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INTERNSHIP REPORT
Submitted By:
NAME
ROLL NO.
MUZAMIL KHATRI
11TE08
GHULAM HUSSAIN
11TE23
NATESH KUMAR
11TE48
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INTERNSHIP REPORT
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INTERNSHIP REPORT
Mr.Mumtaz
Dyeing.M
Mr Tariq
Finishing.M
Mr.Hamid
Printing.M
MR.Hamid
Mr.Kamran
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PREFACE
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Yunus textile mill basically deals with home textiles and has following
international customers:
Germany:
MGB METRO, KAUFHOF.
USA:
JC PENNY, TARGET,WALL-MART,MARMAXX,KOHLS,SEARS,LINEN-NTHINGS,BED BATH AND BEYOND
Italy:
GABEL, CAMAGNOLO
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Products:
YTM has its own products includes:
Bed linen,
Curtains,
Bath Shower Curtains,
Kitchen Curtains,
Table Covers,
Blended Fabric,
Cotton Fabric,
Dyed Fabric,
Grey Fabric,
Printed Fabric,
Bleach Fabric,
Mercerized fabric,
Finished fabric.
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Sewing or Stitching
Singeing
De-sizing
Scouring
Bleaching
Mercerizing
Dyeing
Printing
Finishing
Final Inspection
Delivery
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Planning:
Planning is the most important step of every stage of the process each
and every person involve in the process must know flow of the material
process and parameters .for completing the task accurately on time. A well
controlled network system which connect the planning section with each and
every department in processing and finishing.
The planning section is sub divided ,
Grey planning.
-Seltzer 7.2-8 Million meter use age.
-Air jet 2.2-2.5 Million meter production per month.
Intermediate planning (dyeing, printing).
Post finishing.
Process Flow:
Customer order
Process
Merchandizing calculation
Job Cards:
Basically there are three types of Job cards.
1. Master card.
2. Travel card.
3. Colored card.
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Master card:
Master card is directly given to the department on which Job cards are
stapled.
Travel card:
Travel card travel with the fabric on each and every stage of the
process from starting till finish it guide the operator that what is the process
flow of the material.
Colored cards:
There are 4 different colored cards used for the following processes,
White
Green
Yellow
Pink
Bleaching.
Dyeing.
Sample.
Printing.
GREIGH DEPARTMENT
This is the first department of the wet processing industry. In Greigh department
inspection of fabric is done with the help of 10-100% inspection the fabric fault are
counted and grading of fabric is done.
Production:
Machine speed is 100 m/min.
Maximum width run on machine is 126-130 inches.2.25 lacks for three shifts.
Each shift process about average 32000 meter per machine.
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Inspection / Grading:
Weaving Faults:
Double Ends, Loose Ends, Broken Ends, Wrong Dent/Draw, Loose Selvedge, Double
Pick, Miss Pick, Design Cut, Knots, Hanging Threads, Float,
Mechanical Faults:
Yarn Faults:
Others:
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The fabric is placed on conveyor belt the pile is threaded through the tension rods and the
guide rolls works on the electronic sensing to run the fabric in center the fabric is than enter the
scray than the fabric is passed through the expanding roll which expands the fabric to run in
smooth through the machine. After it the fabric entered into the brushing section to brush the
contaminants and fluff and fly because they may create problems in next process especially in
dyeing and printing. The fabric is than rolled on a frame to make our required batch wheel rotaes
and measure how much fabric is wounded. There are two Tacoma machines installed in YTM.
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Machine Components:
Guide rollers
Pre drying
Pre rushing
Cooling drums
Post brushing
De-sizing unit
Winder.
2
Mehran UET Jamshoro
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1. Tension rod:
The purpose of tension rods is to give tension to the fabric and to Stay away from crease
formation.
2. Guide Roll:
Fabric is passed above the guide rollers for feeding the fabric in to the brush rollers.
4. Singeing box :
After brush roller the fabric is moved over projectile of gas burner to burn protruding
fibres.4 burners are installed on this machine. The flame is composed of 70% of air and 30% of
gas. To avoid fabric yellowish shade thats why we use blue flame.
5. Chemical Bath :
Later than the achievement of singeing the fabric immediately feed in to the chemical tank
to remove the size of fabric.
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SDL de-size
RGN wetting agent
1g/l
4g/l
NE sequestering agent
1.5g/l
6. Winder :
The winder roll the fabric over the batcher and than it is left for 4 to 6
hours.
7. Cooling drums:
In singeing section the fabric passed over the cooling drums to down the temperature of
the fabric after burners. The water circulates inside the drums.
8.Donier rolls:
The donier rolls move in to and fro motion evenly distribute the fabric. The time,
temperature and pH must be maintained because the enzyme will be active when the conditions
are provided.
Parameters:
Machine name
Made
Max. Width of singe de-size 1
Max. Width of singe de-size 2
Max. speed
Flame intensity
Pressure of the padder
OSTHOFF
Germany
126
110
100 m/min
10-16 cm
2.5 bar Flame angles 90,45,90
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SCOURING;
The process of scouring is to make material highly and uniformly absorbent. (i-e the
removal of natural impurities like wax, fats, oils). When oils and fats are heated with a solution
of sodium or potassium hydroxide, they hydrolyzed into glycerol and the alkali salts of fatty
acid, these salts of fatty acid are soaps therefore his particular hydrolysis is referred to as
Saponification ,
BLEACHING;
Scouring removes almost all the impurities except natural coloring matters which are
ultimately broken down with bleaching agents. Bleaching is necessary for producing white goods
either as finished products or for dyeing pastel shades.
There are two scour bleach machines both the machines are continuous and gives average
2.5 production per day.
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Machine parameters:
Speed
125 m/min
Caustic
48 Be
H2o2
50%
Stabilizer
KEB
Wetting agent
RGN
Pre washing:
100 lit water is present in 3 chambers of pre washing range. The
temperature of pre-washing range is kept 98C.
Chemical Pad-1:
The fabric is padded with scouring chemicals.
Steamer-1:
After padding with scouring chemicals the fabric enters the
steamer for reaction at about 103-105 C for 16-20 min.
Chemical Pad-2:
The fabric is padded with bleaching chemicals.
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Steamer-2:
The fabric is again enters into the steamer for reaction.
Post Washing-2:
5 chambers present 4 chambers for hot washing at 98C and last
one for neutralization at 0C.
Dryer cylinders:
24 cylinder dryers are present to dry the fabric and at last the
batch is make.
Machine components:
Pre washing:
2 chambers for pre washing at 90-98 C.
Chemical padding:
Chemical padder in which scouring and bleaching chemicals are
paded.
Steaming:
The fabric is entered into the steamer 103-108 C for 22 min.
Post washing:
4 chambers in post washing 3. chambers for washing at 70-98 C
and last 1 for neutralization.
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MERCERIZATION
OBJECTIVES
To increase luster.
To increase the affinity for dyes.
To increase the tensile strength.
To give dimensional stability
Use of dye after mercerizing is less
Width control
After mercerizing increase cost of fabric Rs 2.70 per meter.
In this process cotton is dipped in a solution of NaOH so that NaOH
penetrated in to the fibre and then NaOH is washed out completely by
neutralizing by dilute acid like formic acid. When mercerizing fibre are
examined under microscope. It is seen that each fibres in twisted ribbon like
form. After mercerizing fibres become cylindrical and free from twists.
To increase the luster cotton must be prevented from shrinkage. This
can be achieved by stretching the yarn or fabric. Shrinkage of the fabric can
also controlled by mercerization.
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MACHINE 1:
Goller (Germany)
Mercerize chambers 1
Stabilize chambers 1
Washing chambers 5
Speed 36 m/min
MACHINE 2:
Goller (Germany)
Mercerize chambers 2
Stabilize chambers 2
Washing chambers 7
Speed 60 m/min
Process:
After bleaching the Ends/Picks of the fabric are disturbed and also
fabric is shrink up to 5-10%, therefore to regain fabric original width and
Ends/Picks fabric is conditioned to be passed through the STENTER MACHINE,
it is also depends upon the material requirement. After pre-stenter the fabric
batch is placed on a mercerizing machine The fabric is passed through a
number of guide and Bow rolls. After that the material is dipped in to the
main section, which is a STRONG LYE containing chamber. The number of
chambers in mercerizing machine is different and depends upon the
manufacturer of the machine. In this chamber the material is continuously
treated with caustic soda of about 26-30Be @ 60c. The lye is showered in
zigzag manner the fabric is rolled over a number of padder. Load cell are
used to maintain tension to the coming fabric.
If the material is subject able for reactive print mercerization is
necessary, where as on the other hand for pigment print no mercerize
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material is required. After strong lye the fabric is passed through weak lye
chamber. The temperature is increased up to 85c and caustic concentration
is decreased up to 7-8Be, this gradually reduction in caustic concentration
stabilize the mercerized material, then in the stabilizing section caustic
concentration is decreased up to 4-3Be through counter flow of water. The
mercerized material is rinsed and washed and PH is maintained in a washing
range. The next stage after weak lye section is washing. In goller machine
there are four chambers as compare to FAISLABAD MERCERIZE. The
temperature of starting chamber is about 90-95c and last washing chamber
contain room temperature. In continuous washing range of GOLLER
MACHINES, neutralization is also alone by using formic or acetic acid. After
neutralization the wet fabric is wound on a batch with the help of tension and
winding arm.
IMPORTANT FACTORS:
During operation there are numerous factors, which can effects mercerizing
process. Some of them are listed below;
Crease on the fabric can be formed this can be recovered by changing
position of guider.
Black spots or caustic spots can be produce on the fabric due to air
lock occur in the padder.
If proper neutralization objective is not achieved there is a chance of
acid remains in the fabric, which will result in degradation of fabric.
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Disperse
Vat
Reactive
Pigment
Screy
Cooling drums
Padding
IR ( pre-drying)
Cooling drums
Screy
Batcher
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Cooling cylinder:
A cooling cylinder present with water circulation inside to cool down the fabric if it
contains soem heat becasue dye cracking may take place.
Padder:
Dye and otehr dyeing auxiliaries are padded on to the fabric.We can do one bath or two
bath dyeing.
Airing zone:
Airing zone is used because some times the light GSM fabric has face back variation so
we use airing zone.
IR :
IR is used to dry the fabric upto 25-30% and alo to avaoid thermal shocking becasue we
are padding at low temperature and the dryin temperature is far away from padding temperature.
Chamber
120 C
Chamber
140 C
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Chamber
3,4
210 C
Working of Machines:
The fabric is unwound and then pass through brushing section here the fluff is brushed and
fabric is collected and stored in screy. fabric passes over cooling drums to cool down the
temperature of fabric because when we are dyeing PC fabric then after RC fabric is hot
enough.the fabric is then passed through Kuster padders, two types of pressure used in Kuster
padders hydraulic and neumatic.the central pressure is hydraulic and sides pressure is
neumatic.we can adjust the pressure of the padders .
Then there is given I.R system the temperature of I.R is about 60- 50 c. there are two I.R
installed the temperature of first I.R kept 850 c and second 800c.the function of I.R is to remove
30-35% moisture. the fabric is then passed through the thermos, 5 chambers are provided,
1-2 Drying.
3 Drying.
4-5 Fixation.
The fabric is then passed through cooling drums and finally fabric is collected on a batcher.
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Kuster Padder:
Dyes and other auxiliaries are padded to the fabric.
Steamer:
The dyed fabric is entered to the steamer for fixation of dyes. Two chambers are
provided .the temperature of the steamer is 103-105C but the roof temperature kept higher about
108-109 C to avoid dropping effect.
Water Lock:
The function of the water lock is to stable steam to come out from the steamer and also to
avoid thermal shocks and also to avoid dyes to be diluted its temperature kept about 40-45C.
Washing range:
There are 8 chambers counter flow system is used. The chambers are used for number of
process a/c to the requirement of dyes by showering of different type of chemicals.
RC.
Vat develop.
Neutralizing.
1,2 and 3
Chamber
4,5,6
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Chamber
7,8
Neutralizing
Cylinder dryers:
There are 20 cylinder dryers last 2 cylinders contain water and 18
cylinders contains super saturated steam 120 C.
Exit:
There is also provided a J-screy at exit to store the fabric and the fabric
is wounded on to the batcher.
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PRINTING
In YTM there are 3 m/c of REGGIANI having max fabric length 130 and
97 and length is 40 m. on Printing 1 and 2 ,16 colors can be printed and
on Printing 3 12 colors can be printed at a time.
CAM CAD:
The design given by the customer may be on a paper or directly they given a sample fabric
to the cad cam department they scan the design in the computer.
Software used:
Ram Set
Photoshop......Lucher
Stork
After the approval of the design by the customer design is sent to the engraving department.
Screen Coating:
The screen is made up of 100% nickel. Screen is coated with coated material SCR 64 or
SCR 61. Screen is coated upside down for 15-30 min at high temp over 180-200c and left for dry
about 10-30 min.
Screen exposing:
There are 3 exposing machine in YTM,
Ink jet.
Laser exposing.
Laser light bombarded. SCR 102+101 coat is used only curing, exposing and endering.
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Screen Developing:
The screen is developed which means only that parts where patterns are printed on screen
are removed from coating while other remains same
Hindering:
The screen is thoroughly washed normally to make sure the patterned area is open i.e.
Mashes are not closed by coating or another dust.
30,40,60,80
2. Panda
3. Nova
Repeats:
1. 640 mm
2. 819 mm
3. 914 mm
Recipe:
Thickener
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Liquor
Binder
Water
Pigment
For reactive:
Urea
Sodium bi carbonate
Alginate
Revatol
Process flow:
Components of machine:
Entry
Suction
Flat rollers
Trolley
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Printing zone
Sensor
Dryer
The fabric is passes through guide screen rollers to the suction area here the sucker sucks the
fabric fluff and dust particles. Flats are provided when we use knit fabric. The fabric enters into
the trolley where PVA is applied to stick he fabric with the blanket belt. The machine is provided
with an I.R system and cambered plate to give temperature to the thermoplastic glue. Then the
fabric enters into the printing zone. The fabric is sandwiched b/w the rollers and the blanket,
magnetic system of printing is used.
Color is dozed into the squeegee through pumps automatically. The first screen roller is to
press the fabric and the second gathers the remaining fluff. The printing starts from the third
screen. each screen prints a single color. the number of the screen depends on the type of design.
The sensor is used to control the speed of the blanket. The fabric than entered into compact HC
dryer 160-180 c. the dryer has 5 burners. The dryer has three passages air is blown into the
chambers 2 times. Finally the fabric is collected by a crank gear mechanism to a trolley.
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Pigments fixing
Hot air from oil boiler.
Steam (saturated)
Disperse dyes fixing.
High temperature from oil boiler.
Disperse
Reactive
10-12min 102c.
Pigments 6min
110-165c.
PROCESS:
Entry
Curing
Exit
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The fabric entered into the curing chambers for about 80 min in loop form for the fixation.
Suction system is provided the rollers present in the machine for loop formation moves with the
help of chains.
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FINISHING
Stenter machines (Monforts Montex):
The purpose of the stenter machine is to bringing the length and width to pre determine
dimensions and also for heat setting and it is used for applying finishing chemicals and also
shade variation is adjusted.
Components of Machine:
Padders
Weft straightner (Mahlo)
Burners
Heat recovery
Attraction rollers
Circulating fans
Exhaust fans
Winder
Clips
Pins
I.R
Cooling drums
The fabric is collected from the batcher to the screy and then it is passed
through the padders where the finishes are applied and some times shade
variation is corrected. The fabric is entered into the mahlo (weft straigtner)
the function of the mahlo is to set the bow and also weave of the fabric is
griped by the clips and pins are also provided but the pins has a
disadvantage that they pins make holes at the selvedge but the stretching of
the pins are greater than the clips. These clips and pins are joined to endless
chain. There are 8 to 10 chambers provided on the machine each chamber
contains a burner and filters are provided to separate dust from air. The
circulating fans blow air from the base to the upper side and exhaust fans
sucks all the hot air within the chambers. Attraction rollers are provided to
stretch the warp yarn.
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Production/ day
Purpose
STENTER 1
75000
STENTER 2
65000
STENTER 3
60000
Stenter dye
STENTER 4
85000
Print finish
STENTER 5
105000
STENTER 6
80000
White,set/wet, set/print,dyed
finish
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To upgrade the fabric hand and to impart a smooth silky touch to the
fabric.
The mechanical finish is done for softness and shining of the fabric or
stiffness according to the nature of the chemical, this process is done after
the chemical finishing as per buyer requirement. Speed of the machine is 10100 m/min.
There are two calendering m/c in ytm
production of 1 machine is 1.5 lac / day
Components of machine:
Winder
Metal detector
Seam detector
Rollers (cotton, reclon and steel)
Anti static rod
Oscillating roll
Batcher sensor
cooling drum
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Seam detector:
Function of seam detector is to bypass the seam.
Metal detector:
Metal detector to detect metal partials.
Small winder:
When we have to calendar short width fabric and we can also run short
width fabric with long width fabric.
Oscillating roll:
To avoid selvedge overlapping on batcher.
Cotton roll:
For soft finish the fabric is passed through cotton bowl. This roller is
made up of cotton.
Steel roll:
To give smoothness and luster. The temperature is provided to steel
roller about 32-200 c with help of electric heater as we increase the
temperature shining will increases only used for cotton CVC and percale and
PC.
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Reclon roll:
When fabric passes through Reclon roll and steel roll giving smooth and luster effect is
generated. When it runs with steel roll and reclon roll and cotton roll dull effect is generated.
When it runs b/w steel and reclon gloss effect is generated.
Cooling drum:
Cool down the fabric water circulates inside the cooling drum.
SANFORISING MACHINE:
Monforts Sanforizer: (Germany 2003)
The processed fabrics are subjected to elongation during processing.
The shrinkage is controlled in the mercerize and stenter to some extent and
it is ultimately brought within the norms in the latest monforts sanforizer
made in Germany. The width ranges from 40cms to 325cms. Sanforising is a
mechanical of treating the textile fabrics to prevent the normal dimension
alterations of warp weft, which occur in the finishing operation; especially
those carried on in laundering &allied operations.
Production / day70,000
Speed 50 m/min but max is 120 m/min
Rubber roller length 305- 312
MECHANICAL COMPRESSIVE SHRINKAGE: The fabric is compressed by the contraction of the conveyor surfaces
on which the fabric has been made to adhere. The conveyor takes the form
of a rubber belt or sleeve. The outer end expands as it passes over a roller
and at this point the fabric is applied. The surface contracts with it,
expansion and contraction are controlled, precise and predetermined length
can be obtained, hence the process is positive.
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Lab Dip:
A lab dip is a swatch of fabric test dyed to hit a color standard. Several lab dips may be
submitted for feedback until the standard is achieved and the lab dip is approved. There is also
now a machine used to read lab dips called a "spectrometer which will give the same feedback.
As not everyone sees color as well as the next (and you can be tested to see how well you see
color) a machine can take out human error.
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CHEMICAL TESTING:
WASHING TEST:
Sample size= 10x4
Standard=ISO -105
CO1 CO6
CO1 and CO2 are for the leather garments
CO4 for the Vat dyes
CO6 for the fabric
Recipe:
EC soapSoda ashSodium perborate
4gm/l
1gm/l
1gm/l
SHIRINKAGE TEST:
Sample Size:
For ISO=50x50 cm
For AATCC=38x38cm
Standards:
SO-6330 2A-9A
AATCC-135
Washing machine for ISO wascator
Mehran UET Jamshoro
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pH METER:
It is important machine in any chemical lab to check out the pH.
PERSPIRATION TEST:
Perspiration test is performed for both acidic and alkaline mediums.2 samples that are
sandwiched between the multi-fiber fabrics are dipped in acidic and alkaline solution. then these
fabrics are placed on perspirometer under a weight of 5 kg for 4 hours for ISO and 6 hours for
AATCC. Then the stains on the multi-fabric are matched with the grey scale.
HARDNESS TEST:
To check the hardness of water, 1 ml of buffer of pH 10 is added in the sample and is
titrated with EDTA. Eurochrome black t (EBT) is used as an indicator. The point at which the
sample gives blue color is noted and is hardness of water.
Hardness= burette reading * 20
BLEND RATIO:
VC blend,
60% sulphuric acid at 20 C for viscose and for cotton 70% sulphuric acid is used at 38C.
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PC blend,
Cotton is dissolved in sulphuric acid because metacresol is hazardous to use as it is
carcinogenic.
PURITY OF CAUSTIC:
The % purity of Caustic used by titration with acid and by using phenophtalein as an
indicator.
Spectrophotometer meter:
Spectrophotometry involves the use of a spectrophotometer. A spectrophotometer is a
photometer (a device for measuring light intensity) that can measure intensity as a function of the
color, or more specifically, the wavelength of light. We can take each and any type of test
including shade matching, CIE whiteness test, Burger whiteness test and also this instrument
give us the composition of shade.
Data Color D650 Dual Beam Spectrophotometer.
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Physical Testing:
All the physical tests on a textile sample or material is conducted in physical portion of
the lab. The tests conducted by the physical portion are,
Tensile strength
Seam.
Abration
Air permeability.
Pilling.
Appearance.
Rubbing fastness.
Washing fastness.
Color fastness.
Water fastness.
Perspiration fastness.
Dry cleaning fastness.
Light fastness.
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Whirlpool:
Whirlpool Washing Machine is recommended by AATCC for AATCC test methods requiring
repeated home laundering.
Standard:
AATCC 135
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Gyrowash:
This tester is an instrument for fabric, cotton, wool, linen, silk chemical fiber, knitting and
woven fabric etc to test the fastness to washing, to milling and to dry clean. Also it can be
applied to exam the fastness of the colorant. So it is necessary apparatus for textile quality
monitor department.
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Srandards:
ISO 5034,1393
ASTM 5035
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GSM Cutter:
This instrument is a circular fabric sample cutter with which a uniform
circular fabric is cut without measuring. The specimen which is cut with the
help of the Fabric GSM Cutter is 100 cm2 areas. This instrument is complete
with a piece of cutting board and 12 spare blades.
Light box:
light box is used to check the fabric in following conditions;
day-light
incandescent
back-light
U-V light
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Folding
Taking samples from each and every roll and faults are detected and the grading is done
then shade is forwarded to the shading department. The rolls are separated in shade wise. The
defected fabric is separated. The grading is done a/c to the customer requirement.
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Utilities
YTM has its own mill utilities based on latest technologies and work 24
hours to supply and complete the energy requirements of the mill. Average
load of the mill per hour is 2.5-3.2.the utilities are as follows,
Turbine.
Generators.
Boilers.
Compressors.
RO plant.
Caustic recovery plant
Turbines:(TURBO MAKE):
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Engine (Generators):
Boilers:
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Compressors:
Process:
Pretreated water is pumped into the membrane housings along the membrane surface. Pure water
is permitted to pass through the membrane while ionic, organic, colloidal and bacterial
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contaminants are swept away in a concentrated solution. Consequently, a reverse osmosis system
always creates two continuous exit streams: pure water (permeate) and brine (concentrate).
Normally 50 to 75 percent of the feed water can be recovered as permeate.
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