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Ibrahim Group of Companies

Polyester Plant
Internship Report
Kamal Mustafa | Khaqan Majeed | Usman Zafar
29-Jul-11

Submitted to: Mr. Muhammad Saeed (Senior Deputy Manager Training)

Polyester Plant 2011

1 DECLARATION
July 29, 2011 Mr. Muhammad Saeed Senior Deputy Manager Training Ibrahim Fibers Limited, Polyester Plant

Dear Sir: Submitted for your review is our internship report for Ibrahim Fibers Limited, duly completed within the deadline. We hereby declare that the report is submitted in long report format, as per the guidelines and is based on peer reviewed information as guided by our instructors and supervisors at the plant facility.

Regards Kamal Mustafa, 2008-NUST-BE-Chem-20 | Khaqan Majeed, 2008-NUST-BE-Chem-21 School of Chemical and Materials Engineering (SCME) National University of Sciences and Technology (NUST) H-12 Campus, Islamabad Usman Zafar 09-Poly-11 University of Engineering & Technology (UET), Lahore

Polyester Plant 2011

2 SUMMARY
The report produces a peer based review and learning outcome about the working and processes of polyester fiber at a plant. Polyester fiber is a fundamental commodity in a textile plant. The report comprehensively describes all the processes that take place at the facility. The basic raw material for this purpose is Pure Terepthalic Acid and Monoethylene Glycol. The two materials are mixed and reaction takes place in the presence of a catalyst to produce an ester. Two types of fibers are produced in this facility viz. semidull and bright. Titanium dioxide is used as a dulling agent. The paste produced is then sent for spinning to produce filaments. Filaments then combine to form a tow which is sent to draw lines for its drawing to resemble natural cotton fiber. Having treated well, the fiber is now ready for cutting and making bales for commercial sale and usage. The plant also contains some common facilities such as cooling towers, compressors, water treatment, chillers, boilers listed as utilities. The process emphasizes the safe operation of manufacturing process and usage of equipments.

Polyester Plant 2011

3 Table of Contents
1 2 4 5 DECLARATION ....................................................................................................................................... 1 SUMMARY ............................................................................................................................................. 2 ACKNOWLEDGMENTS ........................................................................................................................... 5 Introduction .......................................................................................................................................... 6 5.1 5.2 6 Process Overview .......................................................................................................................... 6 Uses of Polyester:.......................................................................................................................... 7

Polymer Section ................................................................................................................................... 8 6.1 PTA ................................................................................................................................................ 8 Storage & Handling ............................................................................................................... 8 Conveying .............................................................................................................................. 9 Day Silos ................................................................................................................................ 9 Charging Systems ................................................................................................................ 10 Bag Charging System .......................................................................................................... 10

6.1.1 6.1.2 6.1.3 6.1.4 6.1.4.1 6.2 6.3 6.4 6.5

Tank Farm/EGR ........................................................................................................................... 12 EGR (Area Code - 3101)............................................................................................................... 14 HTM and Furnaces (Area Code - 3007) ....................................................................................... 16 TDO & Catalyst Section ............................................................................................................... 19 TDO (Area Code - 1307) ...................................................................................................... 19 Catalyst Section (Area Code - 1402).................................................................................... 21

6.5.1 6.5.2 6.6

Paste Preparation........................................................................................................................ 23 PTA Charging ....................................................................................................................... 23 EG Charging System ............................................................................................................ 23 Final Paste ........................................................................................................................... 23

6.6.1 6.6.2 6.6.3 6.7

Esterification ............................................................................................................................... 24 Temperature ....................................................................................................................... 24 Amount of MEG .................................................................................................................. 24 Level .................................................................................................................................... 24

6.7.1 6.7.2 6.7.3 6.8 7

Polycondensation........................................................................................................................ 27

Utilities ................................................................................................................................................ 30 7.1 Water Treatment Plant ............................................................................................................... 30

Polyester Plant 2011


7.1.1 7.1.2 7.1.3 7.2 7.3 Hard Water Treatment........................................................................................................ 30 De-mineralization Process .................................................................................................. 31 Re-mineralization Process ................................................................................................... 31

Chillers......................................................................................................................................... 32 Compressors ............................................................................................................................... 33 Working ............................................................................................................................... 33

7.3.1 7.4 7.5 7.6

Cooling Tower ............................................................................................................................. 34 Boilers ......................................................................................................................................... 35 Nitrogen Generation ................................................................................................................... 36 Technical Nitrogen Unit ...................................................................................................... 36 Pure Nitrogen Unit .............................................................................................................. 36

7.6.1 7.6.2 8

Spinning & Quench Air ........................................................................................................................ 38 8.1 Spinning: ..................................................................................................................................... 38 Pumping: ............................................................................................................................. 38 Fiber formation: .................................................................................................................. 38 Quench air: .......................................................................................................................... 38 Thread Oiler: ....................................................................................................................... 39 Slub Coater: ......................................................................................................................... 39 Drip detector: ...................................................................................................................... 39

8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.2 9 10 11 11.1 12

Spin Finish Oil Preparation: ......................................................................................................... 40

Fiber Line Process ............................................................................................................................... 41 Baler & Cutter ................................................................................................................................. 43 Auxiliary Section:............................................................................................................................. 44 Spin Pack Regeneration .............................................................................................................. 44 SAFETY PRECAUTIONS..................................................................................................................... 46

Polyester Plant 2011

4 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, Our Instructors Mr. Anis Ahmad Naqvi and Mr. Karim Nawaz in the Polymer Section. Mr. Nazir Ahmed, Senior Deputy Manager Utilities. Mr. Raziq Ditta Senior Area Manager, Spinning and Fiber Line 1 for all his guidance and help. We are also thankful to all the shift engineers, operators and every individual who has helped us even a bit for the completion of this report

Polyester Plant 2011

5 Introduction
Ibrahim fibers polyester plant is for the continuous production of polyethylene terephthalate (PET), staple fibers or chips (textile grade). The plant is divided into two portions IFL-1 & IFL-2. IFL-1 has the capacity of 186 tons/day with two lines line - 14 and line - 15 each having 93 tons/day capacity. IFL-2 has a single line#17 with a capacity of 410 tons/day.

Area - 15 was started on 29th Dec 1996 and area - 14 on 26th Feb 1997 as far as IFL-2 is concerned was started recently on 02 June 2002. Whole plant is equipped with Distributed Control System (DCS) in which software like PROVOX or DELTAV are being used. The plant is situated at 38 - km Sheikhupura Road Faisalabad. Today it is the highest production company of Pakistan and its vision is to be sustainable, growth oriented company and achieve scale to remain competitive on the barrier free global economy.

5.1 Process Overview


Today polyester is made by continuous polymerization process using PTA (Pure Terepthalic Acid) and MEG (Mono Ethylene Glycol). Catalyst like antimony triacetate Sb(CH3COO)3 is used to start and control the reaction. TiO2 (titanium di oxide) TDO is added to make the polyester fiber/filament dull. Spin finishes are added at melt spinning and draw machine to provide static protection. PTA which is a white powder is fed by a screw conveyor into hot MEG to dissolve it. Then catalyst and TDO are added. After that, esterification takes place high temperature 257.6oC then monomer is formed polymerization is carried out at high temperature usually at this plant the temperature at PP-1 is 268oC then at PP-2 it goes to 269oC the final product has the temperature if about 276.3oC. it is done in totally under vacuum. Monomer gets polymerized into the final product, PET (poly ethylene terephthalate) this is in the form of thick viscous liquid. This liquid is then pumped to melt spinning machine. They have different spinning positions. At each position polymer is pumped which discharges an accurate quantity of polymer per revolution through pack which has sand as filtering media and spinnerets which could be circular having specific number of holes. Polymer comes out of each hole of spinneret and is instantly solidified by flew of cool dry air, process called Quenching. Filaments from each spinneret are collected together to form a small ribbon this combined ribbon is a tow. The material is called undrawn tow next at the draw machine undrawn tows from several cans are collected in form of a sheet and passed through a trough of hot water to raise the temperature of polymer to 70 c which is the glass transition temperature of this polymer so that it can be drawn 6

Polyester Plant 2011

After the drawing is completed each filament has required denier, and has all its sub microscopic chains aligned parallel to fiber axis thereby improving the crystallography and imparting certain strength.

5.2 Uses of Polyester:


The most popular and one of the earliest uses of polyester were to make polyester suits. Due to its strength and tenacity polyester was also used to make ropes in industries. PET bottles are today one of the most popular uses of polyester. Taking care of polyester clothing is really easy and very time efficient. Polyester clothing can be machine washed and dried. Adding a fabric softener generally helps. Dry the fabric at low temperatures to get maximum usage from the clothing. Though polyester does not require much ironing, if you must then iron warm. Polyester can be dry-cleaned with no hassles.

Polyester Plant 2011

6 Polymer Section
6.1 PTA
PTA (Pure Terepthalic Acid) is one of the basic raw materials at Ibrahim Fibers Limited (IFL). The other is Monoethylene glycol (MEG) which will be discussed later in this report. PTA reacts with MEG according to the following reaction to generate Bis-hydroxy Ethylene Terephthalate (BHET) and water. PTA + MEG BHET + H2O

Two BHET molecules react together to give back MEG and PET (Polyethylene Terephthalate). BHET + BHET PET + MEG

This reaction is carried by the poly-condensation, the type of polymerization in which a byproduct is formed. This PTA is used in its pure form and is produced by the oxidation of pxylene in the presence of air. The code used for all the equipments and utilities in the PTA section is 1204. Following are the four main processes which are carried out in the PTA section. 1. Storage 2. Handling 3. Conveying 4. Charging These are explained as follows.

6.1.1Storage & Handling


Ibrahim Fibers Limited uses PTA in pure form (as the name suggests) instead of impure form. This pure form ensures the achievement of high quality products. The daily PTA demand is furnished by the following two companies. Lotte Pakistan PTA Ltd. Siam Mitsui PTA Co. Ltd.

The former is a Korean based company that provides bags of PTA weighing 1.1 ton each. The bags consist of an outer polypropylene layer supported on a polyethylene layer which protects PTA from moisture and contact with air. The latter is a joint venture of Cementhai 8

Polyester Plant 2011 Chemical Company (Thailand) and Mitsui Chemical Inc. (Japan). They provide PTA in a containers weighing 22 tons each (container casing weighs 3 ton). PTA is used in the form of white crystalline powder of particle size of 75 m which increases the reactivity and ensures that no PTA is left unreacted. The plant produces 600 tons/day of PET. Whereas the PTA required is 860 kg/ton of PET. Therefore, daily consumption of PTA is 516 tons/day.

6.1.2Conveying
The PTA feed is conveyed by high pressure N2 that comes from compressors (rotary type). PTA is not allowed to come in contact with air because if it comes in contact with 5% air, it forms an explosive mixture. That is why N2 is used as a conveying medium. Nitrogen is separated form air in an in-built plant facility. This N2 is compressed in the compressors and is then supplied to both IFL-1 and IFL-2 facilities. The following compressors are used for both lines. IFL-1 1204-K01 1204-K02 1204-K05 A compressor consists of: A filter A cooler IFL-2 1204-K11 1204-K12

The filter cleans the gas from any solid particles that may be present whereas cooler lowers the temperature of the gas that rises due to compression, because compression is an adiabatic process. The gas leaving the compressor is further cooled down to 53oC in a shell & tube heat exchanger with a co-current flow of N2 and water. Water flows in shell side while nitrogen flows through a bunch of 70-80 tubes. If compressor is being started for the first time, the gas recycled for a few times to build up pressure. The gas when leaves heat exchanger passes through a static jumper. Its purpose is to remove charges that may be induced as a result of rubbing of dry particles of PTA which would otherwise cause an explosion.

6.1.3Day Silos
A day silo is named so as it can hold up stock for 1 day. Three day silos are used in PTA section. 1204-T01 is for IFL-1 while 1204-T11 and 1204-T12 are for IFL-2. Two tanks are 9

Polyester Plant 2011 always in operation whereas third one is standby. The former has a capacity of 490 tons while latter two can hold up to 590 tons each. All the tanks are allowed to have minimum of 25% and maximum of 70%. Level Alarming Low (LAL) and Level Alarming High (LAH) are sounded respectively for both levels.

6.1.4Charging Systems
Following two types of charging systems are used for PTA.
6.1.4.1

Bag Charging System


In this 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 1204-V01. This silo opens up in a feeder 1204-X08. This feeder prepares batch to be moved for compression and finally to a large storage silo1204-01.

Pan

Pan

Screen

Screen

1204-V01

1204-T01

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Polyester Plant 2011


6.1.4.2 Container Charging System

This system uses the 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 25-30o. The maximum elevation provided is 45o. The container is opened and PTA is loaded in a 1204-X57 feeder after passing through vibrating screens.

1204-X57

1204-K11

1204-T11

1204-T12

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Polyester Plant 2011

6.2 Tank Farm/EGR


Area Code is, 1107 for IFL-1 1110 for IFL-2

This section discusses the storage and recovery of Monoethylene Glycol (MEG), the second raw material used in fiber manufacture. Ibrahim Fibers Limited imports this raw material from the following three companies, SABIC (Saudi Arabian Basic Industrial Chemicals) Saudi Arabia Mobil Saudi Arabia Equate - Kuwait

This MEG comes in the form of 40 ton tankers that are unloaded at the Port Qasim Terminal of IGC. MEG quality is analyzed for recommended purity. They are then transported from Karachi to the IGC factory. Tracking devices are installed on the trailers for safety purposes. MEG is hygroscopic in nature i.e. it absorbs water and moisture form atmosphere. Hence care must be observed while its transportation and storage. The general physical and chemical properties of MEG are as follows. Property Formula Molecular Weight Boiling Point Auto-ignition Temperature Flash Point (Closed Cup) Color Odor Taste Specific Gravity Value HO-CH2-CH2-OH 62.03 g/mol 197oC 398oC 111oC Colorless Odorless Mild Sweet 1.116

The PET produced in esterification requires 340 kg/ton of PET. The daily production of PET is 600 tons/day. Hence, 201 tons of MEG is required each day. The unloaded MEG at IGC factory is again analyzed for quality before transferring to storage tanks. 4 storage tanks are available for MEG storage, each having maximum capacity of 2000 tons. The tanks are filled up to a maximum level of 90%. Prior to the storage, MEG is pumped to a flow meter that shows both flow rate and quantity. The flow rate of pump is 2000 kg/hr. It is then filtered for any suspended solid having a polyester bag medium. Form here, MEG is moved to tank equipped with a level transmitter. The following pump and storage tank assembly is available at storage farm. 12

Polyester Plant 2011

Fiber Line

Storage Tank 1107-T01

Pumps 1107-P02 1107-P03 1107-P01 1107-P04 1110-P02 1110-P03 1110-P01 1110-P04

1107 1107-T02 1110-T01 1110 1110-T02

MEG intake

Pump

Pump

Flow Meter

Filter

Tank

Tank

A general diagram of MEG storage

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Polyester Plant 2011

6.3 EGR (Area Code - 3101)


PTA + MEG BHET + BHET BHET + H2O PET + MEG

The MEG produced in the second step contains moisture, aldehyde and monomer. This whole is called as sludge. From this sludge, we are concerned with the distillation of MEG and water. The boiling point of MEG is 197oC; hence it is recovered as bottom product. Water is obtained overhead and is drained. The distillation process is as follows. The MEG produced in the second step is taken to the distillation column where an evaporator is installed. The evaporator is fed form the MEG storage vessel 3101-V01. This evaporator heats the feed by the Heat Transfer Media (HTM) moving in coils. The temperature of this kettle type evaporator is maintained at 165oC. The feed is fed at the sixth plate of the column. There are a total of 16 plates in the column. They are assembled in bubble cap arrangement with average tray temperature of 120oC. The whole column is operated under vacuum conditions of 300 mbar. This vacuum is created with the help of eccentric type vacuum pumps. The water is evaporated and is collected at the top in a condenser 3101-D01. The condenser is a shell & tube type heat exchanger with vapors at the shell side. Part of the condensed water is refluxed while remaining is sent for treatment. This water contains <1% MEG which does not affect desired Chemical & Biological Oxygen Demand i.e. COD & BOD. This water is only treated for its acidity with the help of a base. The MEG collected at the bottom is 25% of the total being used at the plant. This is obtained at 160oC and stored in the vessel 3101-V04. This is then forwarded to 1117-T01. The remaining sludge which contains impurities is collected in the barrels and is sold as fuel. 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. The block diagram for EG recovery is as follows.

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Polyester Plant 2011

Water Vapor Condenser

Reflux Overhead Water

Vacuum Pump

Distillation Column

3101-V04

Reboiler/ Evaporator

1117-T01

Sludge Barrel

3101-V01

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Polyester Plant 2011

6.4 HTM and Furnaces (Area Code - 3007)


The process of esterification is an endothermic reaction. Thus, heat is required to achieve desired process conditions. This heat must not be provided directly as this is not favored for the products being formed. Therefore, a proper Heat Transfer Medium (HTM) is needed to carry out all the heating operations in the plant. Because the process is very sensitive and a change of even 0.3oC can cause drastic effects on the process. The medium thus chosen must have the following properties. 1. Low Viscosity: This is required so that the HTM does not choke the process lines or cause resistance in flow. It must not show significant viscosity change due to change in temperature. 2. High Thermal Conductivity: The HTM chosen must have high thermal conductivity for efficient heat transfer. 3. Low Freezing Point: So that it does not form solid deposits at normal temperature. 4. Thermally Stable: HTM must be thermally stable and should not decompose upon heating. 5. High Flash Point: So that the vapors of HTM do not form explosive mixture in vessels and lines. 6. Non-flammable: The HTM should be non-flammable. 7. Low Density: Low density offers easy flow of HTM in the lines. The HTM used in IFL is of following two types, i. ii. Liquid Santo therm (Phenyl Benzene) Vapor Dow therm (Biphenyl Ether)

The HTM is heated in a top fired furnace which is fired with the help of either Natural Gas or Bunkers Crude Oil (BCO). This BCO is stored in an 1127 vessel from where it is moved to 3007-V03. The level of this vessel is maintained from 50-80%. Positive displacement pumps are used for its transfer. The consumption of Natural Gas & BCO is 5.6 m3 & 3.0 m3 respectively. Two furnaces are being used for the heating of HTM viz. 3007-F01 & 3007-F02. One of these is standby furnace. It must be noted that the standby furnace in this section is not kept completely out of order. The furnace in operation is fed at 343 m3/hr. whereas standby furnace receives 20 m3/hr. of HTM. The temperature of the furnace is 327oC. The furnaces are normally operated on a three month schedule. A furnace has refractory at the top which does not let the heat escape the furnace. Then there is a diffuser plate which contains cuts. These cuts provide swirling movement of the gas & air so that it is spread evenly through the furnace. Having completed certain passes in the furnace, it is moved to the stack emission.

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Polyester Plant 2011 In the furnace, Natural Gas is used in the furnace while Santo therm is used in the coils. Natural Gas enters in a ball valve and then through a strainer to remove any solid particles and impurities. It then passes through a Pressure Regulating Valve (PRV). Then it reaches furnace through a Blocking Tightness Control. This system consists of two XV valves. The gas through first XV valve and is closed. The pressure of the gas is measured. If pressure of the gas does not change then it is sent through second valve for ignition. But if there is reduction in pressure, then this an indication of leakage and ignition wont start. The system also has an Air/Fuel Ratio adjustment (CAMS system). The furnace is ignited with the help of LPG when ignited for the first time as LPG has higher burning value. The pressure across Santo therm coils is constantly measured. The flue gases from the furnace are passed to an economizer which is a Shell & Tube heat exchanger system for heating the air. Flue gases pass through tubes while air passes through the shell side. The temperature of the air is raised up to 200oC before entering the furnace. After heating, stack gases are emitted into the atmosphere. If there is smoke in the gases then they are analyzed and readjusted. The temperature of the stack gases is around 350oC which should not be allowed to rise beyond 425oC. HTM is built up in a 3007-V01 vessel and is constantly heated to reduce viscosity. 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. The lines entering the furnace are also provided with steam tracing for easy flow and good atomization of HTM. HTM Usage: In any operation, HTM is used as two systems. In coils as liquid and in vessel boundaries as vapors. Santo therm 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 Dow therm into vapor state in an evaporator. This Dow therm 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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Polyester Plant 2011

3007-V04 (Leakages)

Air

Furnace

BCO

3007-V03

Economizer

Stack Gases

A simple HTM Section Flow Chart

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Polyester Plant 2011

6.5 TDO & Catalyst Section


6.5.1 TDO (Area Code - 1307)
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, TDO provides matt finish to the final product. It increases the durability of the product. TDO Anatase has high refractive index close to diamond, which causes glitter-ness. 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.

TDO bags are added through 20 small bags of 25 kg each or 1 big bag of 500 kg in the feeder. TDO is then directed to 1307-V01 vessel where it is agitated for 4 hours. This mixture then moves to 1307-V07 where 1610 L of EG are added. It is again mixed for 1 hour before moving it to centrifuge (1307-A02). In centrifuge, the concentration of TDO is 18% and mixture enters at a set point of 452 L. The centrifuge separate oversize and undersize particles. The coarse particles are produced due the agglomeration caused by the charges developed due to agglomeration. Centrifugation is done by 4 classifying cycles of 50 minutes each in which undersize particles are separated and moved to 1307-V02 in which 1800L of EG are added. Oversize particles are separated by 4 dispersion cycles of 25 minutes each. Peelers in the centrifuge remove coarse particles and send them to 1307V08 and then to the Pearl Mill (1307-A01). 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%.

Muller

A simple Pearl Mill

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Polyester Plant 2011

TDO Feeder

Centrifuge

Pearl Mill

1307-V01

1307-V07

1307-V02

1307-V08

Bright

1307-V04

1307-V03

Semi-Dull

4363L EG

1307-V05

TDO Section Flow Diagram

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Polyester Plant 2011

6.5.2 Catalyst Section (Area Code - 1402)


The process of fiber making is an endothermic reaction. It means that the energy required to start reaction is high. To lower this energy, called as activation energy, catalyst is used. Catalyst lowers the activation energy by associating itself with the reactants which also helps in reducing the residence time. The catalyst used is Antimony Triacetate Sb(CH3COO)3 or Di-antimony Triacetate Sb2(CH3COO)3. It helps the reaction in the stage of polycondensation which will be discussed later. It is imported in the form of bags, each weighing 15 kg, from USA. It occurs in the form of granules and is fed as two catalyst vessels Feed vessel Preparation vessel

The general procedure of catalyst preparation can be illustrated as: 2000 Liters EG + 75 kg Catalyst Solution + 1250 Liters EG Solution True Solution

The whole procedure is carried out at 75-80oC. The mixture is constantly agitated for 4 hours and 1 hour is provided as settling time. An analysis of the solution is done after 5 hours and it is ensured that the concentration of catalyst is 2% in the solution. Out of this 2%, only 0.8% is the active catalyst that actually takes part in the reaction. The quantity of catalyst in the melt is 185 ppm by weight. The standard concentration is 175 ppm by weight. 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 are attached which send the measured quantity of EG in the catalyst vessel. The batch in the 1402-V01 is then sent a filter 1402-S02 in which batch is filtered for any suspended solids. Clear solution is now ready for paste preparation tank.

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Polyester Plant 2011 N2 PTA from Silo + N2 Filter Day Silo 1413-T01

Fresh + Recovered EG

Paste Tank

1st Est. Reactor

3250L MEG

Catalyst Feed Hopper

1402-V01

Filter (1402-S02)

Catalyst & Paste Preparation Process 22

Polyester Plant 2011

6.6 Paste Preparation


After the preparation of all the raw materials and catalysts, the process is now taken to next stage of paste preparation in which all the components are mixed in such a way that they form a paste which is then further taken to the main reaction vessel. 6.6.1 PTA Charging The PTA prepared in the PTA section is stored in day silos. From these silos, PTA is carried by pressurized N2 to a day silo at 25 m top of the IFL-1. The mixture is filtered prior to its entry into the silo. In the day silo, PTA settles down while N2 leaves the silo through nitrogen discharge system. The PTA then enters a Schenk System which consists of a motor operated rotor assembly. This system is attached for the proper distribution of PTA in the paste tank. PTA enters the tank at a mass flow rate of 7000 kg/hr. 6.6.2 EG Charging System The EG charged in the paste preparation is consist of fresh MEG and spent EG which is recovered in the distillation column. The column EG is obtained at 182oC. An important thing to remember in this section is the E/T ratio. This indicates the ratio of moles of EG to the moles of PTA. In paste preparation tank, this ratio is adjusted at 1.14. However, the required ratio in the reaction is 2. Since, no reaction is occurring in this tank, therefore, it is maintained below 2.

6.6.3 Final Paste 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 which operated at 16-17 Amperes. 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.

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6.7 Esterification
The main reaction of any polyester plant occurs in the esterification section and IFL-1 is no different. The paste prepared in the previous section now enters the main reaction lines where the following reaction pattern is followed. Alcohol + Acid Ester + Water

Although, two types of products are being prepared at the facility, however, the main reaction takes place in a large esterification reactor 1424-R01 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 not let any solid deposition on the walls of the reactor. An agitator with blades having angle of 38o provides agitation for complete mixing and efficient heat transfer. The temperature inside the reactor is maintained at 258oC. Following are some other factors that determine the efficiency of the reaction.

6.7.1 Temperature
Since the process is endothermic, hence a high temperature favors the reaction in forward direction.

6.7.2 Amount of MEG


An increased amount of MEG is normally desired.

6.7.3 Level
The level of the mixture in the tank is another factor that determines the process efficiency. A high level of mixture will result in high residence time. It is measured by dividing the tank level with exit flow rate. The level of the tank is a very important parameter and is constantly observed. The level of the tank is measured by the following two devices which are highly sensitive.
6.7.3.1 Displacer

A displacer consists of a metal rod suspended with help of the spring enclosed in the housing. It works on the Archimedes Principle which states that if a solid is submerged in a liquid, then a reduction in the weight of the solid is observed which is equivalent to the volume of the liquid displaced due to the submerging of solid. This reduction in the weight of the metal rod is calibrated against the level of the tank.
6.7.3.2 Bubbler

This level indicator is in fact a perforated tube through which nitrogen is circulated at 0.1 m3/hr. As the level of the reaction mixture rises, the pressure of the nitrogen decreases. This decrease in pressure is measured against a reference pressure at the top. The total pressure drop P is calibrated to show the level of the tank. 24

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Approximately 92% of the reaction is completed in the main ES-1 tank. After 4 hours of reaction, a sample is drawn to check its Acid Number. The acid number tells how much KOH will be required to neutralize all the acid in the sample. The acid no. of the sample must be 525 mg KOH/mg sample. If it is lower than this, then more EG is added to maintain the desired acid number. All product lines in this lines are jacketed and lined with, Insulation Cladding From this ES-1 reactor, the mixture is separated into two lines for ES-2 reactors. For semidull product, it is moved to line number 14 in the reactor 1421-R02, where bright product is manufactured in the line number 15 in reactor 1521-R02. Each has a capacity of 11.8 m3. Each reactor has 4 coils of Santo therm and an external Dow therm lining. Dow therm is heated in an evaporator in which Santo therm is moving in coils at 327oC while Dow therm is heated up to 278oC. TDO is also added in ES-2 vessels of each product line. The product of ES-2 reactor has acid number of 212 mg KOH/mg sample. EG which evaporates in each reactor vessel, ES-1 & ES-2, is moved to an internal distillation column 1424-C01 where it is fed at the sump of the column. The sump is maintained at a level of 85%. The whole column is heated with the help of HTM to which a steam tracing is provided so that the temperature of the HTM does not fall down. The temperature of the column is at 185oC. A safety pressure valve is also available which automatically open when the column pressure reaches 3.5 bars. This safety line leads to a safety vessel 1424V02.

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Polyester Plant 2011 Esterification Process Block Diagram Paste Tank

Reflux

HTM

Esterification Reactor-1

Distillation Tank 1424-C01

Safety Line

Bottom

1421-R02

1521-R02 1424-V02

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Polyester Plant 2011

6.8 Polycondensation
The purpose of this process is to increase the chain length of the ester up to 104 monomers in a single chain. This is carried out in the following three reactor systems. PP1 PP2 DRR

PP1 is the first tank which has no agitation system. It only has internal circulation due to fringes which increases control over process parameters. This reactor is operated at 260oC and 120 mbar vacuum pressure. This vacuum is created with the help of vacuum pumps. The moisture in the PP-1 is 30%. 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. 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. At the bottom, a scrapper shaft is attached which scraps any solids that may deposit in the condenser walls. From PP-1 tank the solution moves to the second polycondensation tank PP-2. This tank is also equipped with an agitator. The operating conditions of this tank are 273oC temperature and 18 mbar pressure. Moisture in the tank is 10%. Hence, the rate of evaporation of this tank is higher than PP-1 tank. Sometimes this causes the choking of the evaporator condenser system in case of PP-2. The pressure across this system is measured and drop in pressure is sensed by the controller system. This ceases the supply of EG showering due to which the temperature of the condenser system rises. This rise in temperature melts any depositions and EG showering is re-opened by the control valves as the pressure is maintained. 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. The liquid EG that is showered has temperature of 40-45oC after it has condensed the vapors. This EG is then taken to a plate and frame heat exchanger to reduce the temperature to 38oC. Both PP-1 and PP-2 tanks also have Barometric Leg System. This system is devised to move the condensate against the pressure difference. The condenser is placed at a height of 33.91 ft. above the receiver, because air exerts a pressure of 33.91 ft. H2O. For systems other than water, the barometric leg (which is the suitable height above receiver) is calculated as;

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Polyester Plant 2011

In this case the sp. gr. of EG is 1.116 at 25oC. The condensed EG is collected in a receiver submerged in a tank. The level of the receiver is at 90%. Any overflow passes through sieves at the side of the receiver and falls into the tank beneath it. Its level is kept at 40%. From this tank, the EG passes through the strainer to remove any suspended solids and is then pumped again to the top of the showering system. From PP-2, the solution is fed to DRR (Disc Ring Reactor). The only purpose of this reactor is to reduce the intrinsic viscosity (viscosity due to components, not temperature) of the solution so that it is prepared for the fiber line process. This is done in a horizontal reactor in which rings are attached on a shaft passing across the length of the reactor. The reactor reduces the concentration of EG to reduce viscosity by evaporating it. Following are factors on which the efficiency of DRR depends. Vacuum Temperature Exposed Area

The vacuum is provided by the jet system which is explained later in this section. Temperature of the DRR vessel is kept at 280oC at a very low pressure. Rings attached to the shaft constantly expose the mixture to empty area so that EG evaporates and is vented through the jet system. A high viscosity mixture will produce drips whereas low viscosity gives high elasticity. The jet system, used to create vacuum, uses Blast EG at a very high pressure. The blast EG has similar properties as steam but at a high temperature. This EG passes through a jet to which PP-2 and DRR are attached. Vapors of EG from both of these tanks are taken to the jet which reduces the pressure in the tanks. This blast EG then passes through a series of coolers where cool EG is showered. The cooler condenses certain part of the EG and rest is sent to next cooler. In the third cooler, the uncondensed part is pumped and is vented into the atmosphere. This part mainly contains aldehydes and ketones due to which it is not possible to condense it. All the reactors in this section are operated at same conditions, but at different parameters. The product from Polymer (DRR) and Pre-polymer (PP-2) tanks are first filtered in filters in which candles are placed in capsules. The filter of the pre-polymer contains 27 candles in each capsule. The code number of these filters is 1451-S01 & 1451-S02. One of this is in operation and other is standby. Similarly, polymer process also has a set of two filters, 1481-S01-A & 1481-S01-B. In 1481 filters, each filter has 19 candles each. Contaminated candles are first cleaned by TEG (Triethylene glycol) in two cycles. Then they are cleaned by water jet at pressure of 80 bars.

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Polyester Plant 2011 DEG (Diethylene glycol) is used in the seal systems of this section. TEG is stored in the vessels 3310-V01 & 3310-V02. The water which is released is softened uses chemicals stored in 3320-V01 & 3320-V02.

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Polyester Plant 2011

7 Utilities
7.1 Water Treatment Plant
7.1.1 Hard Water Treatment
For all the supplies water is the major requirement, which is pumped from ground. The conductivity of the ground water is very high i.e. 3000-3300 S, so the water is treated initially to reduce its conductivity in the water treatment plant. In this plant the ground water is treated through physical & chemical processes to make it useful in the processing. Ground water is pumped through 3 turbines & stored in an overhead tank with a capacity of 5300 gallons then supplied to Water Treatment Plant for purification. Two pumps pump the water to the top of the two multilayer filters, which have beds of sands, having three layers of sand of decreasing particle size. These filters are used primarily to remove the suspended particles from the raw water. The filtered water is then passed through an HCL dosing unit where its pH is maintained at 6.3 by dosing 33% HCL through a control valve. The HCL reacts with the carbonates & thus removes the hardness. The reaction occurring here is as follows, HCl + CaCO3 HCl+MgCO3 H2CO3 +Air CaCl2 + H2CO3 MgCl2 + H2CO3 H2O + CO2 + Air

The filtered water at a pH 6.3 is passed through candle filters also called as bag filters. The water is then pumped through multi-impeller pumps, which generate 25-bar pressure output, which is used as a feed for the Reverse Osmosis unit. In the RO unit we have 6 banks in which filters are fitted. Here almost 70% of the water passes through the cellulose membrane whose conductivity is very low (100 S), called as Permeate. The remaining 30% water whose conductivity is very high (10,000-11,000 S) is disposed off. In this process salt contents of raw water are reduced from a TDS (total dissolved solids) of 2000 ppm to 20-60 ppm of soft water with the yield of 70%. The soft water is sent to the hydrocyclones where the air is blown with the help of a blower, which after absorbing CO2 from the water is discharged to the atmosphere. Here 80-85% of CO2 is removed & water is sent to the storage tank. The permeate is soft water which is then divided into four lines. To the cooling tower as a make-up stream To the process To the mixed bed for De-mineralization To the Re-mineralization process 30

Polyester Plant 2011

7.1.2 De-mineralization Process


The soft water is treated through a mixed bed ion exchange process in a De-mineralizer where we get the water whose conductivity is less than 1 S. This water is called Demineralized water.

7.1.3Re-mineralization Process
The soft water is also used to make a drinking water, so a soft water line is passed through a re-mineralize to add necessary minerals (Ca-hydrolite) in the water to make it potable. The drinking water is then sent to the storage tank of 5 ton capacity.

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Polyester Plant 2011

7.2 Chillers
Chillers are used to chill (cool) the water. Here the temperature of the water is reduced to 6-7oC. The chilled water circulates in the plant through a closed loop. The water returns to the chillers at a temperature of 11-12oC. We have three Water Cooled Centrifugal chillers of 2000 kW cooling capacity. The chilling operation is like a refrigeration cycle. It has mainly 4 parts. Evaporator Compressor Condenser Expansion valve

The evaporator is basically shell & tube heat exchanger in which the chilled water is in the tube side & the refrigerant (Freon) is on the shell side. The heat exchanger used here is a 12 pass heat exchanger. The WC (chilled water) stream from the process (11-12oC) enters the evaporator in the tubes & is discharged at a temperature of 6-7oC. It is present in the liquid form & when the WC stream passes through the evaporator tubes, the refrigerant gets heat from the water and evaporates. The vapors of the refrigerant are sent to the two-stage compressor. The compressor should be of such capacity that it should intake same amount of vapors from the evaporator as being produced in it if the capacity is low then the pressure in the evaporator will increase & thus the saturation temperature of refrigerant will increase. When the vapors are compressed their temperature & pressure increases. The compressed stream is sent to the condenser in the tubes, where cooling water is circulated for the cooling purpose in the shell side. Here the vapors are discharged at the same pressure but at lower temperature & sent to the economizer. A nozzle is fitted in the economizer, which acts as an expansion valve. Here the vapors are sprayed so their pressure decreases due to sudden expansion cooling occurs & most of the vapors go to liquid form. From the economizer these streams are discharged. To the evaporator (in liquid form) To the evaporator (in the vapor form) To the 2nd stage of compressor as an inter-cooler (in vapor form)

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7.3 Compressors
Compressors are used to increase the pressure of a gas. Compressors are very important in industry because at many places in process we require air at pressure higher than the atmospheric pressure. At IFL, the purpose of installing a compressor is, For nitrogen generation For PTA charging

Screw type compressors are used here in positive displacement types of compressors. Five double stage screw type compressors are installed here of capacity 1339 m3/hr, having maximum working pressure 10.5 bar. One compressor is used for normal consumption, and one is stand by, whereas remaining are used depending upon load. There are also four air refrigerant driers. Two types of air are produced here having following specifications. Plant Air 9.5 bar 35oC Dew Point < 4oC Instrument Air 6 bar 35oC Dew Point < -20oC

7.3.1 Working
Double stage screw type compressor takes air from the atmosphere. This air is pre filtered and then it passes through intake filters in order to remove dust and other suspended impurities. In first stage, this air is compressed to 2.7 bars, its temperature rises to 240oC. This compressed air passes through intercooler (Shell and tube type), where water is used as cooling media. Temperature of air falls to 35oC. Now it passes through the second stage, where it is compressed to 9.5 bars and its temperature rises to 245oC. It is passed through after cooler where water is used as cooling media and temperature of air becomes again to 30oC. Now this compressed air at 9.5 bars and 30oC enters in air refrigeration dryers. This air enters into an evaporator, where moisture of air condenses by giving its heat to refrigerant causing it to vaporize. The condensed moisture is drained off. This moisture free air enters again in air to air heat exchanger, where it takes heat from the incoming compressed air. The vaporized refrigerant is compressed in reciprocating compressor. This refrigerant enters the condenser where water is used as cooling media. This condensed refrigerant is again ready for moisture removal in evaporator. The compressed, dried air is stored in compressed air storage. From the supply of compressed air to process; one stream is taken into the instrument air dryers. They contain two cylinders filled with hygroscopic compound (Al2O3). One cylinder operates at a time, when its pressure becomes high and temperature becomes low and it becomes saturated, its pressure falls and refrigeration occurs. Meanwhile, at the same time other cylinder become active and prepares instrument air. The instrument air produced is stored in vessel. 33

Polyester Plant 2011

7.4 Cooling Tower


Cooling tower is used to cool the process water. Cooling of water in cooling towers depends upon wet bulb temperature and humidity of air. The cooling tower cools the water by direct contact of water to the air so water can not be cooled below the wet bulb temperature of the area. The cooling towers are of three basic types Natural Draft cooling Tower Forced Draft cooling tower Induced Draft cooling tower The induced draft cooling tower is the one in which the fan is placed on the top of the tower and air enters into the tower from side slits or louvers. So the induced draft cooling tower is more efficient. In the IFL Induced Draft cooling tower are used. The water from the process returns to the top of the tower where it is spread all over on the tower through the distribution nozzles onto the wood fills, where the air coming through the louvers cools the water due to heat transfer. Wood fills are used to increase the contact area of air and water. Corrosion inhibitors, such as sodium or zinc based are added in the water to reduce corrosion in the piping. The zinc reacts with access oxygen and a superficial layer of oxide is developed which prohibits rusting and corrosion. Scaling does not occur in this stream due to low temperature. Maximum temperature lowered by cooling tower is 6oC.

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Polyester Plant 2011

7.5 Boilers
The boilers are used for the production of steam, which is then used on many types of equipments in the plant. The basic consumption of steam is in the fiber draw line, heavy furnace oil & polymerization section. There are basically two types of boilers, i. ii. Fire Tube Boilers Water Tube Boiler

Three fire tube boilers are used in the IFL. One is stand by while 2 are in operation. Fuel for boiler: i. ii. Natural gas (mostly used) Furnace oil (stand by)

The steam condensate (70%) returning from the plant comes to the feed water tank where a de-aerator is also attached to remove the air from the steam condensate. In this vessel chemicals are added to condensate. i. ii. iii. Hydrazine - for removal of free oxygen Caustic soda - for maintaining pH Ammonia gas - also added for maintaining pH

After the feed water tank the condensate is pumped by two pairs of pumps (one pump of each pair is standby) to the boiler. The condensate along with 30% de-mineralized water enter 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 form the super-heater exits at about 250oC. The steam at 25 bar pressure is then divided in to 3 different pressures, i. ii. iii. 25-bar 10-bar 6-bar

Types of Steam: i. ii. iii. Wet steam Saturated steam Superheated steam (steam 50% & water 50%) (steam 75% & water 25%) (steam 100%)

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Polyester Plant 2011

7.6 Nitrogen Generation


Nitrogen required for the process must be at high pressure and low temperature. Nitrogen produced at IFL is classified into following two types. i. ii. Technical nitrogen Pure nitrogen

7.6.1 Technical Nitrogen Unit


NT is produced in a pressure swing adsorption unit consisting of Air compressor Chilled water air cooler Pressure Swing Adsorption (PSA) Unit

A two stage air compressors giving compressed air at a pressure of about 8 bar. Currently unit is operated is at external supply. Compressed air passes through pressure relieving valve where its pressure reduces from 9.4 bar to 8 bar. This air then passes through chilled water cooler. The water supplied lowers the temperature from 30oC to 12oC, also moisture trapped is removed. This air is transferred to Buffer Vessels containing cyclones, which remove moisture. Air from the buffer vessel, reaches adsorber-1 through the bottom and flows through the carbon molecular sieve bed. During this process the oxygen of the process air is adsorbed that is attached to the CMS at a high pressure and low temperature. The nitrogen reaches into technical storage tanks Downstream of anti-storage tanks tubing, takes sample gas to the analyzer for the measurement of O2 contents in the NT produced. The NT flows to the storage vessel or to the atmosphere depending on its O2 contents. If O2 contents exceed the set point, then N2 vents to atmosphere. If O2 contents are within a range, then it flows to NT storage vessel. The regeneration process is of 1 min cycle. First pressure equalization occurs of both absorbers then the absorber to the regenerator releases adsorbed O2 to the atmosphere and the other come in operation to absorb oxygen. The NT produce from plant A and B is stored. The NT produce must contain O2 <1%. The production of NT takes place at a rate of 195 m3/hr. in each section.

7.6.2 Pure Nitrogen Unit


It also contains 2 units. Each stream is divided into further two streams; one for each plant. There are two hydrogen cylinders for each plant. A highly exothermic reaction occurs, forming N2 and H2O vapors. The reaction of hydrogen and oxygen occurs at 195oC and in the presence of Palladium used as catalyst in a De-Oxo Reactor. The reactors maximum allowable pressure is 13 bars and maximum allowable temperature is 240oC. 36

Polyester Plant 2011 This stream containing NP and water vapors is passed through finned type heat exchanger to lower its temperature. It is cooled down in the exchanger resulting in the condensation of water vapors releasing NP. The production of nitrogen is 10 m3/hr.

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Polyester Plant 2011

8 Spinning & Quench Air


8.1 Spinning:
It is operation by which molten polymer is converted from amorphous condition to crystalline state by making long continuous filament or thread under certain temperature and pressure. It is physical process. In IFL, direct or molten spinning process is done. Polymer from polycondensation comes in form of melt at 288oC. Semi dull is being processed in 71 line while bright is processed in 73 line. The process line (circular bright) is heated by Dow therm in order to maintain temperature at 288C. The melt distribution through pipe lines is uniform and proper. There are 30 spinning positions in which spinning are occurring. Each position contain pump, spin pack and distribution line. It is processed in following steps.

8.1.1 Pumping:
The molten polymer is pressurized so that fiber formation can be given to it. There are 30 pumps in each line. These all are gear type pump. Molten polymer is pressurized to 70 bar at 288C temperature. Throughput for semi dull is 98 ton/day and for bright is 95 ton/day. Each pump is controlled by attached reducer. It controls the speed of pump. It also increases torque.

8.1.2 Fiber formation:


Below each pump, there is spin pack. On top of spin pack, a plate is kept containing 3750 holes in IFL-1. Outer diameter of each hole is 0.25 micro meter. Pressurized molten polymer at 288oC and 70 bar is passed through the plate. Holes are in radial formation. Center is empty. There is fiber formation. These fibers are at 288oC temperatures.

8.1.3 Quench air:


The extrude filaments passed through a quenching duct in which these filaments are cooled and solidified by uniform flow of quenching air whose temperature is 20oc. Each spinning position has a separate vertical quenching tube supplied by quench air at temperature of 20oC. In the lower part of the quench air duct, there is a quench air exhaust duct. The vapor containing and monomer component with the hot air, tend to escape through the exhaust duct and exhausted to the atmosphere by monomer scrubber unit showered with soft water, which dissolves the monomer contents and make the air pollution free and hazard free.

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Polyester Plant 2011

8.1.4 Thread Oiler:


After solidification, the filaments pass through the ring oiler device. The oil is applied to filaments in order to maintain 30% moisture content. Ring oiler device also applies S.F. Oil to the filaments in order to remove the static charge. Ring oiler pumps are inverter driven pumps through DCS and one RO pump applies S.F oil for the two spinning positions.

8.1.5 Slub Coater:


Before thread oiler devices, there is ceramic coated rod called slub coater, which holds the filaments bundle for each position. Each position is provided with suction and cutting device, as is used to cut the position as per requirement and waste through hose pipe at the back of the wall. Suction cutting device is operated at air pressure of 6 bars.

8.1.6 Drip detector:


The filaments then passed through drip detector. Whenever drip or plastic comes with filaments, it operates the drip detector and signal comes at the local panel with alarm. Rollers: Then the filaments are deflected from vertical to horizontal direction with deflector roller. The deflector rollers are undriven and one deflector roller is for one position. These filaments are guided with ceramic coated guides. The filaments are gathered from each position in the form of sub tow. Then the sub tow travels at godet rollers and sunflower unit and collected into two at can traversing area. Tow achieved in spinning section has 4 - 4.2 denier, 0.08% OPU and tenacity 1.7g/d. In IFL-1, fiber production is 98 tons in line 71 and 95 tons in line 73.

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Polyester Plant 2011

8.2 Spin Finish Oil Preparation:


In the preparation of the spin finish the oils used are HC-19/P-40 and TD-180. The color is white, the spillage, and the liquid binding material such as sand dolomite, acid binders and sawdust. These two oils are used in the spin finish area. The SF oil is antistatic in nature i.e. it removes abrasion. It also removes cohesiveness, as a result of which filaments do not combine and remain separate. In SF oil preparation, HC-19/P-40 (40% solution) and TD-180 (100% pure) are used. 31 kg HC-19/P-40 and 5 kg TD-180 are mixed. Water at 80oC is heated then HC-19/P-40 is added to it. They are agitated for hour. Then TD-180 is added to them and again agitated for hour. The quantity of oil to be prepared is calculated by the following equation.

At spinning section, following specifications are ensured. Specification Denier (d) Elongation Tenacity Moisture Oil Pick Up (OPU) Value 4 4.2 400 450% 1.7 g/d 30% 0.08%

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Polyester Plant 2011

9 Fiber Line Process


Creel Area
In this area the can are placed and the sub tow is used to form a larger tow. 25 cans are being used in each line at same time. The formed tows are arranged and guided on rollers.

Dipping Bath
Tow is dipped in dipping both which contain SF oil. Tow is dipped to achieve uniform temperature of 24C and pre-lubrication of tow to avoid slippage and entangle.

Draw frame 1
The draw frame is used for the drawing of the polymer along its length. In which first roller is also attached to a nip roller to drip off spin finish oil from the dipping bath. The treatment of the tow starts here. The roller speed is kept 62 m/s approximately this is first stage drawing which is also called soft drawing.

Draw bath
This is a closed tank where the spin finish oil at 80oC is showered on the tow. The steam in the plate type heat exchanger heats the spin finish oil.

Draw Frame II
This is the second draw frame present in the fiber line. It has 7 rollers having a rotational speed of 198.5 m/min. The rollers of this draw frame are provided with steam at 95oC to heat them. The drawing is done at glass transition temperature 79oC. At glass transition temperature, the drawing of fiber is done maximum.

Draw Frame III


Between DF-II and DF-III, steam is showered to achieve rest of 13% drawing. In DF-III, rollers speed is 235m/min.

Thermosetting Unit
In this chamber the properties achieved by the tow are stabilized. It has 12 rollers and is divided in to two parts each containing 6 rollers. There rotational speed is 234 m/min. The temperature of tow is kept about 207oC.

Draw Frame IV
This unit consists of seven rollers rotating at 232 m/min. The purpose of the DF-IV is to grip the tow and make a speed control for the next units.

Over Lapper & Three Roller Frame


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.

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Polyester Plant 2011

Tension Roller
The unit maintains the tension of the roller & again sent to the steam unit to gain the cotton like property.

Crimper Unit
Now tow is crossed through the crimper unit. This unit induces crimps on the fiber at a rate of 14 crimps per inch. The crimps are made for necessary fiber flexibility & cohesion.

Traversing Unit
The 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 Drier
In 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.

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Polyester Plant 2011

10 Baler & Cutter


After making tow in spinning section, fiber is cut down to desired length. Tow is dried and cold before it is sent to baler and cutting section. There are following steps in balers and cutting section.

Cooling
Fiber tow formed in spinning is at high temperature. It should be cooled, before it is sent to baler and cutting section. Fiber from dryer, moves on chain. In chain there are small holes on chain through which air from atmosphere is sucked by pump. This air cause cooling of fiber.

Knot Detector
There may be knots in tow which may damage cutter. Two rollers above another are used in assembly line. As they passes through them , one roller will rise which give alarm. This knot will be cut down by operator.

Grip Roller
To grip the tow, two rollers are used. These are assembled one above another. They are also called gripper.

Tension Roller
A proper tension is created in tow so that it can be cut down easily. If tow is lose, it will rape around the cutter. Tension roller maintains the tension. If tow is tight, it will increase its speed.

Cutters
The tow coming from tension roller will wind around the cutter. The cutter is circular which contain blades on edge in circular form. These blades will cut down the tow.

Free Pin
As tow is cut down, the fiber will fall down on plate that is called free pin. This will be close when plate below it will be opened.

Wear Pin
As plate of free pin falls down, it will be collected wear pin. This plate weight the fiber. Upon 50 kg batch , plate will be opened.

Push Pin
Fiber is pressed in push pin section. 300 kg pressed batch is prepared. This is packed in polypropylene.

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11 Auxiliary Section:
11.1 Spin Pack Regeneration
Spin pack is most important unit in the spinning section. It has specific life time for good performance after which we have to change it. The spin pack is changed after 40 days. After this we regenerate the spin pack in auxiliary workshop.

Disassembling
So in the first step, spin pack is removed out from specified spinning position with the help of pack manipulator. Then it is brought to the auxiliary workshop by a trolley and placed on dis-assembling device. Here hydraulic machine disassemble immediately spin pack as it is removed. If this is not disassembled immediately, spin pack would stuck and cant be disassembled.

Washing and Cleaning


Spin pack contain different parts which cant be washed in same bath. Because some bear high temperature while other cant bear. Two different cleaning devices are used.

Vacuum Cleaning
At vacuum of -0.4 to -0.7 bars, spin packs parts are heated. The polymer melt stick on the parts will be melt down at 320C. After that paralysis at 420C and then oxidizes the polymer at 450C. This process takes place about 10.5 hours.

TEG Section
The spinnerets are cleaned in TEG bath. In TEG bath, Tri-Ethylene Glycol is charged in TEG bath. A batch of five spinnerets is charged in TEG bath. The cleaning process continues at temperature of 270oC. Here residence time is 8 hours and 3 hours take to cool down the parts. After cleaning the spinnerets batch is removed out from the TEG bath and charged in 5% NAOH bath. After 5 no of batches used TEG is drained and fresh TEG is charged in TEG bath. 5 spinnerets can be charged in one batch of TEG bath.

Ultrasonic Bath
TEG cleaning is charged into ultrasonic bath for 30 min. Also we clean the distributed plates and S-fold filters for 15 min each. All these parts are charged individually.

Air Drying Device


The spinnerets and other parts of the ultrasonic cleaning are dried in this device with the application of the process air. Then cover the dry spinnerets in polythene sheet and placed in store for inspection while 5-fold filter and ring distribution plate are placed in assembling room.

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Inspection
The dry spinneret is brought into spinneret inspection room. The holes are magnified inspected of individual hole is done. If any hole is choked, then the spinneret is recharged in TEG bath or in ultrasonic bath. Or dust is removed out from choked hole by compressed air or needle. The pack body or pack lousing, bolts & filling rings are cleaned with brass brush.

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Polyester Plant 2011

12 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. So for this company follow following steps: Give knowledge Give training

Even a small mistake on the plant can cause a serious damage so man, machine & material is very important. 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 guider 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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