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Polyester Plant
Internship Report
Kamal Mustafa | Khaqan Majeed | Usman Zafar
29-Jul-11
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
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.
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
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
Paste Preparation........................................................................................................................ 23 PTA Charging ....................................................................................................................... 23 EG Charging System ............................................................................................................ 23 Final Paste ........................................................................................................................... 23
Polycondensation........................................................................................................................ 27
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
Fiber Line Process ............................................................................................................................... 41 Baler & Cutter ................................................................................................................................. 43 Auxiliary Section:............................................................................................................................. 44 Spin Pack Regeneration .............................................................................................................. 44 SAFETY PRECAUTIONS..................................................................................................................... 46
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
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.
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.
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.
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
Pan
Pan
Screen
Screen
1204-V01
1204-T01
10
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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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
Fiber Line
MEG intake
Pump
Pump
Flow Meter
Filter
Tank
Tank
13
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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Vacuum Pump
Distillation Column
3101-V04
Reboiler/ Evaporator
1117-T01
Sludge Barrel
3101-V01
15
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.
17
3007-V04 (Leakages)
Air
Furnace
BCO
3007-V03
Economizer
Stack Gases
18
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
19
TDO Feeder
Centrifuge
Pearl Mill
1307-V01
1307-V07
1307-V02
1307-V08
Bright
1307-V04
1307-V03
Semi-Dull
4363L EG
1307-V05
20
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
3250L MEG
1402-V01
Filter (1402-S02)
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.
6.7.3 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
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.
25
Reflux
HTM
Esterification Reactor-1
Safety Line
Bottom
1421-R02
1521-R02 1424-V02
26
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;
27
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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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
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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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
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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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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.
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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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.
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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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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.
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.
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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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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.
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.
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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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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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