lowering the temperature to
point where moisture disengages from the gas. Now, air temperature is reducedto 20oC and it is stored in storage vessels (4300-VO1, VO2).
Air from storage vessels enter into a buffer vessel (4300-VO1). The function of this
buffer vessel is to absorb sudden pressure surges. From 4300-VO1, air enters into a
vessel which contains carbon molecular sieves. Air enters at high pressure.
Oxygen gas is entrapped into the carbon molecular sieves due to its small
molecular size while air, containing less than 2% Oxygen at 6.7 bar, exits through
the vessels. This stream is called Technical nitrogen and it is stored in a vessel.
Pure nitrogen is produced by passing technical nitrogen stream through a reactor
(4300-RO1) which contains Palladium catalyst. Reactor is fed with controlled
amount of hydrogen to reduce oxygen gas to water. Exothermic reaction occurs
and a temperature of 185oC is produced. Outlet stream is cooled by enhancing
the heat transfer area and through water. The gas passes through a desiccant
chamber with absorbs moisture from the stream. Now, pure nitrogen stream is
available for storage and use.
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Process Flow Diagram
ApplicationsOne of the primary applications of PSA is in the removal of carbon dioxide (CO2)
as the final step in the large-scale commercial synthesis of hydrogen (H2) for use
in oil refineries and in the production of ammonia (NH3). Refineries often use PSA
technology in the removal of hydrogen sulfide (H2S) from hydrogen feed and
recycle streams of hydrotreating and hydrocracking units. Another application of
PSA is the separation of carbon dioxide from biogas to increasethe methane (CH4) content. Through PSA the biogas can be upgraded to a
quality similar to natural gas.
PSA is also used in
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1.
Hypoxic air fire prevention systems to produce air with a low oxygen
content.
2. On purpose propylene plants via propane dehydrogenation. They
consist of a selective media for the preferred adsorption of methane
and ethane over hydrogen.
3.
Small-scale production of reasonable purity oxygen or nitrogen from air.
PSA technology has a major use in the medical industry to produce
oxygen, particularly in remote or inaccessible parts of the world where
bulk cryogenic or compressed cylinder storage is not possible.
4.
Nitrogen generator units which employ the PSA technique to produce
high purity nitrogen gas (up to 99.9995%) from a supply of compressed
air.
Cooling Towers
Basics
The equipment which are used to cool water based on the difference between
wet-bulb and dry-bulb temperature of air. There are two basic types of cooling
towers:
1.
Natural draft cooling towers
2.
Mechanical cooling towers
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Some specifications of cooling towers are mentioned as follows:
Process Water Cooling Towers
IFL-1 process water cooling tower 3
IFL-2 process water cooling tower 1
IFL-3 process water cooling tower 3
Cooling water supply 34oC
Cooling water return 42oC
Chiller Water Cooling Towers
IFL-1 chiller water cooling tower 3IFL-2 chiller water cooling tower 1
IFL-3 chiller water cooling tower 3
Chiller water supply 34oC
Chiller water return 39oC
WATER TREATMENT
Water Treatment plant is a very important part of Utilities Section.
Water required:We need three type of water at IFL Plants:
1.
Soft Water
2.
Demineralized Water
3.
Drinking water
Purpose
Water treatment plant is responsible for the generation of the required water.
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ions to get separate from the raw water we provide osmotic pressure on the outer
shell that helps us to separate the maximum ions on the membrane.
Degasser
Degasser is equipment used to remove CO2 from soft water. It consists of a
vertical column that has packing’s (Rashing Rings).
We provide feed from the top and air from the base that helps the CO2 to escape
from the soft water.
Mixed Bed Ion Exchanger (Demineralization)
Mixed bed Ion Exchanger consists of Cathodic and Anionic Resins, that removes
maximum ions from the soft water and reduces the conductivity of water up to
one micro Simons per centi meter. These resins become inactive after few days.
We doze 5% by volume NaOH and HCl for the regeneration of these resins. HCl is
effective for Anodic resins and NaOH is effective for Cathodic Resins.
Process DescriptionRaw water from the source is pumped by centrifugal pumps to Multi Layer Filter.
In Multilayer Filters we remove maximum suspended impurities. The capacity of
Multilayer Filter is 4.5 m3/hr. Water just after the Multilayer Filter is dozed by HCl.
HCl maintains a pH of 6.5 in the filtrate. After this the acidic water is filtered in
Bucket Filters. The Purpose of HCl dozing is to convert CaCO3 into CaCl2. Calcium
chloride has large particle size than the mesh no of Permeable Membrane of RO
Section. The reaction that takes place at RO is given below:
CaCO3 + 2HCl CaCl2+ CO2+H2O
RO plants reduce the conductivity of raw water from 3000 uS/cm to 65 uS/cm,
which is our soft water. The Rejected water of the first RO assemblies is then passed
to the next RO plants for further generation of soft water. After these plants the
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CHILLERS
A chiller is a machine that removes heat from a liquid via a vapor-compression
or absorption refrigeration cycle. A chiller is usually factory assembled and
shipped to the facility where final electrical and plumbing connections are made,
but may be shipped in sections for field assembly. It has four primary components:
the compressor, the compressor drive, the evaporator, and the condenser.
Chillers can be categorized based on the type of compressor. Usually occurring
types of chillers include:
Electric Chiller
Steam Absorption Chiller
However, the choice of chiller is affected by the following decisions:
First Cost
Operation Cost
Maintenance Cost
Life Cycle Cost
In Ibrahim Fibers Limited, Polyester plant we in total have 11 chillers at the utility
section. These include both types of chillers. Chillers are used to chill (cool) the
water. The chilled water circulates in the plant through a closed loop. Each chiller
along with the phenomena is discussed further:
Electric ChillerElectrically driven chillers utilize electric motors to drive the compressor. These
chillers can be further categorized according to the type of compressor which is
used. Few of the types include
Reciprocating Compressor Chillers use cylinders with pistons acting as
pumps to increase refrigerant pressure. Compressors may have anywhere
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Process Description
Electric Chiller follows exactly the refrigeration cycle in thermodynamics. The main
components of this chiller are discussed individually:
Compressor Drive
The compressor drive or pump is responsible for suction of refrigerant vapors from
evaporator to the discharge in compressor.
Compressor
The compressor receives the refrigerant vapors from pump and compresses it
down to achieve high pressure. The vapors are then forwarded to condenser.
Condenser
The condenser acts as a shell and tube heat exchanger and exchange of hest
occurs between WC and refrigerant vapors causing vapors to condense to a
liquid form.
Evaporator
Here the l high pressure condensed refrigerant is atomized resulting in evaporation
due to very low boiling temperature ultimately creating cooling effect. The
condensate is prayed on the tubes carrying WCC. The chilled water exchanges
heat and leaves the chiller at 6-7˚C. The cycle goes on and the vapors are sucked
again by the pump.
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Type Centrifugal water cooled
Company Trane
Refrigerant LiBr Solution
Capacity 550 refrigerant tons/hrWC In temp. 30˚C
WC Out temp. 35˚C
WCC In temp. 11-12˚C
WCC Out temp. 6˚C
Process DescriptionThis chiller also follows the refrigeration cycle with the addition of few things. By
being double stage chiller it is 30 % more efficient in providing cooling effect. The
main components of this chiller are further discussed in detail individually:
High Temperature Generator (HTG)
In HTG the 6 barg steam is running in the tubes causing the dilute LiBr solution to
vaporize the water and become a saturated solution. The vaporized vapors are
passed to LTG.
Low Temperature Generator (LTG)
In LTG the water vapors from HTG cause further evaporation from the LiBr solution
present already. The vapors altogether go right to the condenser.
Condenser
The condenser is responsible for exchanging heat between WC and water vapors
from generator. The WC carries away the heat of water vapors eventually causing
the vapors to liquefy.
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Evaporator
The condensed water vapors are then sprayed over the tubes carrying WCC. The
water vapors are passed through atomizer which causes evaporation which in
turn provides the cooling effect in this area. Water is chilled in here and the vapors
are then attracted by the absorber. Here water serves as the refrigerant.
Absorber
Absorber contains the rejected saturated LiBr solution from HTG and LTG. LiBr
being hygroscopic attracts away the water vapors from evaporator and
becomes diluted again. This cycle goes on like this. It is a closed loop cycle i.e.
refrigerant doesn’t leave the system.
Process Flow Diagram
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Spinning Section
Some of the main parts of spinning section includes:
Heat Exchanger Heat Exchanger is at the 13M of IFL-1. It helps to attain the temperature of PET at
288 C. The HTM used in the Heat Exchanger is Santotherm. The line of PET is
provided a continuous jacket of Dowtherm to maintain the temperature and
specific flow rate. The Complex arrangement of lines of PET is for the generation
of homogeneity mixture under some static mixers.
Spin PumpsIFL-1 has two lines of spin pumps. Each line contains 30 pumps called as positions.
There are 5 assemblies of 6 positions. Each spin pump is provided a feed at 288 C
and at 70 bars pressure. Each pump is screw type and has a throughput 2268
g/min.
Spin PackSpin Pack has two types on the basis of number of holes at IFL.
1.
3750 Holes (Circular)
2.
2250 Holes (Trilobal)
Filaments from the spin pack is drawn in a 50mm draw section. The spin pack is
changed after 48 days for semi dull product and after 38 days for circular bright.
After this we regenerate the spin pack in auxiliary workshop. So in the first step,
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spin pack is removed out from specified spinning position with the help of pack
manipulator. Then it is brought to auxiliary workshop by a trolley.
Quench AirAir coming from A/C Section is at 21 C and 85% Humid, known as Quench Air. This
air is provided through the air filter just after the spinet. Air is provided to the filers
in axial direction and filter supply that air to the filaments in radial direction, to
avoid fusing of filaments. The flow rate of air is equal in all directions to cancel the
opposite forces. The flow rate of this air is 1150 m3/hr. The purpose of humidification
is to enhance the rate of heat transfer as the specific heat of water is greater than
that of air.
Air Discharge
Air from each position is discharged at the base through a suction line that leads
the air at Scrabber.The temperature of this air is 60 C and flow rate is 1100 m3/hr.
PolymerMelt
Fiberformation
Quenchair
Ringoiler
Slubcatcher
Threadoiler
V-GuideSuctionNozzle
Cutter Drip
Detecter
DeflectiveRollers
FingerGuider
Dia BlowRoller
GodetRoller
SunflowerRoller
Sub Tow
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This air is processed in scrabber where water is shavered on air that contaminate
the monomers and environment friendly air is discharged into the atmosphere.
Spin Wall Spin wall has following equipments with the stated functions:
Slub Catcher
Slub Catcher catches the thread coming out from the spinet.
Thread Oiler
Thread Oiler sprays the Spin Finish Oil on the threads coming from Slub Catcher.
The function of SF Oil is to reduce the static charge and enhance the cohesive
properties.
V-Guide
There is a V shaped guide that collects the filaments from the thread oiler. The
purpose of this is to create single tow of many filaments.
Suction Nozzle
Suction nozzle is there to facilitate the cutter. It sucks the filaments near the
effective part of cutter.
Cutter
After closing the filaments to the cutter with the help of suction nozzle. Cutter
cuts the filaments.
Drip Ejector
Drip ejector consist of two slides. These slides have a defined path for the
filaments between them. If a drip gets into it, it doesn’t allow the drip to pass. So
at the end filament gets break.
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Four Fold Filter
These four fold filters have this arrangement on the basis of mesh size.
17000+4500+540+64
Five Fold Filter
These fivefold filters have this arrangement on the basis of mesh size.
17000+4500+540+64+4500
Ring Distribution Plate
Ring distribution plate is fitted just after the 5 fold filter.
Five Fold Filter
These fivefold filters have this arrangement on the basis of mesh size.
17000+4500+540+64+4500
Spinneret
1.
3750 holes(Circular)
2.
2250 holes(Trilobal)
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Fiber Line Section
Creel Area The fiber line starts from the Creel Area till Cutter and Bailer. UDY cans are placed
in the creel area. Placement of the number of cans depend on the number of
working positions at spinning line. Number of working spin pack positions and
number of cans placed in the creel area are defined by over plant capacity; the
capacity to process a certain band of denier, for IFL-1 its value is ~3.2 Md (Mega
Denier). Mega Denier is defined by the width of crimper unit which, in fact, defines
the whole capacity of a particular draw line. For IFL-1, the width of crimper unitfor both the lines (71, 73) is 350 mm.
UDY from cans passes through tension adjustment equipment in the creel area. UDY or
sub-tow passes through following equipment during its journey:
1. Horn Guides
2.
H-Guides
3.
Knot Detector
4.
Loose end detector (uses photovoltaic detectors)
5.
Ring guides
Non-adjustment of tension results in poor product quality.
Finger Guides and Guiding RollersUDY enters into the fiber line draw zone after passing through finger guides which
guide the sub-tow towards the rollers in the later stages.
Tow guiding frame-1 (YO1) consists of seven rollers which adjusts the tension of
sub-tow and make it uniform for each filament of UDY. It is basically a 3-4
arrangement of rollers. Rollers are driven by a variable speed motor which adjusts
its revolutions according to the drawing speed.
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Thermosetting Unit (Y10)Here the setting of all the thermal properties of polyester is carried out. Y10 has 12
rollers which revolve at variable speeds. There are actually three sets of rollers, four
in each set. Y10 is provided with 25 barg steam while pressure adjustment is
carried out in each set of rollers to achieve a specific temperature range to
achieve thermosetting of properties.
Rollers Temperature
1st set 190OC
Second set 191 OC
Third set 204 OC
Setting of following properties takes place in Y10:
1.
Tensile strength
2.
Denier
3.
Shrinkage
4.
Elongation
It is actually a thermal treatment process which does not infer any further
elongation in the fiber but maintains a high temperature and provides large
surface area for the properties to set.
TOW Cooler (Y11)It is a rapid cooling system which decreases the temperature from 205oC to 70oC
with the help of SF Oil which is showered at 50oC. Cooling results in the fixation of
polymer structure which had been set in the thermosetting unit.
Spin finish oil is sprinkled by 12 nozzles arranged at a 30 angle having 6 nozzles on
both sides.
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Draw Frame-IV (Y12)The function of Y12 is to prevent shrinkages in tow. The frame has different
arrangement of rollers, i-e 4-3 (four rollers at top and three rollers at the bottom).
Unique roller arrangement facilitates tow converging and easy band formation.
TOW Converger and Three Roller Frame (Y13 & Y14)This unit overlaps the three tows used in the drawing & forms a single tow whose
width is comparable to the width of the crimper intake.
Tension Roller (Y15)The unit maintains the tension of the roller & again sent to the steam unit to gain
the cotton like property.
Pre-Steam Chamber (Steam Box Y16)This equipment finds its place before the crimper unit. It uses steam at 3 barg
pressure to heat tow band. If heating is not done then the crimpers will not form
permanently. Heating the tow will result in the formation of stable crimps.
Crimper Unit (Y17)Now tow is crossed through the crimper unit. This unit induces crimps on the fiber
at a rate of 13 crimps per inch. The crimps are made for necessary fiber flexibility
& cohesion with the natural fiber. Width of crimping section is 350mm.
Crimper thumb rule = 9350 denier/mm
Crimper width = 350 mm
= 3.2 Md
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Traversing UnitThe tow leaves via traversing unit where spin finish oil is sprayed on the crimp tow
depending on the type of product. The traversing chute spreads the tow on the
tow drier plate.
Tow DrierIn this section the tow is dried & cooled. 10-bar steam is supplied for the heating
zone. After being dried the tow is transported to the cutter vertically to free roller.
Tow band temperature is reduced to ~52oC, drying takes place in four sections.
Fibre Cutter Unit (7458-Y23)After braking rollers tow has already attained much tension and it is passed to the
cutter. The cutter is a circular ring having blades of different sizes on edges. The
tow is passed through the pressure plate which presses the tow to wind around
the cutter ring. Due to winding the pressure on the inside increases and makes the
tow cut down according to the blade size. Once the tow has been cut it passes
down to the baler section.
CreelArea
Towguiding
Dippingpath
Drawframe 1
Drawbath
Drawframe 2
SteamBath
Drawframe 3
Thermosetting Unit
TowCooler
Drawframe 4
Overlapper
ThreeFrameRoller
Crimp unit Traveser
DryingUnit
Cutter Baler
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A/C Section
A/C station is utilized for providing following types of air to the spinning and fiber
line:
Quench Air
Comfort Air
This station provides quench air to the spinning unit and comfort air for the
ventilation/ atmospheric temperature maintenance purpose in spinning and fiber
draw line plant.
Procedure:The fresh air from the atmosphere is sucked by K01 fan in the A/C station. Air while
entering the station passes the back filters to remove any suspended particles. On
the way to back filters the fresh air combines with the returned comfort air from
Cutter Pre-Bin Weigh-Bin
Pusher Pre-Press
RamRevolving
Unit
Main Ram Packing
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plant, the returned comfort air is coming via K04 fan. Here the dampers are
placed. The dampers are there to decide the fresh air to return air ratio. It is done
in order to achieve the quench air temperature easily. After back filters is the
steam showering unit which only works if air has low temperature than 19-20Cusually in winters. The heat transfer coefficient of air is lesser than that of water.
That’s why air is being made humid to achieve better heat transfer. For this reason
there is showering of WC on air to make it humid. There is also a soft water filter
there in A/C unit which filters the soft water before being showered at the air
coming from back filters. Soft water showering is done to achieve 100% humid air.
Then further this humid air is passed through WCC coolers. WCC does heat transfer
with the humid air to achieve air at 19-20C. This quenched air is passed throughthe drift eliminators to remove excess water in order to achieve final 85% humid
air for quenching. Next this air is taken up by fans named K02 and K05 for the
quenching in spinning unit. Here one fan is stand by. And K03 takes away comfort
air for venting to the whole plant.
Process Flow Diagram
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Single Filament Denier (d)
Single filament denier is the denier of a mono filament. It is observed in an
instrument called Vibroskop.
Position Denier (d)
Position Denier is the total denier of the number of filaments at each position.
= . . ∗ . ℎ
Tenacity (
⁄ )
Tenacity is defined as the ultimate (breaking) force of the yarn (in gram-force
units) divided by the denier. It is measured with an instrument called Vibrodyn.
We take one filament of UDY and place it in the machine. As the test starts, a
stress vs. strain graph is also plotted on the computer. A tensile force is applied
to the filament. The point just before which the filament breaks indicates the
tensile strength of the filament. It is calculated as:
=
Moisture (%)
Sample is weighed initially and then wrapped in a paper and placed in an
oven for 140˚C. After 30 minutes the sample is weighed again and the
difference in weight gives away the percent moisture.
OPU (%)
Oil Pick Up is the amount of oil, fiber can retain after being finished with spin
finish oil. In this test, we take 5g of UDY filaments in a burette and let 40g of
methanol run through it. Methanol absorbs the oil present with UDY. A flask is
placed below to collect the methanol and oil solution. It is heated to 100C,
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methanol evaporates away and the amount of oil remaining is measured and
OPU is calculated.
Elongation (%)
The elongation at break is the increase of the length produced by stretching
a yarn to its breaking point. It is expressed as a percentage of its initial length. It
is examined via an instrument called Vibrodyn.
PSF
Denier (d)
Denier is defined as the 1 g per 9000meters fiber. It is examined using Vibroskop
in textile lab. A single fiber is clamped and then put it in the Vibroskop. The
vibroskop measures the denier and give digital results.
Tenacity (
⁄ )
Tenacity is defined as the ultimate (breaking) force of the fiber (in gram-force
units) divided by the denier. It is measured with an instrument called Vibrodyn.
We take one filament fiber and place it in the machine. As the test starts, a
stress vs. strain graph is also plotted on the computer. A tensile force is applied
to the filament. The point just before which the filament breaks indicates the
tensile strength of the filament. It is calculated as:
=
T-10 (
⁄ )
It is the tenacity of fiber at 10% elongation. It is calculated graphically from
the stress vs. strain graph obtained while measuring tenacity.
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Elongation (%)
The elongation at break is the increase of the length produced by stretching
a yarn to its breaking point. It is expressed as a percentage of its initial length. It
is examined via an instrument called Vibrodyn.
Crimp Number (⁄ )
Mono fibers from different chips in sample are hanged via clamp one by one
on device and crimps are counted manually.
Crimp No. = 5.4
Crimp Removal (%)
Here one end of mono fiber from a chip in sample is stuck to a glass slab using
transparent tape initially. The other end is stretched until all crimps disappear
and stuck it too on the slab. Now the length is measured. Then via formula %
no. of crimps removed will be calculated.
Crimps Removed = − x 100
Crimp Stability (%)
Similarly % no. of crimps that stayed will also be calculated from this formula:
Crimps Stablized =−3
− x 100
Shrinkage (%)
In this test, 6-8 filaments from different chips in sample are collectively loaded
with a certain weight on shrinkage drum and readings are noted at shrinkage
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Moisture (%)
Sample is weighed initially and then wrapped in a paper and placed in an
oven for 140˚C. After ̴30 minutes the sample is weighed again and the
difference in weight gives away the percent moisture.
Color Value
Color value of fiber is being checked by comparing it with a standard Cotton.
It’s a manual test. Two types of color values are checked, stated as follows
Color l – show whiteness
Color b – show yellowness
Bulk Density (
⁄ )
A can of measured volume is weighed initially W1. Then it is filled with sample
fiber without any force or weight. It is weighed again W2 and bulk density is
calculated as follows:
= 2 1
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“Intelligence plus character-that is the goal of true education.”
( Martin Luther King Jr.)