Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Year 2015-16
Submitted to:
Er. CHIRAG MEHTA SIR
Submitted by:
AMIT MAKHIJA
ACKNOWLEDGEMENT
I would Like to thank GRASIM, NAGDA for providing
me an opportunity to work with them. The support and the
environment provided to me during my project was more
than what anyone would have expected.
CONTENTS
Acknowledgement
About GRASIM
Plant Overview
Viscose Staple Fibre
Manufacturing Process of VSF
Hydraulic Machinery
Introduction
Components
Baling Press
Introduction
Working
Application
Hydraulic Accumulator
Introduction
Working
Function
Design Considerations
Conclusion
Bibliography
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ABOUT GRASIM
Grasim Industries Limited is an Indian building materials manufacturing company based
in Mumbai, Maharashtra. It was started in 1948 as a textile manufacturer. Since then
Grasim has diversified into Viscose Staple Fibre (VSF), cement, sponge iron and chemicals.
The company is a subsidiary of Aditya Birla Group, which operates over 40 companies in
12 countries on four continents. Grasim is the world's largest producer of viscose rayon
fibre with about 24% market share. Textile and related products contributes to 15% of the
group turnover. Ulmale Industries Limited was incorporated in 1948 Grasim is the largest
exporter of Viscose Rayon Fibre in the country, with exports to over 50 countries. Grasim
is headquartered in Nagda, Madhya Pradesh and also has a plant at Kharach (Kosamba,
Gujarat) and Harihar, Davangere in the state of Karnataka
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PLANT OVERVIEW
DIVISION
PC-1
(LINE: - 1 to 7 & 10)
PC-2
PC-3
PC-4
(EC:- 1 to 5)
VISCOSE
SPINNING
AFTER-TREATMENT-1
AFTER-TREATMENT-2
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(6) Dissolving: The yellow crumb is dissolved in aqueous caustic solution. The
large xanthate substituents on the cellulose force the chains apart, reducing
the inter-chain hydrogen bonds and allowing water molecules to solvate and
separate the chains, leading to solution of the otherwise insoluble cellulose.
Because of the blocks of un-xanthate cellulose in the crystalline regions, the
yellow crumb is not completely soluble at this stage. Because the cellulose
xanthate solution (or more accurately, suspension) has a very high viscosity, it
has been termed "viscose".
(7) Ripening: The viscose is allowed to stand for a period of time to "ripen".
Two important process occur during ripening: Redistribution and loss of
xanthate groups. The reversible xanthation reaction allows some of the
xanthate groups to revert to cellulosic hydroxyls and free CS2. This free CS2
can then escape or react with other hydroxyl on other portions of the
cellulose chain. In this way, the ordered, or crystalline, regions are gradually
broken down and more complete solution is achieved. The CS2 that is lost
reduces the solubility of the cellulose and facilitates regeneration of the
cellulose after it is formed into a filament.
(C6H9O4O-SC-SNa)n + nH2O ---> (C6H10O5)n + nCS2 + nNaOH
(8) Filtering: The viscose is filtered to remove undissolved materials that
might disrupt the spinning process or cause defects in the rayon filament.
(9) Degassing: Bubbles of air entrapped in the viscose must be removed prior
to extrusion or they would cause voids, or weak spots, in the fine rayon
filaments.
(10) Spinning - (Wet Spinning): Production of Viscose Rayon Filament: The
viscose solution is metered through a spinneret into a spin bath containing
sulphuric acid (necessary to acidify the sodium cellulose xanthate), sodium
sulphate (necessary to impart a high salt content to the bath which is useful in
rapid coagulation of viscose), and zinc sulphate (exchange with sodium
xanthate to form zinc xanthate, to cross link the cellulose molecules). Once
the cellulose xanthate is neutralized and acidified, rapid coagulation of the
rayon filaments occurs which is followed by simultaneous stretching and
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8-10%
16-24%
1-2%
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HYDRAULIC MACHINERY
(BALING PRESS & HYDRAULIC ACCUMULATOR)
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HYDRAULIC MACHINERIES
Introduction
Hydraulic machines are machinery and tools that use liquid fluid power to do
simple work. In this type of machine, hydraulic fluid is transmitted throughout
the machine to various hydraulic motors and hydraulic cylinders and becomes
pressurised according to the resistance present. The fluid is controlled directly
or automatically by control valves and distributed through hoses and tubes.
The popularity of hydraulic machinery is due to the very large amount of
power that can be transferred through small tubes and flexible hoses, and the
high power density and wide array of actuators that can make use of this
power. Hydraulic machinery is operated by the use of hydraulics, where a
liquid is the powering medium.
A fundamental feature of hydraulic systems is the ability to apply force or
torque multiplication in an easy way, independent of the distance between
the input and output, without the need for mechanical gears or levers, either
by altering the effective areas in two connected cylinders or the effective
displacement (cc/rev) between a pump and motor. In normal cases, hydraulic
ratios are combined with a mechanical force or torque ratio for optimum
machine designs such as boom movements and track drives for an excavator.
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Control valves
Control valves are used for control the pressure and discharge. Valves like
Pressure relief valves, Check valves, Sequence valves etc.
Actuators
Hydraulic cylinder
Swashplates are used in 'hydraulic motors' requiring highly accurate
control and also in 'no stop' continuous (360) precision positioning
mechanisms. These are frequently driven by several hydraulic pistons
acting in sequence.
Hydraulic motor (a pump plumbed in reverse)
Hydrostatic transmission
Reservoir
The hydraulic fluid reservoir holds excess hydraulic fluid to accommodate
volume changes from: cylinder extension and contraction, temperature driven
expansion and contraction, and leaks. The reservoir is also designed to aid in
separation of air from the fluid and also work as a heat accumulator to cover
losses in the system when peak power is used. Design engineers are always
pressured to reduce the size of hydraulic reservoirs, while equipment
operators always appreciate larger reservoirs. Reservoirs can also help
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separate dirt and other particulate from the oil, as the particulate will
generally settle to the bottom of the tank. Some designs include dynamic flow
channels on the fluid's return path that allow for a smaller reservoir.
Hydraulic Fluid
Also known as tractor fluid, hydraulic fluid is the life of the hydraulic circuit. It
is usually petroleum oil with various additives. Some hydraulic machines
require fire resistant fluids, depending on their applications. In some factories
where food is prepared, either an edible oil or water is used as a working fluid
for health and safety reasons. In addition to transferring energy, hydraulic
fluid needs to lubricate components, suspend contaminants and metal filings
for transport to the filter, and to function well to several hundred degrees
Fahrenheit or Celsius.
Filters
Filters are an important part of hydraulic systems. Metal particles are continually produced by mechanical components and need to be removed along with
other contaminants. Filters may be positioned in many locations. The filter
may be located between the reservoir and the pump intake. Blockage of the
filter will cause cavitation and possibly failure of the pump. Sometimes the
filter is located between the pump and the control valves. This arrangement is
more expensive, since the filter housing is pressurized, but eliminates
cavitation problems and protects the control valve from pump failures. The
third common filter location is just before the return line enters the reservoir.
This location is relatively insensitive to blockage and does not require a
pressurized housing, but contaminants that enter the reservoir from external
sources are not filtered until passing through the system at least once. Filters
are used from 7 microns to 15 micron depends upon the viscosity grade of
hydraulic oil.
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BALING PRESS
Introduction
Baling Press is a simple hydraulic press which is used for compressing the fibre
by the application of a much smaller force. It is based on Pascals law, which
states that the intensity of pressure in a static fluid is transmitted equally in all
directions.
Working
The hydraulic press consists of two different cylinders of different diameters.
One of the cylinder is of large diameter and contains a ram, while the other
cylinder is of smaller diameter and contains a plunger as shown in fig.
The two cylinders are connected by pipe. The cylinders and pipe contain a
liquid through which pressure is transmitted.
When a small force F1 is applied on the plunger in the downward direction, a
pressure is produced on the liquid in contact with the plunger. This pressure is
transmitted equally in all directions and acts on the ram in the upward
direction as shown in above fig. The heavier weight placed on the ram is then
lifted up.
Let
F2 = Weight to be lift
F1 = Force applied on the plunger
A1 & A2 = Piston area of smaller & larger cross section respectively
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Due to Pascals law, intensity of pressure will be equal in all direction. So,
Pressure = Force/Area
P = F1/A1 = F2/A2
F2 = F1*(A2/A1)
BALING PRESS
Baling Press consists of two parts: one of pneumatic (half press) & other of
hydraulic (full press)
Hydraulic Part consists of following accessories:
Oil Tank
Pump
Cylinder
Hydraulic pipes
Ram / Piston
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HYDRAULIC ACCUMULATOR
Introduction
The hydraulic accumulator is a device used for storing the energy of a liquid in
the form of pressure energy, which may be supplied for any sudden or
intermittent requirement. In case of hydraulic lift or the hydraulic crane, a
large amount of energy is required when lift or crane is moving upward. This
energy is supplied from hydraulic accumulator. But when the lift is moving in
the downward direction, no large external energy is required and at that time,
the energy from the pump is stored in the accumulator.
Working
Fig. shows a hydraulic accumulator which consists of a fixed vertical cylinder
containing a sliding ram. A heavy weight is placed on the ram. The inlet of the
cylinder is connected to the pump, which continuously supplies water under
pressure to the cylinder. The outlet of the cylinder is connected to the
machine (which may be lift or crane etc.)
The ram is at lowermost position in the beginning. The pump supplies water
under pressure continuously. If the water under pressure is not required by
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the machine (lift or crane), the water under pressure will be stored in the
cylinder. This will raise the ram on which a heavy weight is placed. When the
ram is at the uppermost position, the cylinder is full of water and accumulator
has stored the maximum amount of pressure energy. When the machine (lift
or crane) requires a large amount of energy, the hydraulic accumulator will
supply this energy and ram will move in the downward direction.
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ADVANTGES:
Used to meet heavy industrial requirements.
Extremely high capacity at low cost.
Rugged and durable construction.
LIMITATIONS:
Extremely bulky and heavy.
Problem in sealing.
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APPLICATIONS
Accumulators are devices used to store fluid power to do the following:
Agricultural Machinery & Equipment.
Forestry Equipment.
Oil Field & Offshore.
Machine Tools and Off- Road Equipment.
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CONCLUSION
So what are the benefits of using accumulators?
Lower installed system costs, accumulator assisted hydraulics can
reduce the size of the pump and electric motor which results in a smaller
amount of oil used, a smaller reservoir and reduced equipment costs.
Less leakage and maintenance costs, the ability to reduce system shocks
will prolong component life, reduce leakage from pipe joints and
minimize hydraulic system maintenance costs.
Improved performance, low inertia bladder accumulators can provide
instantaneous response time to meet peak flow requirements. They can
also help to achieve constant pressure in systems using variable
displacement pumps for improved productivity and quality.
Reduced noise levels, reduced pump and motor size couple with system
shock absorption overall machine sound levels and results in higher
operator productivity.
Flexible design approaches. A wide range of accumulator types and
sizes, including accessory items, provides a versatile and easy to apply
design approach.
Reduced energy costs, cost savings of up to 33% are achievable in high
performance industrial machinery using accumulators.
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BIBLIOGRAPHY
www.wikipedia.com
www.scribd.com
www.slideshare.net
www.researchgate.in
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