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POLYESTER FILAMENT YARN

PLANT DESIGN DATA FOR POLYESTER FILAMENT YARN
SR. NO. PARTICULARS DETAILS
1. PLANT POLYESTER FILAMENT YARN
2. YEAR OF ERECTION SPINNING - 1992
POLY- CONDENSATION (CP) - 1994-95
 
3. YEAR OF COMMISSIONING SPINNING - 1992
POLY- CONDENSATION (CP) – 1995
 
4. TECHNICAL COLLABORATION M/S. LURGI GMBH, GERMANY

 

5. DETAILED ENGINEERING M/S. ENGINEERS INDIA LIMITED

 

6. PLANT :
LICENSED CAPACITY POLYCONDENSATION
SPINNING (YARN) IN TERM OF 76 DENIER

20,000 MTA PER ANNUM
8,000 MTA PER ANNUM
7. INSTALLED CAPACITY SAME AS ABOVE

DESIGN & SALIENT FEATURE

POLYCONDENSATION :
It is a CP Plant suitable for both DMT and PTA feed stocks. The entire plant comprises of 6 reactors. The daily output is 60 MTA on DMT feedstock, out of which 24 MT can be diverted to Direct melt spinning and balance for the production of chips. The Plant has been commercially commissioned and operated on only DMT feed stock. The Plant is fully automatic equipped with DIDC System from M/s. HONEYWELL, GERMANY. The various Utilities requirement except chilled water are met and shared from the centralised utilities section. For the requirement of chilled water, three machines of VOLTAS make each of 400 MT capacity are housed inside the main plant building. The requirement of heat for the polycondensation plant is met from the two oil fired HTM units each of 2.65 M Kcal per hour units supplied by M/s. BHPV. Most of the Polycondensation equipments and reactors are manufactured indigenously by M/s. BHPV. Only the critical equipments like agitators and finisher reactor etc. are imported from Germany. Provisions have been made to supply critical utilities to the Plant from emergency D.G. Sets in case of power failure.

The power for the entire complex is drawn from Achalia through two independent 132 KV conductors up to Taluka : Valia and from there to the main sub-station in the Petrofils Complex. The complete details of power distribution to the PFY Plant, connected load and peak demand load are given in details separately.

SPINNING SECTION :
Direct Melt Spinning comprises of 4 Spinning Lines of 12 positions each with 8 ends per position. Entire equipment is imported and supplied by M/s. BARMAG, Germany. On 76 Denier per day capacity works out to 24 MTD.

CHEMICAL AND PHYSICAL LABORATORIES :
For carrying out Chemical and Physical testing of raw material, semi-finished and finished products, the well-equipped laboratories are provided.

CENTRALISED WORKSHOP :
To carry out minor repairs and modifications there exists a small-centralised workshop.

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PROCESS DESCRIPTION

1.0 Continuous P.T.A. - Esterification :
Esterification occurs continuously in two series connected esterification reactors (C-050, C-052).
The PTA/EG-Paste is fed continuously into the first reactor C-050 by means of a level control. The reaction water occurring during esterification is separated from the ethylene glycol in a fractionation column K-050 above the reactor. The esterification is completed in reactor II (C-052). Both reactors are located on the same level. The reaction water is condensed in the condenser (W-053) and the divided in a reflux separator into 2 streams. One stream is reflux to the column while the other is routed to waste water.
The stabilizer at dulling agent is dissolved in preparation vessels and charged from a surge drum into the esterification reactor II C-052 respectively before filter F-054 by means of a metering pump.

Throughput variations due to downstreams polycondensation are handled by level control in the reactors and compensated by varying the relative proportions of the feed steams.

From reactor II C-052 the esterification product is conveyed by means of a pump P-054 through a precondensate filter F-054 to first polycondensation autoclave C-100 of the polycondensation step. The filter F-054 is heated with Dowtherm vapour from Dowtherm evaporator W-056.

2.0 Continuous DMT-Transesterification :
The liquid DMT is constantly transferred from the daily work tank B-46 by a pump P-049 to the transesterification reactor I C-050. A flow controller is provided for accurate proportioning.

Ethylene glycol is supplied from elevated tank B-052 through a preheater to the mixing chamber of transesterification reactor C-050.
Catalyst for accelerating the transesterification reaction is fed to the same chamber of the reactor. The methanol vapour occurring during reaction is separated from the glycol in a column K-050 above the reactor. In reactor C-051 and C-052 the transesterification product is heated and reaction occurs until approximately 99 % of the product is reacted into prepolymer.

The catalyst and stabilizer required for polycondensation are dissolved in a preparation vessel and charged from a surge drum to esterification reactor C-052 by means of a metering pump. Operation of the plant is fully automated. DMT glycol and transesterification catalyst solution are charged continuously to transesterification reactor C-050 and polycondensation catalyst and stabilizer to reactor C-052 at predetermined relative proportions. Throughput variations in polycondensation are handled by level control in the reactors and compensated by varying the relative proportions of the feed streams.

From reactor C-052 the esterification product is conveyed by means of a pump through a precondensate filter to the first polycondensation autoclave of the polycondensation step. The filter is heated with Dowtherm vapour from a Dowtherm evaporizer.

3.0 Continuously Polycondensation :
Polycondensation of the precondensate from the esterification section occurs continuously in 3 series-connected autoclaves. The product from the precondensate filter F-054 is fed into polycondensation autoclave I C-100. This autoclave is heated by means of an incorporated Dowtherm evaporator.

Reaction in the autoclave takes place under a vacuum of approx. 70 mbar. This vacuum is generated by a glycol jet V-100. The glycol set free during reaction is condensed in the spray condenser W-100 of the glycol jet and fed into the recovery via a glycol receiver B-100. The glycol used for the spray condenser W-100 is removed from the glycol receiver B-100 by means of a pump P-103, cooled down by a cooler W-104, fed into the spray condenser and flows then back to the glycol receiver together with the condensed reaction glycol. The product leaving autoclave I C-100 has a degree of polymerisation of Pn = 12 - 15.

In the autoclave II C-101 the reaction takes place under a vacuum of approx. 7 mbar generated by glycol jet V-101. The autoclave is heated by means of a Dowtherm evaporator W-107. The autoclave is equipped with an agitator R-101. The glycol set free during reaction is condensed in a spray condenser W-101. The product leaving autoclave II C-101 has an average degree of polycondensation of Pn = 40.
The final viscosity of the product is reached in the finisher (autoclave C-102) which is designed as a disc cage type reactor. The autoclave C-102 is equipped with driven disc cage. The product passes consecutively through all rotating discs, which guarantees a defined product residence time. Polycondensation in the finisher occurs under a high vacuum. The vacuum is generated by means of steam jets V-102 - V-105. Condensation of reaction glycol occurs in two inline arranged spray condensers W-109, W-110. The finisher is heated by means of Dowtherm vapour W-108.

When the polymer has reached its final viscosity in the finisher it is continuously discharged by means of a special gear pump P-102. The melt is fed to the chips production unit and is also connected directly to the spinning section through melt pipes. The throughput of the polycondensation has to be kept as constant as possible in order to prevent product variations. To meet this requirement, the feeding is controlled backwards from the end of polycondensation.

4.0 Chip Production and Storage :
For chips production, the polymer produced in the finisher is converted into chips in an underwater granulator. Continuous discharging of the polyester out of the vacuum of the finisher and feed to the extrusion head X-150 is achieved by means of a special discharge pump P-102. The extrusion head and the melt outlet valve are heated with Dowtherm, which is evaporated in a Dowtherm evaporator W-108.
The strands of molten polyester emerging from the nozzles of the extrusion head X-150 are gravity fed to a guide plate with longitudinal slots, which is supplied with overflow water from a weir. The still molten strands are transported - surrounded by water - by gravity to the feed rolls of a chip cutter A-150. On their way down cooling and solidification occurs, starting from the surface.

The feed rolls of the cutter A-150 catch the strands and guide them to the cutting tools. Cutting occurs between a fixed terminal strip and a revolving rotor. After the cut the chips are floated out of the machine with water and thereby furthermore cooled down. The demineralized water necessary is supplied by pump P-150. During chipping, the demineralized water temperature is kept constant by cooling and chilled water through demineralized water cooler W-150, W-151. The chips are floated to a water separator where the main part of the water is removed in the dryer T-150 the water content is reduced to approx. 0.5 wt %. Before the chip drop into the analysing silo B-151 A/B the chips will be removed from fines in a sieving machine S-150. From the analysing silos the chip will be transported by a pulsation-conveying device X-152 into a chip storage and blending silo B-158.

5.0 High Speed Spinning of Polyester Melt into Pre-Oriented Filament ` (POY) :
From the final autoclave the melt is supplied through distribution pipes via one common non-stop filter to the spinning boxes with two spinning positions each. Each spinning position is associated with 2 four-fold spinning pumps and 8 spinnerets. Each four-fold spinning pump meters the melt to 4 spinnerets.

Downstream of the spinning pumps the melt is filtered and is then pressed through the boreholes of the spinneret plates in the form of filaments. The route of the melt from the final autoclave to the spinnerets is short which ensures uniform properties of all filaments.
The spinning boxes are heated with Dowtherm vapour which is generated in a vaporizer. The temperature is maintained at a constant level. The filament bundles leaving the spinnerets are cooled in blow ducts by a horizontal current of air Dowtherm of the blow ducts the filaments are guided through spinning tubes to the winders of the take-up machine. The spun filament is provided with finish oil by means of precision metering pumps, which are located below the quench duct.

The finish oil gives the filament the necessary antistatic properties, good sliding properties, proper adhesion of the individual filaments and adequate moisture and facilitates the subsequent further processing. Static inverters with high precision frequency adjustment feed the drive rolls of the winding heads. The grooved rolls and the traverse motion devices are also fed by static inverters with frequency adjustment and sweep generators for varying the speed periodically. The filament (POY) produced on this type of machine is pre-oriented, which means that it can be stored and transported without the need of special climatic conditions. It can further be processed on such texturing machine which allow to draw the yarn in the first heater simultaneously with a ratio of upto 1 : 2. Four spinning lines each with 12 spinning positions are provided.

6.0 AUXILIARY UNITS :
6.1 PTA Storage, Conveying and Pasting :
The basis is that the PTA is supplied in 1 t bags, which are unloaded into a funnel B-001. From the funnel, the PTA is fed with a screw convey H-001 into a hopper B-002 from where it is supplied by a pneumatic conveying system to the PTA-storage silo B-050. The PTA and the EG are well mixed in the paste mixer B-051 by an agitator of special design. The paste produced is discharged by means of a paste pump P-052 feeding into the esterification reactor I C-050. For homogenization, part of the paste is recycled. The catalyst required for the polycondensation is also charged into the paste mixer B-051 by means of a metering pump.

6.2 Glycol Storage System :
Two storage tanks B-020 1/2 are provided for the storage of ethylene glycol. The ethylene glycol is supplied from the storage tanks by a centrifugal pump P-020 into the daily work tank B-021 and from there with pump P-022 via filter F-020 to the glycol elevated tank B-052.

6.3 DMT Melting, Storage and Conveying System :
The basis is that the DMT is supplied in bags of 25 or 50 kg, which are unloaded manually. In the melter B-045 the solid DMT is molten. The heating of the melter is done by steam, N2 blanketing is foreseen for protection of discoloring of the liquid DMT. With a circulation pump P-048 a certain quantity of molten DMT is pumped into the DMT daily work tank B-046, while the other amount is recirculated back into the melter. On this route the molten DMT is passing a heat exchanger W-049. The daily work tank has N2 blanketing, for same reasons as provided for the melter. From the daily work tank, the molten DMT is transferred through a candle type filter F-049 to the transesterification reactor-C-050.

6.4 Central Dowtherm heating System :
A central heating system supplies the heat requirements for the overall plant. The heat is generated in a Dowtherm heater which is equipped with oil-fired burner and then carried to the various consumers by circulation of the heat transfer fluid.

Primary Dowtherm System

The primary Dowtherm system is forced circulation system.
The heat transfer medium is circulated by the primary Dowtherm pump P-700 and heated in the tubular heater D-700. It transfers its heat, as required, to the various consumers in the transesterification, polycondensation and spinning section. To ensure adequate flow and temperature in the heater during commissioning or in the event of low heat requirements, a direct connection with control valves is provided between supply and return line parallel to the consumers.

The entire system is pressurized with nitrogen to prevent vaporization of Dowtherm in the primary system ( hazard of cavitations in circulation pumps). The nitrogen connection is provided at the Dowtherm expansion vessel B-701 which is connected to the Dowtherm system at the suction side of primary Dowtherm pumps.

A Dowtherm storage tank B-700 and a Dowtherm slop tank B-702 are provided for partial or complete draining of the Dowtherm system. All Dowtherm heat exchangers can be isolated and drained or filled separately. The drain line is also used for filling. Filling is accomplished by a Dowtherm reloading pump P-702 from the slop tank.

The Dowtherm storage tank B-700 is connected directly to the atmosphere via a Dowtherm condenser W-700, Hot ascending Dowtherm vapours are condensed in this condenser. Dowtherm losses and air pollution are so avoided. The tubular heater D-700 is a vertical cylindrical unit with refractory lining and is fired with fuel oil. The Dowtherm flows through coils and the heater walls of the combustion chamber and is heated by convection and radiation. Combustion air is taken in from the atmosphere by a fan V-700 and passes to the combustion chamber.

The tubular heater is equipped with a flow-controlled by-pass to assure that the same flow rate passes through the tubular heater
independent of the heat. The primary consumers are supplied with hot Dowtherm from the heater supply line and return it at lower temperature to the heater return line.

Secondary Dowtherm System

The secondary system is connected directly to the primary system by a supply and return line. The supply line, in which a control valve is installed, connects the primary discharge side with the secondary suction side. The return line connects the primary suction side with the secondary discharge side.

The temperature of the secondary system is controlled by mixing the hotter heat transfer medium from the primary system with that from the colder secondary system. The heat transfer medium is circulated by pump P-704.

6.5 Glycol/Methanol Recovery :
The by-products from the (trans)-esterification and polycondensation stage are accumulated in a receiver B-240 from where they are charged to a discontinuous recovery unit for distillate treatment. Glycol is recovered from the multicomponent mixture of such high purity that it can be reused as feedstock for (trans)-esterification. Also methanol of technical grade can be recovered. The other components are waste products.

From the receiver the feedstock is pumped to the still B-242 of the sieve tray column K-240. The batch is heated whereby methanol is removed. Distillation occurs under vacuum in order to ensure gentle separation of glycol (at high temperatures it decomposes into di- and tri-glycol). When glycol and methanol (methanol is only gained if DMT is used as raw material) are removed, the other components are discharged as residue via pump P-242 into a residue tank B-241. From there it can be transferred to the Dowtherm heater for burning with the help of the special residue burner.

6.6 Cleaning Unit for Filter (F-054) and Non-stop Melt filter :
The contaminated precondensate filters and non-stop melt filter are boiled out in TEG and then rinsed with water in a separate tank.
The filters are finally subjected to ultrasonic cleaning.

6.7 Cleaning Unit for Spinnerets, Spinning Pumps, Filters and Spinneret Testing Device :
A burnout furnace serves for the cleaning of spinnerets, spinneret packs and spinning pumps. A glycol-cleaning unit serves for the cleaning of filters and spinnerets. An ultrasonic set is used for final cleaning of the spinnerets. The spinnerret testing unit serves for testing the cleaned spinnerets with special projector. This eliminates the use of insufficiently cleaned spinnerets and cuts down the amount of waste.

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PLANT PERFORMANCE DATA
SECTION INSTALLED CAPACITY MTA 1991-92 1992-93 1993-94 1994-95 1995-96 1996-97 1997-98 1998-99 (HALF YEAR)
POLYMER 20000       1058 12438 1605 13436 6841
% UTILIZATION         5 62 8 67 69
YARN PRODUCTION 6000/8000 531 3923 5073 5036 4648 664 7175 3219
% UTILIZATION   9 65 85 84 77 11 90 81


POLYMER SECTION WAS COMMISSIONED IN 1994-95.
YARN PLANT WAS COMMISSIONED IN 1991-92 ON EXTRUDERS.
DMS (DIRECT MELT SPINNING) WAS COMMISSIONED IN 1996-97.

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RAW MATERIAL & OTHER INGRADIENTS’ STORAGE CAPACITY
SR.No. ITEMS CAPACITY
1. MEG VIRGIN 1130 M3
2. MEG RECOVERED 127 M3
3. MEG DAY TANK 44 M3
4. METHANOL CRUDE 184 M3
5. METHANOL PURE 266 M3
6. DMT SURGE TANK MELTER 30 MT
7. PTA PASTE TANK 5 M3
8. DMT/PTA PLANT STORAGE 180 MT
9. PTA STORAGE SILO 48 MT
10. PLANT FINISH PRODUCT BSR-II 15 X 55 M2
11. POLYESTER WASTE BSR-VIII 100 X 50 M2
12 * RAW WATER STORAGE 3000 M3 (1500 X 2)
13. * LSHS 500 M3
14. * HSDO 225 M3
15. * EFFLUENT STORAGE
A) CTBD & DM EFFLUENT
B) PROCESS EFFLUENT
C) PROCESS WASTE EFFLUENT
400 X 3 M3
400 M3
400 M3
400 M3
16. * FINISHED PRODUCT BSR-I 36 X 80 M2
17. STORE FOR PACKING MATERIAL 40 X 18 M2
18. STORES FOR SPARE CHIPS 44 X 30 M2
40 X 48 M2
19. * RAW MATERIAL /CHIPS STORAGE BSR-IV 15 X 25 M2
20. CEMENT GODOWN 40 X 18 M2
21. * LDO 17.5 M3
NOTE : WHERE FACILITIES ARE COMMON AND SHARED HAVE BEEN MARKED AS *

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CONSUMPTION OF RAW MATERIALS AS PER LICENSE AGREEMENT
SR. No.
MATERIAL
DMT-ROUTE
PTA-ROUTE
 
 
Kg/t Chip
Kg/t Yarn
Kg/t Chip
Kg/t Yarn
1
DIMETHYLTEREPHTHALATE
1009
1031
-
-
2
PURE TEREPHTHALIC ACID PTA
-
-
863
883
3
GLYCOL,EG + DEG WITH RECOVERY
349
356
347
354
4
CATALYST & ADDITIVES
1.6
1.63
1.0
1.02
5
DULLING AGENT TIO2 (AS 0.4% IN POLYMER)
4.2
4.3
4.2
4.3
6
SPIN FINISH
-
4.5
-
4.5

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CONSUMPTION OF RAW MATERIALS AS PER LICENCE AGREEMENT
SR. No.
MATERIAL
DMT-ROUTE
PTA-ROUTE
 
 
Kg/t Chip
Kg/t Yarn
Kg/t Chip
Kg/t Yarn
1
DIMETHYLTEREPHTHALATE
1009
1031
-
-
2
PURE TEREPHTHALIC ACID PTA
-
-
863
883
3
GLYCOL,EG + DEG WITH RECOVERY
349
356
347
354
4
CATALYST & ADDITIVES
1.6
1.63
1.0
1.02
5
DULLING AGENT TIO2 (AS 0.4% IN POLYMER)
4.2
4.3
4.2
4.3
6
SPIN FINISH
-
4.5
-
4.5

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DISTRIBUTION OF CENTRALISED UTILITIES
SrNo Utilities Unit Capacity
Consumption
       
NFY
PFY
SDX
UTY
Others
1 RAW WATER m3 3000
1500/Reservoir-2 Nos
 
200
200
200
200
100
2 COOLING WATER m3/ hr 4000
1000/Cell-4 Nos
 
200
300
150
2100
 
3 CHILLED WATER TR 3100
600/Chiller-3 Nos
400/Chiller-3 Nos
100/Chiller-1 No
 

1000


 

550
 

100
 
30
 
4 DM WATER B.F.W. m3 720
40
15
15
350
 
5. STEAM T/hr 30
10/Boiler- 3 Nos
Pr”=17 Kg/Cm2
2 NESTLER Make
1 THERMAX Make
 
4.5
3.5
1.5
2.0
 
6 NITROGEN Nm3/hr 125
60
20
9
 
 
7 COMPRESSED AIR Nm3/
hr
 
5000/CENTAC-2 Nos
8 kgs(L.P.)
2000/KGK-2 Nos
8 Kgs(L.P)
1500/IR-2 Nos
17 Kgs(H.P.)
500/KGK-1 No
600/KGK-1 No
 
5000
L.P.


1200
H.P.
 

2000
L.P.
 
250
L.P.
 
200
L.P.
 
 
8 DIPHIL Kcal/hr PFY PHU 2.65
MKcal/Unit-2 Nos.
NFY PHU 0.75
MKcal/Unit-2 Nos.
SDX PHU 0.30
MKcal/Unit-1 No
 
0.5
1.5
0.24
 
 

 

UTILITY CONSUMPTION AS PER LICENCE AGREEMENT
Sr.No.
Particulars
Unit
DMT Process
PTA Process
1
ELECTRIC POWER
Kwh/day
27.500
26.300
2
STEAM
T/day
109
22
3
COOLING WATER
M3/day
8.500
4.300
4
FRESH WATER
M3/day
60
60
5
CHILLED WATER
Kcal/day
11.6 x 106
5.8 x 106
6
DEMINERALIZED WATER
M3/day
4
4
7
INSTRUMENT AIR
Nm3/day
4.500
4.500
8
PROCESS AIR
Nm3/day
14.500
14.500
9
NITROGEN
Nm3/day
230
120
10
FUEL OIL (HEATER EFFICIENCY 90%)
MT/day
4.800
4.600
11
QUENCH AIR REQUIREMENT POY SPINNING FOR EACH QUENCH CHAMBER 2.200 N m3/hr,

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TESTING EQUIPMENTS FOR PHYSICAL LABORATORY
SR. NO.
 
NAME OF EQUIPMENT QUANTITY
1 USTER EVENESS TESTER, MONITOR-C SWIZ
 
1
2 STAR TEST CONTROL, ZELLEWERGER-SWITZERLAND, STAR ELECTRONIC PVT.LTD. INDIA
 
1
3 STRENGTH AND ELONGATION TESTER PETRIFIES
 
1
4 STRENGTH AND ELONGATION TESTER, ZWICK-1510, GERMANY
 
1
5 DIGITAL ELECTRONIC BALANCE, CAPACITY - 15 KG., PRECIBA-BOMBAY
 
1
6 DIGITAL ELECTRONIC BALANCE, CAP.-100 KG., LIBRA-BOMBAY
 
1
7 YARN WRAPE REEL, KAMAL METAL, AHMEDABAD
 
1

 

TESTING EQUIPMENTS FOR CHEMICAL LABORATORY

SR.NO.

NAME OF EQUIPMENT
UNIT
1
VACCUM DIGITAL OVEN SHIVANI SCIENTIFIC IND. KW 1.5
1
2
OVEN, 230 VOLTS PATHAK ELECTRICAL WORKS,BOMBAY
1
3
I.V. BATH WITH TWO UNITS LAUDA THERMOSTAT,GERMANY
1
4
ROTARY VACUUM PUMP HIND PUMP, BANGALORE
1
5
MOISTURE MEASUREMENT EQUIPMENT JIVANI
 
6
OVEN , W-2000 MEMMERT,GERMANY
1
7
HEATING CHAMBER
1
8
WATER BATH REMI INDUSTRIES
1
9
EQUIPMENT WITH TEMPERATURE CONTROLLER KUMAR INDUSTRIES
1
10
JAYMAT LABORATORY EQUIPMENT SIZE - 5 LIT. JAY SCIENTIFIC INSTRUMENT
1
11
AQUA- BATH SKAN
1
12
FURNACE ABROL INDUSTRIES
1
13
HOT PLATE
1
14
REFRIGERATOR KELVINATOR SMALL
1
15
GAS CHROMATOGRAPH, BARODA
1
16
KARL FISCHER
1
17
UV SPECTROPHOTOMETER WAVELENGTH UPTO 1000 NM
1
18
ELECTRONIC SERVO VOLTAGE STABILIZER CAP. 1.5 KVA
2
19
CONDUCTIVITY METER
1
20
TURBIOLITY METER SYSTRONICS
1
21
COLOURI METER MARRYLAND-USA GARDENOR LABORATORY BETHESDA
1
22
MEGNETIC STIRAER REMI EQUIPMENT, BOMBAY
1
23
HEATING CHAMBER WITH FOUR ZONE KUMAR INDUSTRIES, BOMBAY
1
24
BOD INCUBAATOR DURGA ESTATE, BARODA
1
25
MELTING POINT APPARATERS MELTER INDUSTRIES, SWITZERLAND
1
26
MELTING POINT APPRATERS HEERBRUGG SWITZERLAND
3
27
ELECTRONIC BALANCE SARTORIOUS GMBH
2
28
SPECTROPHOTOMETER
1
29
FLAME PHOTOMETER
1
30
FPM COMPRESSOR UNIT SYSTRONICS
1
31
CONDUCTING METER
1
32
WATER BATH
1
33
TURBIDIMETER(APLAH) APPLIED ELECTRONICS LTD.
1
34
MINI OIL BATH KUMAR INDUSTRIES BOMBAY
1
35
CENTRIFUGE REMI EQUIPMENT BOMBAY
1
36
ATCO WEIGH SCALE CAP.6 KG. ATCO IND.LTD.
1

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INDIGENOUS EQUIPMENTS
SR. NO. EQUIPMENT NAME
1. VESSELS Bharat Heavy Plate & Vessels, Vizakaptnam
Shrinivas Plates & Struct Co (P) Ltd, Baroda
Prabha Steel Industries, Baroda
2. TANKS Bharat Heavy Plate & Vessels, Vizakaptnam
Shrinivas Plates & Struct Co (P) Ltd, Baroda
3. REACTORS Bharat Heavy Plate & Vessels, Vizakaptna
4. COLUMNS Bharat Heavy Plate & Vessels,Vizakaptnam
5. FILTERS Bharat Heavy Plate & Vessels, Vizakaptnam
Octokline Plates & Equipments Ltd,Bombay
Multitex Filteration Engg (P) Ltd, New Delhi.
6. PUMPS Kirloskar Brothers Ltd, New Delhi
Akay Industries, New Delhi
Precision Pneumatic Indu., Ahmedabad
Khimline Pumps Ltd ,New Delhi
Beacon Wair Ltd, Madras
V.K.Pumps Indu (P) Ltd ,Bombay
Sulzer Ltd, Pune
7. BLOWERS Swam Penumatics(P)Ltd, Ghaziabad
Venture Fabrication(P)Ltd, Bombay
Slm-Maneklal Ltd
Idustrial Fans(India)Ltd, Madras
KSB Pumps Ltd ,Thane
8. HEAT EXCHANGER Bharat Heavy Plate & Vessels, Vizakaptnam
Dalfab Engg (P) Ltd., Baroda
Fabwell , Baroda
P.J.Surotia & Co. ,Ahmedabad
Anand Engg (P) Ltd, Bombay
Alpa Level(I) Ltd., New Delhi
9. BAGGING AND STITCHING/SEALING UNI
 
Reed Medway Packing Co.,New Delhi
10. BELT CONVEYER FOR DMT SCREW CONVEYER FOR PTA
 
Indiana Engg Works (P) Ltd, Bombay.
11. AGITATORS Bharat Heavy Plate & Vessels, Vizakaptnam
12. TRANSFORMERS Voltamp; Baroda.

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ASSETS ON LEASE
Sr. No. EQUIPMENT DESCRIPTION NO. LESSOR
1. PRIMARY HEATING UNIT
CAPACITY: 2.65 M Kcal/HR.
BHPV
1 & 2 IDBI,BOMBAY
2.* STEAM BOILERS
2 NESTLER
1 THERMAX
3 IDBI, BOMBAY
* STEAM BOILERS CATER TO THE NEED OF ALL THE THREE PLANTS.

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SPANDEX YARN PLANT

PLANT DESIGN DATA FOR SPANDEX YARN PLANT
SR. No.
PARTICULARS DETAILS
1.
PLANT SPANDEX ELASTOMERIC YARN
2.
YEAR OF ERECTION 1993-94
3.
YEAR OF COMMISSIONING 1994
4.
TECHNICAL COLLABORATION M/s. TOYOBO JAPAN
TECHNOLOGY THROUGH
M/s. MARUBENI, JAPAN
5.
DETAILED ENGINEERING M/S. ENGINEERS INDIA LIMITED.
6.
PLANT LICENSED CAPACITY 300 MTA

7.

INSTALLED CAPACITY POLYMER : 554 MTA
SPINNING : 518 MTA
(In terms of 70 & 1120 Denier)
COVERED YARN : 30 MTA

DESIGN AND SALIENT FEATURE

PLANT DETAILS:
Spandex Yarn Plant having dry spinning technology based on PTG & MDI as main ingradients was set up and commissioned in the year 1994 with M/s. TOYOBO TECHNOLOGY which was obtained through M/s. MARUBENI, JAPAN. The 2 spinning lines are imported and supplied by M/s. ISHIKAVA, JAPAN. Licence was issued for the production of 300 MT of yarn, however the Poly Plant has the capacity to produce 554 MT of polymer and 518 MT of yarn per annum on thick denier basis.
Polymer Plant is PLC controlled fully automatic. There are 2 Spinning Lines of 15 positions each. One line with 4/8 ends/position suitable upto 280 denier production and other having 1/2 ends/position suitable upto 1120 denier production.
In the polymerisation section finisher reactor, agitators, canned pumps and other critical equipments are of Japanese origin while the other equipments are manufactured indigenously.
All the Utilities except (-)13oC chilled water and hot temperature media (HTM) are supplied through the centralised common shared utilities. There is a provision to share HTM and Chilled Water (for Air Conditioning) from the adjoining Polyester Filament Yarn-PFY Plant.

MDI STORAGE :
One of the main ingradients is MDI which is to be stored at (-)5oC for enhanced shelf life. Under Indian Regulations, it is required to be stored away from the main plant. Accordingly separate storage facilities have been created sufficient to store 60 MT of MDI at (-)5oC away from the main plants. This building is fitted with water sprinklers as per statutory requirements.

CHEMICAL AND PHYSICAL LABORATORY :
For carrying out chemical and physical testing of Raw materials, semi-finished and finished products etc; the well equipped instruments have been provided in both the laboratories.
Emergency power form DG Sets have been provided for critical equipments to take care of saving of intermediate and final products in case of power failure.

PACKING FACILITIES :
For packing finished products separate area is earmarked which is equipped with inspection tables, conveyors and computerised weighing facilities.

COVERING MACHINE :
There is a 256 spindles Covering Machine supplied by M/s. MENEGATO, ITALY. Machine can cover bare spandex with all type of covering yarns like cotton, polyester and nylon.

CENTRALISED WORKSHOP :
To carry out minor repairs and modifications there exist a Centralised Workshop.

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PROCESS DESCRIPTION
The process can be divided into the followings :
1. Polymerization section ( Batch system)
2. Spinning Section
3. After-treatment Section
4. Dimethylformamide (DMF) Recovery Section

1. POLYMERISATION SECTION (Batch System) :
The Polymerization process consists mainly of the stages of the first polymerization and second polymerization.
The reaction of polytetramethylene ether glycol (PTG) with diphenylmethane diisocyanate (MDI) is carried out in the first reactor.
Each requisite quantity of PTG and MDI is charged into the first reactor after the measurement is made in the measuring tank or by the flow meter.
The reaction of PTG with MDI proceeds under stirring and the solvent, DMF, is added after the reaction completion.
The reaction temperature has to be controlled to follow the schedule programme.
The resultant product in the first reactor is transferred to the second reactor through the pipe, where the chain extending agent, TiO2 and some kinds of additives are added.
The Polymerization is continued until the polymer solution of the definite viscosity at the constant temperature is obtained. After some kinds of additive agent are added to the reactor in order to complete the polymerization, the concentration of polymer is adjusted by addition of DMF. Most of the above mentioned operations are automatically carried out, but some of them are carried out manually. The dope obtained by above method is transferred by the pump to the dope mixing tank and some kinds of additives are added into the dope mixing tank. Then the dope is transferred by the pump to the feed tank and stored. The dope in the feed tank is filtered with dope filter and fed to the spinning section.

2. SPINNING SECTION :
The dope is dearated and stored in the spin tank and is delivered to the spinnerettes through the gear pumps attached to each spinning chamber. DMF in the dope is evaporated by circulating hot air flow in the spinning chamber and the hot air flowed in the spinning chamber is cooled in the cooler in order to recover DMF and then heated again in the air heater and circulated to the spinning chamber. The special type of heat exchanger is adopted for this process in order to minimise the utility consumption. Expected production in Kg/day per machine is given at Table 1.3
On the other hand, the filament is coagulated by the false twister with motor, oiled and wound by the take up machine. The wound bobbins are carried to the after treatment section by bobbin cart.

3. AFTER-TREATMENT SECTION AND OTHERS :
The cheeses of some kind of assortment on the cart are cured in the curing oven so that the yarn will get the desirable properties.
After being inspected and sorted, the cheeses are packed.

4. DMF RECOVERY SECTION :
Crude DMF, which is recovered in the spinning process, is rectified in the DMF recovery process and the rectified DMF is reused in the polymerization process. Two towers are installed in the DMF recovery process and this process is operated continuously. The low boiling point chemicals are eliminated from the top of Tower-1 and DMF is continuously removed from the bottom of Tower-1 and fed to Tower-2. The rectified DMF is run off from the top portion of Tower-2 and the high boiling point chemicals are continuously removed from the bottom of Tower-2. The rectified DMF is stored in recovered DMF storage tank and transferred to purified DMF storage tank.

5. The quantity and specification of the Spandex yarn are As given below :-

 
Assortment
Quantity MTA
Denier (d)
Breaking Strength (g/d)
Breaking
Elongation (%)
Load at 300%
Elongation(g)
Elastic recovery
from 300% elongation (%)
70 D
40
70+3.0
1.15>
480+75
21+5
=95>
140 D
60
140+4.0
0.95>
460+75
43+9
=95>
280 D
50
280+7.0
0.88>
550+75
60+11
=95>
420 D
70
420+10.0
0.80>
570+75
85+14
=95>
840 D
50
840+20.0
0.7>
610+75
135+20
=95>
1120 D
30
1120+28.0
0.7>
610+75
170+27
=95>
TABLE 1.1

6. MATERIAL BALANCE :
The complete material balance showing the inputs and outputs is shown at Table 1.1. The storage conditions of various raw and auxiliary materials is provided at Table 1.2

7. BLOCK DIAGRAM :
The basic block diagram indicating process flow is given below :
 
MATERIAL BALANCE OF SPANDEX PLANT
MDI 196 Kg
Product{(975+25 Oil)+30 Oil} Kg
PTG 764 Kg Waste Yarn (82+20 Oil) Kg
CEA 29 Kg Waste Oil 15 Kg
ADD.A 77 Kg Waste Dope } Solid 8 Kg
                    } DMF 11 Kg
SPANDEX PLANT
                    
ADD.B 15 Kg
 
Exhaust DMF 26 Kg
Drainage DMF 26 Kg
ADD.C 20 Kg
Distillation Residue (DMF 114 Kg+ADD A,B & C 35 Kg)}
Polymers (1 Kg)
DMF X+200 Kg
Others DMF 23 Kg
Recolleted DMF X Kg
Table 1.2


8.

EXPECTED PRODUCTION Kg/Day/Machine OF SPANDEX
Sr. No.
Denier
No of Holes
Expected ProductionKg/day/mc
No of Ends
1
10
3
72.15
8
2
20
3
144.15
8
3
40
5
288.45
8
4
70
7
504.76
8
5
140
7 x 2
513.78
4
6
210
10 x 2
771.45
4
7
280
10 x 2
770.55
4
8
420
30
767.85
2
9
840
30 x 2
775.05
1
10
1120
45 x 2
905.99
1

TABLE 1.3

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PLANT PERFORMANCE DATA
  CAPACITY 1991-92 1992-93 1993-94 1994-95 1995-96 1996-97 1997-98 1998-99 Half Year
YARN PRODUCTION MT
300
-
-
8
32
-
30
-
-
CAPACITY UTILISATION (%)
100
-
-
Trial Run
Gaurantee Run
-
10
-
-

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RAW MATERIAL AND OTHER INGRADIENTS STORAGE CAPACITY
Sr. No. Items
Capacity
1. MDI Storage
25 MT
2. DMF PURE
18.6 M3
3. DMF Receiving Tank
11.0 M3
4 CRUDE DMF
11.0 M3
5. RECOVERED DMF
18.6 M3
6. Low Speed DISEL For PHU
3.5 M3
7. BARE YARN (Non Duty) BSR-V Storage
15 X 7 M2
8. COVERED YARN(Duty Paid ) BSR-VI Storage
15 X 7 M2
*9. LSHS
500 M3
*10. HSDO
225 M3
*11. PACKING MATERIAL Storage
40 X 18 M2
*12. RAW WATER Storage
3000 M3
(1500X 2)
*13. EFFLUENT Storage

a) CTBD & DM EFFLUENT
b) PROCESS EFFLUENT’
c) PROCESS WASTE EFFLUENT
400 X 3 M3

400 M3

400 M3

400 M3

*14 Store For SPARES
40X 30 M2
40 X 48 M2
*15. FINISHED PRODUCT(COMMON) BSR-I
36 X 80 M2
*16. CEMENT GODOWN
40 X 18 M2
*17. LDO
17.5 M3
NOTE : Where facilities are common and shared have been marked as *

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UTILITY SPECIFICATIONS & TENTATIVE CONSUMPTION
Sr. No.
Utility
Specification
Consumption
 
 
 
Maximum
Minimum
1
COMPRESSED AIR FOR INSTRUMENTS
6 Kg/cm2
Temp=30o max
360 Nm3/hr
90 Nm3/hr
2
DEMINERALISED WATER
2.5-3.0 Kg/cm2
pH=6.8-7.2
Conductivity=1mho
4.0 M3/hr
0.4 M3/hr
3
COOLING WATER
5.0 Kg/cm2
pH=6.0-7.5 Temp=32oC
 
90 M3/hr
80 M3/hr
4
COOLING MEDIA
Ethylene Glycol
Temp=(-)13oC
240 x 103
Kcal/hr
170 x 103
Kcal/hr
5
RAW WATER
3-4 Kg/cm2
pH=7.6-8.2
Temp=28-32oC
9 M3/hr
7M3/hr
6
LOW PRESSURE STEAM
3.0 Kg/cm2
1000 Kg/hr
490 Kg/hr
 
HIGH PRESSURE STEAM
15.5-17 Kg/cm2
720 Kg/hr
700 Kg/hr
7
HEATING MEDIA-
DOWTHERM
(USA)
Temp Supply= 290oC
Return= 280oC
Feed Pressure=5-6 Kg/cm2
Boiling Pt.=257oC
Flash Pt.=124oC
160 x 103 Kcal/hr
160 x 103 Kcal/hr
8
NITROGEN
6.0 Kg/cm2
Dew Pt.=(-)40oC
12.0 Nm3/hr
9.2 Nm3/hr
9
ELECTRICITY
Voltage 230 V
240 Kw
150 Kw
10
CHILLED WATER
For Air Conditioning requirement
For all AHU-Air Handling Unit
Supply=6oC
Return=12oC
160 TR
120 TR

 

UTILITY CONSUMPTION
PER MT OF 280 & 840 DENIER OF SPANDEX YARN
Sr.No.
Utility
Consumption
1
ELECTRICITY
4800 KWH
2
STEAM
35 T
3
HEATING MEDIUM
5,500,000 KCAL
4
DM WATER
33 M3
5
COOLING WATER
2172 M3
6
COOLING MEDIA
4,400,000 KCAL
7
COMPRESSED AIR
5,500 NM3

 

DISTRIBUTION OF CENTRALISED UTILITIES
SrNo Utilities Unit Capacity
Consumption
       
NFY
PFY
SDX
UTY
Others
1 RAW WATER m3 3000
1500/Reservoir-2 Nos
 
200
200
200
200
100
2 COOLING WATER m3/ hr 4000
1000/Cell-4 Nos
 
200
300
150
2100
 
3 CHILLED WATER TR 3100
600/Chiller-3 Nos
400/Chiller-3 Nos
100/Chiller-1 No
 

1000


 

550
 

100
 
30
 
4 DM WATER B.F.W. m3 720
40
15
15
350
 
5. STEAM T/hr 30
10/Boiler- 3 Nos
Pr”=17 Kg/Cm2
2 NESTLER Make
1 THERMAX Make
 
4.5
3.5
1.5
2.0
 
6 NITROGEN Nm3/hr 125
60
20
9
 
 
7 COMPRESSED AIR Nm3/
hr
 
5000/CENTAC-2 Nos
8 kgs(L.P.)
2000/KGK-2 Nos
8 Kgs(L.P)
1500/IR-2 Nos
17 Kgs(H.P.)
500/KGK-1 No
600/KGK-1 No
 
5000
L.P.


1200
H.P.
 

2000
L.P.
 
250
L.P.
 
200
L.P.
 
 
8 DIPHIL Kcal/hr PFY PHU 2.65
MKcal/Unit-2 Nos.
NFY PHU 0.75
MKcal/Unit-2 Nos.
SDX PHU 0.30
MKcal/Unit-1 No
 
0.5
1.5
0.24

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TESTING EQUIPMENTS FOR PHYSICAL LABORATORY
Sr. No.
Name Of Equipment
Quantity
1
TWIST TESTING MACHINE
1
2
DIGITAL BALANCE-60 Kg CAPACITY
Make : PENTA ELECTRONICA MAKE
1
3
TENSILON TENSILE TESTER
Make : RTM-100 ORIENT CORPORATION
2
4
ELONGATION TESTING BOARD
2
5
SINGLE PAN ELECTRONIC BALANCE
Make : AFCO SET
1
6
OVEN 230 V; 45X45X45 CM
Make : UMA IND,BOMBAY
1
7
DIGITAL BALANCE- 15 Kg Cap.
Make : PENTA ELECTRONICS
1

 

TESTING EQUIPMENTS FOR CHEMICAL LABORATORY
Sr. No.
Name Of Equipment
Quantity
1
OVEN 2.0 KW
Make : CHEMIN , BOMBAY
 
1
2
REFRIGERATOR –Small size
Make : GODREJ
 
1
3
OVEN 230 V
Make : KUMAR IND, BOMBAY
 
1
4
ELECTRONIC BALANCE- 180 gms
Make : ATCO SET
 
1
5
CONSTANT TEMPERATURE BATH
Make : INSREF, MADRAS
 
1
6
ROTARY VACUUM PUMP
-Displacement=1000 mtr/min ; RPM=1440
Make : Hindhival Pump-Banglore
 
1
7
MICRO pH SYSTEM- 361
1
8
KARL FISCHER TITRATOR
Make : TOSHNIWAL INSTRUMENT,BOMBAY
 
1
9
DIGITAL TEMPERATURE CONTROLLER OVEN- 2.5 KW
Make : PATHAK ELECTRICAL WORKS, BOMBAY
 
1
10
WATER BATH (RATHING)
Make : KUMAR INDUSTRIES , BOMBAY
 
1
11
SPECIAL POLYMERISER
1
12
MODEL B VISCOMETER
1
13
ELECTRIC CONDUCTANCE METER
1

 

ESSENTIAL EQUIPMENTS FORMING INTEGRAL PART OF PLANT
Sr. No. Name Of Equipment Quantity
1 CURING OVEN 1
2 ULTRASONIC UNIT 2
3 ELECTRIC HEATING FURNACE 1
4 MICROSCOPE 1
5 PACK BURNING OVEN 1
6 SET OF DMF BATH FOR PACK/PUMP/FILTER CLEANING 1
7 VELOMETER (ANEMOMETER) 1
8 WINDING MACHINE FOR COVERED YARN 1

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INDIGENOUS EQUIPMENTS AND MANUFACTURERS
Sr.No. Name of the equipment Manufacturer
1 VESSELS Project Tech nologist (P) Ltd
Fabwel Engineers
Prabha Steel
2 TANKS Shrinivas Plate & Structurals Co (P) Ltd
3 AGITATORS Remi Process Plant & Mahinery Ltd
4 HEAT EXCHANGERS Fabwel Engineers
Prabha Steel Industries
5 PUMPS Khimline Pumps Ltd
Kirlosker Brothers Ltd
KSB Pumps Ltd
6 MELTING CHAMBER Dalfab Engineering Pvt. Ltd
7 RE-BOILER Fabwel Engineering
8 DISTILLATION TOWER Project Technologist (P) Ltd
9 CURING OVEN Standard Fabricators (P) Ltd
10 VACUUM PUMP Mazda Power Engineering
11 STEAM JET EJECTOR Mazda Controls Ltd
12 STATIC MIXER Mixirite Corporation
13 CONVEYOR Air-Mech Engineers
14 PRIMARY HEATING UNIT Isotex Corporation
15 SPRINKLER SYSTEM Mather & Platt (I) Ltd
16 13* C COOLING MEDIA Kirlosker Pneumatic Co.

 

IMPORTED EQUIPMENTS AND TYPE
Sr. No. Equipment Quantity Type
1 DFM TANK BOTTOM PUMP 1+1 CANNED
2 PTG FILTER 1 SET  
3 PTG FEED PUMP 1 SET GEAR
4 MDI FILTER 1 SET  
5 AGITATOR FOR FIRST REACTOR 1 SET SPECIAL TYPE
6 PRE-POLYMER FILTER 1 SET  
7 ADDITIVE – 4 MIXING TANK PUMP 1 SET SCREW
8 ADDITIVE – 4 MILL 1 SET  
9 ADDITIVE – 4S HOLDING TANK PUMP 1+1 SET SCREW
10 ADDITIVE – 4S ADDITION PUMP 1 SET DIAPHRAM
11 CEAS ADDITION PUMP 1+1 SET DIAPHRAM
12 SECOND REACTOR WITH AGITATOR 1 SET SPECIAL
13 VISCOMETER PUMP 1 SET GEAR
14 SECOND REACTOR MOTOR PUMP 1 SET GEAR
15 AGITIATOR FOR DOPE MIXING TANK 1 SET SPECIAL
16 ADDITIVE – 9 FEED PUMP 1 SET CANNED
17 ADDITIVE – 11 FEED PUMP 1 SET CANNED
18 DOPE MIXING TANK BOTTOM PUMP 1 SET GEAR
19 DOPE FILTER 1 SET  
20 DOPE FILTER FEED PUMP 1+1 SET GEAR
21 DRUM PUMP 4 SET CANNED
22 WASHED DMF PUMP 1 SET CANNED
23 REACTOR WASHING DMF PUMP 1 SET CANNED
24 VACUUM DEAREATOR 1 SET SPECIAL
25 VACUUNM EJECTOR 1 SET 3 STAGE
26 SPIN TANK FEED PUMP 1+1 SET SCREW
27 AGIOTATOR FOR SPIN TANK 1 SET SPECIAL
28 SPINNING CHAMBER 30 POSITION  
29 SPINNING GEAR PUMP FOR FINE DENIER 1 LOT GEAR
30 SPINNING GEAR PUMP 1 LOT GEAR
31 SPINNING GEAR PUMP DRIVE UNIT 2 SET  
32 SPINNING FILTER 30 SET  
33 SPINNERET & BLOCK 1 LOT  
34 SPINNERETE & BLOCK FOR FINE DENIER 1 LOT  
35 TAKE-UP MACHINES 1 LOT  
36 SM HEATER & COOLER    
  -HEAT EXCHANGER    
  -AIR COOLER    
  -AIR CIRCULATION FAN    
  -AIR HEATER 1 LOT  
37 PUMP FOR DMF VENT AIR COOLER 1 SET CANNED
38 RECOVERED DMF TRANSFER PUMP 1 SET CANNED
39 AIR COOLER WASHING PUMP 1 SET CANNED
40 SP POLYMERISER 1 SET TOYOBO
41 SP FLASK FOR POLYMERISATION 20 SET TOYOBO
42 MODEL B VISOMETER 2 SET  
43 TENSION TENSILE TESTER 2 SET  
44 SP TOOLS 1 LOT  
45 ADDITIVE ADDITIONAL UNIT 1 SET CANNED
46 CRUDE DMF FEED PUMP 1+1 SET CANNED
47 TOWER REFLUX PUMP 1 SET CANNED
48 TOWER – 1 DIACHARGE PUMP 1 SET CANNED
49 TOWER –2 REFLUX PUMP 1 SET CANNED
50 TOWER – 2 DIACHARGE PUMP 1+1 SET CANNED
51 RECOVERED DMF DISCHARGE PUMP 1 SET CANNED
52 VARIOUS INSTRUMENTS 1 LOT  
53 CONTROL PANEL    
  -POLYMERISATION    
  -SPINNING    
  -DOFFING TIMER    
  -DMF RECOVERY 1 LOT  
54 ELECTRICAL EQUIPMENT INCLUDING    
  -INVERTOR FOR GD    
  -INVERTOR FOR TW    
  -INVERTOR FOR TR    
  -INVERTOR FOR GP & FR    
  -INVERTOR STANDBY    
  -SYNCHRONOUS MOTOR    
  -FALSE TWIST MOTOR 1 LOT  
55 SPARE PARTS FOR EQUIPMENT 1 LOT  

 

IMPORTED EQUIPMENTS AND MANUFACTURES
Sr. No.   Equipment   Manufactures
1   REACTOR   Kimura Machinery Induatrial Co Ltd
2   AGITATOR   Satake Chemical Equipment Mfg Ltd
        Shimazaki Mixing Equipment Co. Ltd
3   SPECIAL CHAMBER   Kimura Machineries Ind Co Ltd
4   FILTERS   Kyowa Iron Works Co Ltd
        Kimura M/c Ind Co Ltd
        Toyobo Co Ltd
5   TAKE-UP MACHINE   Ishikawa Seisakusho Ltd
6   DYNO MILL   Shinmaru Ent Ltd
7   PUMPS   Teikoku Ele Mfg Co Ltd
        Neishin Engg & Equip co Ltd
        Teikiku – Lewa
        Mazda Pumps Mfg Co Ltd
        Daito Kogyo Co Ltd
        Kawasaki Heavy Ind Ltd

 

IMPORTED INSTRUMENTATION AND MANUFACTURERS
Sr. No Instrument Manufacturer
1 SMART TRANSMETERS Yamatake – Honeywell
2 RECORDER Yokogawa
3 SENSORS Omron
4 PROCESS INSTRUMENTS Yokogawa
5 DIGITAL COUNTERS Omron
6 FLOW METERS Oval Tokyo Keiso Co
7 LEVEL SWITCH Ohken
8 CHEMICAL GAUGES Nagano
9 CONTROL VALVES Motoyama
10 SOLENOID VALVES Konak
11 INVERTERS- MEIDEN THYFREL-500 Sumitomo

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ASSETS ON LEASE
Sr. No. Equipment Description NO. LESSOR
1. PRIMARY HEATING UNIT
Capacity: 3.0 Lac Kcal/Hr.
Make : ISOTEX
1 IDBI, BOMBAY
* 2 STEAM BOILERS
2 NESTLER Make
1 THERMAX Make
3 IDBI, BOMBAY
* STEAM BOILERS CATER TO THE NEED OF ALL THE THREE PLANTS.

************************************************************************************************************************************************

NYLON PLANT

PLANT DESIGN DATA FOR NYLON PLANT
SR. No. PARTICULARS DETAILS
1. PLANT NYLON-6 FILAMENT YARN
2. YEAR OF ERECTION 1989-92
3. YEAR OF COMMISSIONING POLYMERISATION – 1992
SPINNING –1989
DRAW TWISTING – 1992
4. TECHNICAL COLLABORATION M/S. LURGI GMBH, GERMANY

 

5. DETAILED ENGINEERING M/S. ENGINEERS INDIA LIMITED.

 

6. PLANT LICENSED CAPACITY POLYMERISATION – 12000 TPA
SPINNING – 6000 TPA
DRAW TWISTING – 4000 TPA
7. INSTALLED CAPACITY SAME AS ABOVE

DESIGN AND SALIENT FEATURE

POLYMERISATION :
Polymerisation section comprises of two V.K. Tubes of 24 MT and 12 MT per day capacity designed for Textile grade Nylon chips of 2.4 RV using Caprolactam as raw material. Reactors have been successfully utilised for the productions of Technical grade 3.4 RV chips. Plant is equipped to recover caprolactam from wash water and solid waste. The process is PLC controlled from a centralised control room.

SPINNING SECTION :
The Spinning comprises of Two dryers, which feed to five individual lines through extruders and CPF. Four lines have been designed for the production of POY while the fifth line is designed for the production of fully drawn Nylon yarn.
Spinning lines are designed in such a manner that these can operate on both Nylon as well as Polyester Chips. Plant was only commissioned in the initial stage on Nylon chips but subsequently commercially run on Polyester chips for the production of Polyester POY only. All lines are having 12 positions and 8 ends per position.

DRAW TWISTING :
There are 11 Teijin seiki draw twisting machines each having 156 spindles. Machines can accommodate cops up to 420 mm and are provided with side creels for POY packages.

UTILITIES :
Air conditioning and chilled water demand for the process is met from the three chillers of 600 TR each supplied by M/s, VOLTAS.
The heating requirements of the polymerisation section is met through two diphyl boilers of 0.75 Mkcal/hr supplied by M/s. BHPV.
The critical equipments are provided with emergency power from DG sets for protection of the product in case of power failures.
The rest of the need of utilities for the process are met from the centralised common utilities provided for all the three plants.

CHEMICAL AND PHYSICAL LABORATORIES :
For carrying out Chemical and Physical testing of raw materials, semi-finished and finished products the well-equipped laboratories have been provided.

CENTRALISED WORKSHOP :
To carry out minor repairs and modifications there exist a Centralised Workshop.

PACKING FACILITIES :
For packing of POY, Flat Yarn and Nylon chips there are independent areas equipped with conveyors inspection tables and computerised weighing facilities.
 
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PROCESS DESCRIPTION

1.0 The Salient features of the Nylon-6 Plant are :-

1.1 Polymer section :
A. Chips Plant capacity – 36 MT/ day having
2 continuous polymerisation VK tube reactors.
B. Continuous monomer extraction line
C. Continuous tube dryer for drying chips
D. Solid waste recovery for recovering solid and fibrous waste back into usable caprolactum. Since spinning section was utilized for the production of Polyester yarn for better utilization , the entire system supplied by M/s. SIECO PLASThas been shifted to Vadodara.

1.2 Spinning section :
A. Chips storage, conveying system
B. Dryers & Extruders
C. High speed Take Up machines for production of POY and spin draw yarn.

2.0 POLYMERISATION SECTION :-

2.1 LACTUM PREPARATION (Lactum Melting) :
Caprolactum Supply
The starting material for the Nylon plant is solid lactum which is received in the paper bags or liquid lactum. The bags are opened by a bag-emptying unit and the solid lactum is charged into the lactum grinder. After crushing the ground material is dropped in to the melter, which is heated with hot water.
Solid lactum is fed from the storage silo in proportioning weight to maintain the batch size into the melter (dissolver). During the addition of lactum the melt temperature is controlled by circulating hot water through the internal tank heater.
A filtration system with two parallel filters is provided. After filtration the lactum melt will be stored in the intermediate lactum storage tank, under a nitrogen blanket. For the polymerisation process, it is continuously metered into the reactor,

2.2 PREPARATION OF ADDITIVES:
The chain stopper is prepared in a mix tank as a solution in water. Based on the desired product viscosity, the chain stopper is continuously metered into the V.K.tube by a metering pump. Titanium dioxide is added in the process as a delustering agent. For this purpose TiO2 is mixed in the preparation tank with demineralised water and the suspension is cycled through a colloid mill to break possible agglomerates.
Metering pump meters the TiO2 suspension into the reactors. From melter liquid lactum is transferred by a pump to the mixing vessel where it is mixed with exact amount of stabiliser + TiO2 suspension. From the mixing vessel lactum flows by gravity directly to the V.K. Tubes.

2.3 POLYMERISATION :
In the polymerisation, caprolactum is continuously polymerised to Nylon-6 at elevated temperature and atmospheric pressure. The polymerisation reactor is of V.K. Tube type, operating at atmospheric pressure. The polymerisation reactor consists of a vertical cylinder with separately adjustable dowtherm heating zones. The reactor is equipped with special internals, which are provided for a uniform throughput rate.
In the upper section of VK tube, the lactum is heated to reaction temperature. The heat required is supplied by a heat exchanger installed in the upper section; the heat generated by the polymerisation reaction is removed from the product in the built-in-moderator. During the first phase, hydrolysis of lactum to aminocaprioc acid takes place
In the presence of water. Polymerisation then proceeds by polycondensation. During the third phase, polymerisation is carried to the degree required by addition of molecular chains.
Flow regulators ensure a unifrom product flow in the VK tube during polymerisation to the required product viscosity. Catalyst water is evaporated from the top of the polymerisation reactor through a packed column system to avoid lactum losses. Vaporous heat transfer
media from evaporators heats the VK tube associated product lines.
The built-in-moderators are heated respectively cooled by liquid heat transfer medium. From the reactor the polymer melt is supplied to the metering pumps, the pumps deliver the polymer melt through a heated pipe to the strand cutting system, which is located above the extractor.

2.4 CHIPS PRODUCTION :
Once the desired viscosity of the polyamide 6 melt has been reached, the polymer is extruded from the extrusion head by a melt pump located at bottom of VK tube. The melt is forced through the extrusion head forming long continuous strands. The strands are quenched under water and cut into required size by granulators. From the extrusion die the strand drop down and they are guided through a cooling water bath and finally fed by two roll take off device to a strand cutter.
The demineralised water used for cooling the strands is circulated and a cooler maintains the temperature. The chips leaving the granulator are screened from oversize and fed to the extraction tube.

2.5 CHIPS EXTRACTION :
In the extraction section the low molecular weight portions are continuously extracted in hot water. The extraction tube is filled to the top with chips. The chips gradually move down the tube in counter current to the extraction tube. By metering the discharge flow of the extract water on the top of the extraction tube, the water/chips ratio is controlled. The chips leaving the extraction tube are continuously conveyed to the centrifuge by a chips water pump.
The uniform chips bed travels from top to the bottom through the extractor. Water flows upwards through the chips bed in counter current operation, whereby water-soluble components (monomers and oligomers) are removed. Due to counter current operation, the concentration of the extract water increases from the bottom to top to the same extent as the extract content in the chips decreases from top to bottom.
The chip level controls the chips discharge rate from the extractor. The chips leave the extractors via the discharge valve and are transferred by a free flow pump to a centrifuge, which is located above the drier.
In the centrifuge a major portion of the entrained water is removed from the chips. This water, after addition of fresh water from the recovery unit is returned to the extraction system.

2.6 CHIPS TRANSPORTATION AND STORAGE :
From the chips receivers they are transported pneumatically to one of the three chips storage silos. To avoid quality degradation, transport and storage have to be carried out under higher purity nitrogen. The chips transportation system conveys the chips from the drier to the storage silos and from these silos to the extruder fed silos in the spinning section.

2.7 HIGH TEMPERATURE MEDIUM (HTM) UNIT :
The HTM unit serves the purpose of supplying the necessary thermal energy by way of liquid heat transfer medium (HTM). To this effect liquid HTM is heated in the heater to a constant feed temperature for the individual consumers by burning fuel oil. An HTM expansion vessel installed at the highest point of the heating system compensates an HTM circulation pump is used to circulate changes in the HTM volume resulting from variations in temperature. HTM is fed into the heating system and replenished from the HTM tank via filling pump. The tank is designed to hold the total amount of HTM used in the heating system.

2.8 LACTUM RECOVERY PROCESS :
The plant is designed to recover pure monomeric lactum out of extraction water from line 1 and line 2 and solid polyamide-6 waste from spinning section.
a) Caprolactum recovery process from recovery water
Recovery water discharged from the top of washing tower is stored in recovery water tank. Recovery water in the tank is then continuously sent to evaporator in which recovery water is condensed upto 85-90% caprolactum solution in such a way that its water content is evaporated by steam heated upto a certain temperature.
This caprolactum solution is then delivered to dehydration tank, where its water content is further evaporated by steam under a reduced pressure so that the solution may be condensed upto 99% solution.
The supernatant of this condensed caprolactum solution is delivered to concentrated liquid tank.
Caprolactum solution stored in concentrated liquid tank is delivered to distillation tank. In this tank, caprolactum solution is being heated with heat transfer oil and evaporated under a reduced pressure. Then it is discharged into recovery lactum tank through condenser.
The residue remaining in distillation tank is drained out of the bottom of the tank to vat, and then this residue is charged into melting tank of depolymerisation process.
Recovered caprolactum thus obtained is delivered from recovery lactum tank to the polymerisation section.
b) Recovery process by depolymerization of Polymer waste
Polymer waste produced in the course of chip manufacturing process and/or yarn waste produced in the course of spinning and stretching process can be treated in depolymerisation and recovery processes which comprising the following steps.
Polymer waste is charged into melting tank in which 75% phosphoric acid is added to such polymer waste, which is heated up under a certain temperature until it is melted.
Molten polymer thus obtained is delivered to depolymerisation tank, where it is heated under a reduced pressure to have its caprolactum content evaporated.
Evaporated caprolactum, passing through condenser is liquidified, and such liquified caprolactum is stored temporarily in product tank.
The residue containing phosphoric acid in depolymerisation tank is drained out of the bottom of the tank to the outside of the line. This residue contains about 30-40% phosphoric acid.
When the crude caprolactum reaches a certain quality in product tank, it is delivered to dilution tank; the crude caprolactum is diluted within distillate from evaporator into 30% caprolactum solution.
A certain quantity of caustic soda is added to such diluted caprolactum solution, which is refined in such a way that impurities contained in diluted caprolactum solution are filtered and absorbed in activated carbon. It needs periodical replacement because it deteriorates its adsorptive capacity after a certain period of use.
Refined caprolactum solution is then delivered to dehydration tank, where its water content is further evaporated by steam under reduced pressure so that the solution may be condensed upto 99% solution.
The supernatant of this condensed caprolactum solution is delivered to concentrated liquid tank, while oligomer setting at the bottom of the tank is discharged from the tank to outside of the line.
Caprolactum solution in concentrated liquid tank is delivered to distillation tank. In this tank, caprolactum solution is heated with heat transfer oil and evaporated under reduced pressure. Then, it is discharged into recovery lactum storage tank through condenser.
The residue remaining in distillation tank is drained out of the bottom of the tank to the outside of line.
Recovered caprolactum thus obtained is delivered from recovery lactum storage tank to polymerisation section.


3.0 SPINNING SECTION :-

3.1 HIGH SPEED MULTIFILAMENT SPINNING (POY) FOR NYLON-6 :
From the silo the chips pass continuously to the feeding zone of the extruder. Due to blanketing with high purity nitrogen ( less than 3 ppm oxygen) the chips entering the extruder are substantially oxygen free. The chip-feeding zone of the extruder is cooled to eliminate bridging.
A special horizontal screw melter is used for the production of high-grade filaments. A single thread screw of specially great length is accommodated in a casting of special steel.
The very long screw (l/d = 24 ) builds up a uniform melt pressure, which is controlled automatically.
In order to ensure proper and gentle melting of the chips the screw casing is heated electrically in several zones and equipped with a temperature control system, which provides the constant temperature required by the process.
From the extruder the melt is supplied through distribution pipes to the spinning boxes.
Each spinning position is associated with 4 double spinning pumps and 8 spinneretes. Each double spinning pump meters the melt to 2 spinneretes.
The spin box is equipped with two 4-fold-pump gears, which are driven by frequency-controlled motors and are fed by static converters with high precision frequency adjustment. Downstream of the spinning pumps the melt is filtered and is then pressed through the boreholes of the spinnerete plates in the form of filaments. The routes of the melt from the extruder to the spinnerets are short which ensures uniform properties of all filaments.
The spinning boxes are heated with Dowtherm vapour which is generated in a vapourizer. The temperature of which is maintained at a constant level. The filament bundles leaving the spinnerets are cooled in blow ducts by a horizontal current of air. This is essential for proper denier evenness.
On the high speed take up machine located underneath the filament connecting tubes the spun filament is provided with finish oil gives the filament the necessary antistatic properties, good sliding properties, proper adhesion of the individual filament and adequate moisture, and facilitates the subsequent texturising operation.
The spun filament is then directly wound on bobbins. The take up machines are generally of without godets. The take up speed is around 5000 M/min. The high-speed take up winders are designed for take up speed of upto 6000 M/min. Two winders per position are provided. Each winder is suitable for taking up of 4 ends. The maximum package weight is approx. 12 kgs.
Static converters with high precision frequency adjustment feed the drive rolls of the take up heads. The grooved rolls and the traverse motion devices are also fed by static converters with frequency adjustment sweep generators for varying the speed periodically.
The filament produced on this type of machine is pre-oriented which means that it can be stored and transported without the need of special climatic conditions. It is after denier and weight control sent to the packing section of the Plant.

3.2 HSO PROCESS FOR NYLON FILAMENT YARN :
M/s. Lurgi, a leading process licensor and engineering company in the world, have developed a modern economic process popularly known as Lurgi HSO (High Speed Only) draw winding process for manufacturing entangled Nylon flat yarn. The denier range is from 22 to 70.
This process is very similar to POY process with increase in spinning speed and introduction of entangled filament points using air jets. Using this godet less draw winding process, the spinning tension is increased to stretch the filament. Aero-dynamic intermingling of the filament using air jets provide the necessary binding points as an alternative to the twists needed to import extra strength and bind the filament together. This process is gaining popularity due to its simplicity in operation and lower investment and conversion cost. Quality of yarn generated is better than that of flat yarn through conventional 2 stage process in respect of denier uniformity and uniformity of strength and elongation leading to uniform dyeing. Properties of flat yarn by different process are tabulated below:

 

SR. NO. PARTICULARS FLAT(COP) CONVENTIONAL FLAT(FOY) SPIN DRAW FLAT (HSO)
1 DENIER 40 40 40
2 CV% (Bobbin to Bobbin) 0.9 0.7 0.6
3 Uster, % 1.0 0.6 0.5
4 Elongation at break 35 30 30
5 Tenacity at break g/den 4.9 5.1 4.0
6 Entangled points / meters - 25-30 25-30
7 Boiling Shrinkage % 12 10  


Due to lower CV % and Uster %, dye uniformity is better. Lower the boiling shrinkage better is the dimensional stability. Higher elongation permits tension variation in subsequent process without capilliary breaks.
Intermingling Density of 25-30 entangle points per Meter enables yarn to run at higher speeds on automatic warp knitting machines and looms. Yarn breakages are much less, hence higher production efficiency.
Some trials have been taken at Surat using HSO yarn. The results were quite encouraging. The weaving efficiency has improved by 15% and dye uptake is better and uniform. The feel of the fabrics is softer. HSO yarn package can be directly used on Sulzer and Shuttle less looms. For shuttle looms, pirns can be made using pirn winding machines. HSO yarn can be directly mounted on warping creel. Upstream of warping, the HSO yarn can be twisted or draw twisted or draws warped directly during warping depending upon application/end use. In warp knitting also the warp beams are installed directly upstream of warp knitting machines, finishing, printing and dyeing of fabrics are also carried out using the process parameters used for cops material without any deviation.

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CONSUMPTION OF RAW MATERIAL AS PER LICENCE AGREEMENT
(Anticipated figures; based on stabilised & continuous operational conditions after running-in of the plant)
Sr.No Raw Material Consumption
1 CaproLactum 0.975 Kg/kg of extracted and dried chips (with Lactum Recovery unit using extract water and dry solid waste from spinning section.
1.11 kg/kg of extracted and dried chips (without Lactum Recovery unit)
2 Chips 1.02 kg/kg of POY on bobbins
1.03 kg/kg of FDY on bobbins
All above mentioned figures include spin finish, water and TiO2
3 TiO2 Approx. 0.003 t/t of dried chips (semi-dull)
Approx. 0.01 t/t of dried chips (full-dull)
4 Finish Oil Approx. 0.009 t/t of yarn on bobbins
5 Acetic acid Approx. 0.0017 t/t dried chips
6 Chemicals for Recovery Unit KMnO2 : 0.05 t/t recovered Lactum
NaOH : 0.12 t/t recovered Lactum
Phosphoric Acid : 0.04 t/t recovered Lactum

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UTILITY CONSUMPTION AS PER LICENCE AGREEMENT
(Anticipated figures; based on stabilized & continuous operational conditions after running-in of the plant and based on the equipment delivers)
 
A. Polymer Production Unit (Case : Full dull Chips) :-
Sr.No Description of Utilities Unit Average Cons/ day Peak Load /hour
1 Electric Power
(installed load 240 kwh)
 
kwh 4200 190
2 Steam, 12 bar g T 14 1
3 Cooling Water Circulation *
(max 32 0C, ?T= 5 0C
 
M3. 1500 75
4 Chilled Water
(max 10 0C, ?T=6 0C
 
M3. 1300 65
5 Demineralized Water M3. 0.5 0.5
6 Nitrogen NM3. 600 35
7 Hydrogen NM3. 5.0 0.5
8 Instrument Air NM3. 2000 85
9 Fuel Oil ( Hu=9600 kcal/kg) Kg 650 35

 

B. Lactum Recovery Unit
Sr.No Description of Utilities Unit Average Cons/ day Peak Load /hour
1 Electric Power
(installed load 240 kwh)
 
kwh 4550 210
2 Steam, 12 bar g t 56 4
3 Cooling Water Circulation *
(max 32 0C, ?T= 5 0C
 
M3. 5700 300
4 Chilled Water
(max 10 0C, ?T=6 0C
 
M3. 300 17
5 Instrument Air NM3. 1200 50
6 Fuel Oil ( Hu=9600 kcal/kg) kg 170 10
Note : Remark :- It is assumed that closed cooling water system with Cooling Tower will be used (^ T= 5 0C )

 

C. FILAMENT PRODUCTION UNIT
Sr.No Description OF Utilities Unit Average Cons/ day Peak Load/ hr
1 Electric Power Kwh 20000 900
2 Cooling Water Circulation * (max 32 0C, ?T= 5 0C M3. 60 3
3 Demineralized Water M3. 1.6 1
4 Nitrogen NM3. 80 5
5 Process Air 12 bar g (includ. Aspirator gun) NM3. 1200 750
6 Process Air 12 bar g (includ. interlacing) NM3. 25600 1200
7 Fuel Oil ( Hu=9600 kcal/kg) kg 180 10

 

D. QUENCH AIR REQUIREMENTS
Sr.No Description OF Utilities Unit Consumption
1 Quantiry NM3/hr 66000
2 Quality 201 0C,752 % RH,1003 mmWG

 

E. HEAT LOAD
Sr.No Description OF Utilities Unit Consumption
1 Spinning kwh 360
2 Take Up & Spin Draw kwh 520

 

F. ROOM CONDITIONS
Sr.No Description OF Utilities  
1 Spinning Max 35 0C
2 Quality 25-272 0C, 65-752 % RH

 

G. AUXILIARY UNIT- BUYER SUPPLY
Sr.No Description OF Utilities Unit Approx. Average Consumption per day
1 Electric Power Kwh 40500
2 Steam, 12 bar g T 12
3 Cooling Water Circulation *
(max 32 C, ?T= 5 0C
M3. 25600
4 Instrument Air, 7 bar g NM3. 100

 

DISTRIBUTION OF CENTRALISED UTILITIES
SrNo Utilities Unit Capacity Consumption        
        NFY PFY SDX UTY Others
1 RAW WATER m3 3000
1500/Reservoir-2 Nos
200 200 200 200 100
2 COOLING WATER m3/ hr 4000
1000/Cell-4 Nos
200 300 150 2100  
3 CHILLED WATER
 
TR 3100
600/Chiller-3 Nos 400/Chiller-3 Nos
100/Chiller-1 No

1000

 

550
 

100
 
30  
4 DM WATER B.F.W. m3 720 40 15 15 350  
5. STEAM T/hr 30
10/Boiler- 3 Nos
Pr”=17 Kg/Cm2
2 NESTLER Make
1 THERMAX Make
4.5 3.5 1.5 2.0  
6 NITROGEN Nm3/hr 125 60 20 9    
7 COMPRESSED AIR Nm3/ hr 5000/CENTAC-2 Nos
8 kgs(L.P.)
2000/KGK-2 Nos
8 Kgs(L.P)
1500/IR-2 Nos
17 Kgs(H.P.)
500/KGK-1 No
600/KGK-1 No
5000
L.P.


1200
H.P.

2000
L.P.
250
L.P.
200
L.P.
 
8 DIPHIL Kcal/hr PFY PHU 2.65
MKcal/Unit-2 Nos.
NFY PHU 0.75
MKcal/Unit-2 Nos.
SDX PHU 0.30
MKcal/Unit-1 No
0.5 1.5 0.24  

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TESTING EQUIPMENTS FOR PHYSICAL LABORATORY
SR. NO NAME OF THE EQUIPMENT MAKE QTY
1 EVENNESS TESTER-80 (FULL SET)
TYPE-C
INTRIGATOR KET – 80
RECORDER KET – 80
POWER SUPPLY – TYMAS KET - 80
 
KAISUKKI, JAPAN 1
2 USTER TESTER
MONITOR-C TYPE ST-1 MOC
 
ZELLEWEGER, SWITZERLAND 1
3 CONTROL TESTER PRINTER, KEY BOARD ZELLEWEGER, SWITZERLAND 1
4 STATIMAT – M ADBACH TYPE FAM/M NO.25500 TEXTECHNA H STEIN, MONCHENGL 1
5 TUBE KNITTING MACHINE TYPE TK-832KRENZLER KRENZLER 1
6 KNITTING MACHINE RISHIKESH ELECTRON, BOMBAY 1
7 KNITTING MACHINE BHARAT ,LUDHIYANA 1
8 STRENGTH & ELENGATION TESTER PETROFILS 1
9 CRUSHING STRENGTH TESTER CAPACITY - 550 HETAL CHEMICAL 1
10 PANCTURE RESISTANCE TESTER TYPE-PRT UBIQECE ENT, SWITZERLAND 1
11 YARN WRAP REEL HANS BAERAG SURICH, SWITZERLAND 2
12 LIBRA SCALE CAP 800 X 0.029 MAX 80 KG LIBRA IND, BOMBAY 2
13 YARN WRAP REEL KAMAL METAL IND 2
14 DYEING MACHINE INDIGENOUS 1
15 DIGITAL WEIGHING BALANCE MAX 10 KG PRECISA TECHNICS,BOMBAY 1
16 OVEN MEMMERL,GERMANY 1
17 SARTORIUS BALANCE SATRORIUS,GERMANY 1
18 DIGITAL WEIGHING BALANCE MAX 310 GM BARMAG, BOMBAY 1
19 POWER REGULATOR JIVAN ELECTRONICS INDIA, BOMBAY 1
20 LIBRA BALANCE CAP 10 KG LIBRA, BOMBAY 1
21 DIGITAL WEIGHING MACHINE CAP 15 KG PRECISA, BOMBAY 1
22 PAPER TUBE STRENGTH TESTER HETAL CHEM., BARODA 1
23 BOX STITCHING MACHINE UIKASH 1

 

TESTING EQUIPMENTS FOR CHEMICAL LABORATORY
SR. NO NAME OF THE EQUIPMENT
MAKE
QTY
1 OVEN 1.1 KW, HZ 50/60 LURGI, GMBH 1
2 VACUUM PUMP PROCTON ENGG,THANE 1
3 IV BATH LAUDA 1
4 HOT PALTE (PEW) PATHAK ELECT WORKS 1
5 WATER BATH 1.5 KW TEMPO 1
6 JAR HEATING EQUIP JAYMET LAB EQUIP 1
7 REFRIGERATOR- 200 LTR GODREJ 1
8 JULABO VE HEATING BISOIAL JULABO LAB ,GMBH 1
9 HOT PALTE (PEW) PATHAK ELECT WORKS 1
10 OVEN RANGE 30-300 MICRON METROHM AG HERISERAL, SWITZERLAND 1
11 BATTERY BACK UP UNIT ELECTROMERIC SYS 1
12 KF COULORMETER METROHM HERISON, SWITZERLAND 1
13 ELECTRONIC BALANCE AFCOSET 1
14 ELECTRONIC BALANCE 40-200 GMS SARTORIUS 1
15 ROTARY VACUUM PUMP
DISPLACEMENT 50 LTR/MIN, 1440 RPM
 
HINDHIVAVE PUMP 2
16 MICRO GENIE UNIVERSAL EQUIP LECTROTEK SYS, PUNE 1

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MAJOR IMPORTED PLANT EQUIPMENTS AND MANUFACTURERS
Sr No Name of the Equipment Item No. Manufacturer
1 BAG EMPTYING UNIT A-050
F-050
V-050
X-050
LUCO
2 COOLOID MILL Z-070 FRYMA
3 P.I.V. GEAR   P.I.V.
4 GEAR PUMPS SPINNING PUMP
1 P-100
MAAG
    SPINNING PUMP
2 P-100
FEINPRUF
    LACTUM SOLID FEED PUMP
P-270
MAAG
5 PROPORTIONING PUMPS 1 P – 071 A/B
2 P – 071 A/B
P – 250
P – 271
LEWA
6 CHIP-PRODUCTION UNIT 1-2 X – 150
1-2 X – 151 A/B
1-2 X – 152 A/B
1-2 X – 153
1-2 X – 150 A/B
AUTOMATIK
7 WATER PRE-SEPARATOR AND CENTRUFUGE 1-2 S – 200
1-2 S – 201
SIEBTECHNIK
8 CHIP-DRYING, STORAGE AND CONVEYING 1-2 X – 200
1-2 X – 230
1-2 X - 231
X – 232
X – 236
X - 237
X – 238
BUHLER-MIAG
9 CENTRIFUGE S - 280 WESTFALIA
10 CLEANING UNIT 900 SCHWING
11 SPINNING & TAKE UP UNIT   BARMAG

 

MAJOR INDIGENOUS EQUIPMENTS AND MANUFACTURERS
Sr. No Name of the Equipment Manufacturer
1 V.K. TUBE G.R. Engineering works
2 EXTRACTION TUBE Gujarat Machinery Mfg Co
3 DRYING TUBE Indus Engineering Co.
4 DEPOLY REACTOR Alpha Lavel (I) Ltd
5 VESSELS/TANKS Indus Engg Co
Gujarat Machinery Mfg Co
P.J.Surotia & Co
Fabwel Engg Co
The Acme Mfg Co Ltd
KTI Limited
Alpha Lavel (I) Ltd
Shrinivas Plate & Str Co Ltd
6 PUMPS Goma Engg (P) Ltd
Calama Submersible Pumps
Beacon Weir Ltd
KSB Pumps Ltd
Akay Industries Ltd
Khemline Pumps
Kirloskar Brothers
Swelore Engg (P) Ltd
7 ELECTRICAL OVEN/ CPF FURNACE United Engg Co
Kantilal Chunilal & Sons
8 VACUUM PUMPS/ EJECTOR Precision Pnematic Industries
Mazda Power Engg
9 SILO Fabwel Engg Co
Mistry Prabhudas Munji
10 BLOWER Akay Industries
SLM-Maneklal Ind Ltd
11 COLUMN Gujarat Machinery Mfg Co
12 AGITATOR Remi Process Plant & Machinery Ltd
R.P.D. & Co Ltd
13 HEAT EXCHANGER Alpha Lavel (I) Ltd
Reliance Heat Transfer Ltd
Dalfab Engg
Bharat Heavy Plate & Vessels
Gujarat Machinery Mfg Co
Anand Engg (P) Ltd
Macneil & Mager Ltd
Prabha Steel Industries
Chemequip Industries
Lloyd Steel Industries
14 FILTERS Grand Prix (P) Ltd
Alpha Lavel (I) Ltd
Multitex Filtration Co.
15 NITROGEN DRYING UNIT Lloyd Steel Industries
16 CHIPS DRYING UNIT Lloyd Steel Industries
17 CONVEYOR Air-Mech Engg
Mech Engg
18 BAGGING/STITCHING & SEALING UNIT Reed Medway Packing Co

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ASSETS ON LEASE
Sr. No. EQUIPMENT DESCRIPTION NO. LESSOR
1. PRIMARY HEATING UNIT CAPACITY: 0.75 M Kcal/Hr.
Make : BHPV
1 & 2 WIPRO FINANCE, BANGLORE
* 2 STEAM BOILERS
2 NESTLER
1 THERMAX
3 IDBI, BOMBAY
* STEAM BOILERS CATER TO THE NEED OF ALL THE THREE PLANTS.

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CENTRALISED UTILITIES

SUMMARY WITH CAPACITY OF UTILITIES
 
Sr. No. Utilities Unit Capacity Make
Centralised Utilities
1 RAW WATER STORAGE M3 3000
(1500 X 2 Nos)
CONCRETE
2 COOLING WATER M3/HR 4000
(1000 X 4 Cells)
SIMPLEX
3 DM WATER M3/DAY 720 ION EXCHANGE
4 STEAM T/HR 30 (17 Kg/cm2)
(10 X 3 Nos.)
2 NESTLER
1 THERMAX
5 NITROGEN NM3/HR 125 BHPV
6 COMPRESSED AIR NM3/HR
8 KG/CM2
8KG/CM2
17KG/CM2
8 KG/ CM2
8 KG/ CM2
18100
(5000x2 Nos.)
(2000x2 Nos.)
(1500x2 Nos.)
(500x1 No.)
(600x1 No.)

CENTAC
KGK
IR
KGK
KGK
7 EMERGENCY POWER KVA 1278 X 2 Nos. DIHATSU
8 EFFLUENT TREATMENT PLANT M3/DAY 850 PARAMOUNT
Specific Utilities
9 CHILLED WATER-(Installed Separately)
-NFY ( 3 Nos)
-PFY (3 Nos)
-SPANDEX (1 No)

TR
TR
TR

1800 (600/unit)
1200 (400/unit)
100 (100/unit)

VOLTAS
BLUE STAR
KIRLOSKAR
10 DIPHYL HEATING (Installed Separately)
-NFY
-PFY
-SPANDEX

MKCal
MKCal
MKCal

2.65 X 2 Nos.
0.75 X 2 Nos.
0.30 X 1 Nos.

BHPV
BHPV
ISOTEX

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FIRE WATER STORAGE
Sr. No. Details Reservoir Tank No. 1 Reservoir Tank No. 2
1 Capacity in M3 Reserved for Fire Fighting above the Pump casing in Flooded function 650 M3 650 M3

 

FIRE WATER PUMP DETAILS
Sr No Details of Pump Pump No. 1 Pump No. 2 Stand By JOCKEY Pump Stand By
1 Make Kirlosker Kirlosker Kirlosker Kirlosker Kirlosker
2 Capacity in M3/hr 275 275 275 20 20
3 Head in Metrr, maximum Pressure 83 83 83 80 80
4 Drive Diesel Diesel Electric Electric Electric

 

HYDRANTS DETAILS & PLNAT WISE FIRE PIPE LINE
Sr. No Details NFY PFY SPANDEX TOTAL
HYDRANT DETAILS
1 Single Headed Hydrant 80 28 8 116
2 Double Headed Hydrant 4 3 4 11x2=2
3 Fixed Monitor
(32 mm Size)
 
7 2 3 12x3=36
4 Internal Hydrant 17 20 9 46
PLANT WISE FIRE PIPE LINE
 
Size(mm)
Length in Running Meter
5 300 1769      
  250 1100      
  200 626      
  150 275      
  100 80      
  80 260      
6 300   775    
  200   190    
  150   150    
  100   210    
  80   75    
7 300     205  
  250     200  
  200     200  
  150     110  
  100     65  
  80     160  
  20     40  

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OTHER COMMON FACILITIES

The various buildings/structures as indicated in plot plan have been shown for of each the plant.
However, there are following additional Structures which exist in the complex.
 
1. Weigh Bridge Mech/Elect. Capacity 40 T Truck Load
2. Fire Tender Mobile Fire Tender is available
3. Canteen Facility Suitable with indoor dining facility for 100 persons at a time with kitchen facility
4. HRD Suitable building housing administrative HRD, computer section and Time office
5. EPABX Centralised EPABX system with approx 100 telephone lines
6. Helipad 3 Nos. Cement Concrete Helipad in open land area.
7. Watch Towers 3 Nos. Watch Towers with Helogen fixtures
8. Road & Storm channel Throught the plant area
9. Treated Effluent Treated effluent utilized for Greenbelt and gardening purpose, hence zero discharge of effluent
10 Boundary Wall 3.7 KM
11 Cable Rack & Pipe Rack For laying Pipes of Various Utilities and Cables

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CIVIL & STRUCTURE DETAILS NALDHARI UNIT AREA OF THE BUILDINGS
SR. NO. ITEM BUILDING UP AREA IN SQ.MTR REMARKS
1 BANK & POST OFFICE 214.96  
2 WEIGH BRIDGE 19.95  
3 FIRE STATION 336.67  
4 PRODUCT WARE HOUSE(OLD) 2909.06  
5 PRODUCT WARE HOUSE (ADDITIONAL) 2909.06  
6 SPARE STORE OFFICE(OLD) 2160.00  
7 SPARE STORE OFFICE (ADDITIONAL) 2640.00  
8 TIME OFFICE 501.00  
9 CANTEEN 523.46  
10 OFFICE BUILDING (GROUND FLOOR) 752.36  
11 OFFICE BUILDING (FIRST FLOOR) 368.10  
12 SUB-STATION BUILDING 1736.76  
13 UTILITY BUILDING 1234.80  
14 COOLING TOWER 530.00  
15 FIRE WATER PUMP HOUSE 187.06  
16 RAW WATER PUMP HOUSE 180.00  
17 WASTE WATER TREATMENT PLANT (GROUND FLOOR 196.00  
18 WASTE WATER TREATMENT PLANT (SECOND FLOOR) 196.00  
19 GUARD POST (CABIN) 13.66  
       
20 NFY MAIN PROCESS BUILDING    
(A) 0.0 MTR. LEVEL 4378.32  
(B) 3.8 MTR. LEVEL 1440.00  
(C) 5.6 MTR. LEVEL 2286.00  
(D) 8.1 MTR. LEVEL 1126.20  
(E) 10.5 MTR. LEVEL 1242.36  
(F) 11.8 MTR. LEVEL 367.20  
(G) 12.5 MTR. LEVEL 432.00  
(H) 15.5 MTR. LEVEL 1480.00  
(I) 21.0 MTR. LEVEL 1008.00  
(J) 26.0 MTR. LEVEL 144.00  
       
21 SPANDEX MAIN PROCESS BUILDING & MDI COLD ROOM    
(A) 0.0 MTR LEVEL 2545.2  
(B) 3.7/4.5/5.7 MTR. LEVEL 1505.7  
(C) 8.7/11.7 MTR. LEVEL 970.2  
(D) 13.7 MTR.LEVEL 144.0  
(E) MDI/SAS COLD ROOM 127.87  
       
22 PFY MAIN PROCESS BUILDING    
(A) 0.0 MTR.LEVEL 8593.50  
(B) 3.8/6.5 MTR.LEVEL 6096.08  
(C) 12.5 MTR.LEVEL 2324.70  
(D) 18.5 MTR. LEVEL 1092.00  
(E) 24.5 MTR.LEVEL 108.15  
       
23 D.T. HOUSE 4385.04  
24 D.G. HOUSE 570.00  
25 BOUNDARY WALL (ON PILE FOUNDATION 3.5 M HEIGHT) 3.7 RUNNING KMS.  

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TOTAL CONTRACT DEMAND (POWER)
PETROFILS CO-OPERATIVE LTD., VADODARA RECEIVES HT POWER FROM GEB , NANDESARI SUBSTATION AT 33000 VOLTS THROUGH DOUBLE LINES.
TOTAL CONTRACT DEMAND
GIPCL
6.002 MVA
GEB
3.000 MVA
 
9.002 MVA
NOTE: NORMALLY 90-95% CONTRACT DEMAND IS DRAWN WHEN ALL PLANTS ARE RUNNING ON FULL PRODUCTION SPECIALLY DURING PEAK SUMMER SEASON WHEN AIR CONDITIONING IS VERY HIGH.

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UTILITIES :

(CENTRALISED & SPECIFIC UTILITIES)
Petrofils Co-Operative Ltd., Naldhari Complex comprises of 3 grass root plants viz.
1. Nylon-6 and Draw Twisting Yarn Plant
2. DMT/PTA-Polyester Filament Yarn Plant
3. Spandex Yarn Plant

Centralised Utilities have been provided to cater to the demand of individual plants. In addition; certain specific utilities have been housed within the boundries of individual plants on the consideration of economy.
The other relevant details about the utilities are described as under.
CENTRALISED UTILITIES

1.01 ELECTRICAL POWER
Electrical Power for the entire complex has been brought through two independent 132 KV conductsors from GEB grid Achhalia situated around 28 Kms from Valia. From Valia two independent lines feed the power to Petrofils Switch Yard and is step down to 6.6 KV through two independent 10 MVA Transformers. This step down power is fed to PCCs and MCCs to either High Tension (6.6 KV) consumers OR LT consumers by further steping down the voltage to 440 volts.
The major electrical installations are by M/s. EEC, M/s. NGEF and M/s. L&T etc.

1.02 EMERGENCY POWER
To cater to the critical need of process lighting etc. in case of power failure two DG sets of 1278 KVA each have been provided. The distribution of power for the critical equipments has been provided as shown in the SLD.

1.03 WATER REQUIREMENT
The water requirement of the complex is met from the GIDC water which is pumped by GIDC Authorities from Jolly Reservoir through pipe line situated at a distance of 8 Kms. To store Raw Water two concrete sumps of 1500 M3 each capacity have been constructed. Thus at any time 3000 M3 water is available for use.

1.04 WATER TREATMENT PLANT
Separate facilities have been provided to treat the Raw Water according to the quality including clorination treatment etc.

1.05 COOLING WATER
Requirement of Cooling Water for heat exchangers etc. is met through 4 cooling water concrete cells having a total circulation capacity 4000 M3/hr constructed by M/s. Simplex.

1.06 STEAM
The requirement of steam is met from three installed Boilers of 10 MT/hr capacity each having pressure rating of 16-17 kg/cm2.
Two Boilers have been supplied by M/s. Nestler and one by M/s. Thermax..

1.07 NITROGEN
Nitrogen requirement is met by Plant supplied by M/s. BHPV which operates on liquification of Air having capacity of 125 NM3/hr in terms of gas production.

1.08 COMPRESSED AIR
There are batteries of compressors generating compressed air at 8 kg/cm2 pressure. The total generation capacity 18,100 NM3/hr, moisture free air. The compressors are supplied by M/s.

1.09 EFFLUENT TREATMENT PLANT
The Effluent from all the three plants is collected and treated in a centralised treatment plant which is having treatment capacity of 850 M3/day. The trreated effluent conforming to GPCB norms is utilised in-house for gardening and irrigation of green belt planted inside the campus. The plant is supplied by M/s. Paramount.

1.10 DM WATER & BOILER FEED WATER
Requirement is met from a 30 M3/hr DMW plant supplied by M/s. ION Exchange. The same plant supplies BFW-Boiler Feed Water to Boiler as well.
1.11 FIRE FIGHTING/HYDRANT SYSTEM
All the three Plants, Stores, Ware Houses are covered through a network of Fire Water Pipings, Water Hydrants, Water Hosereels & Fixed Monitors etc duly designed by EIL and approved by BRC. The water lines are laid above ground and remains always energised through jockey pumps at the pressure of 8.0 kg/cm2. There is a separate DG Set operated pump which energies the entire system in absence of GEB power.

1.12 SMOKE DETECTORS
For early detection of fire the smoke detectors have been installed in the entire building and plants of PFY and NFY which generate alarm in case of any fire.

2 SPECIFIC UTILITIES-PLANT WISE

2.01 CHILLED WATER - NYLON PLANT
To cater to the need of Air Conditioning and Process, 60C Chilled Water is produced. There are 3 centrifugal machines of 600 TR each operating on 6.6. KV supplied by M/s. VOLTAS and are situated in the premises of Nylon plant.

2.02 CHILLED WATER - PFY & SPANDEX
Requirement of Chilled Water for Air Conditioning and Process for PFY and Spandex plant is met through 3 centrifugal chiller of 400 TR capacity each, supplied by M/s. BLUE STAR. Three machines operate on 6.6 KV electrical power and are housed in the premises of PFY Plant.

2.03 -130*C CHILLED WATER - SPANDEX PLANT
The process requirement of spandex plant is met through a 100 TR screw compressor refrigeration machine supplied by M/s. Kirlosakar. The Chiller operates on 440 V and is housed in the spandex building.

2.04 -50*C MDI & SAS COLD STORAGE ROOM
This facility is specifically provided for storage of MDI & SAS and is supplied by M/s. Blue Star by providing two 5 TR refrigerating machine.

2.05 DIPHYL HEATING
Requirement of Diphyl heating for Polymer and Spinning units except Nylon spinning where extruders are installed, is met through
(i) Two independent HTM units of 2.65 Mkcal/hr each in Polyester Plant.
(ii) Two units of 0.75 Mkcal/hr each for Nylon plant.
All the four units supplied by M/s. BHPV and
(iii) One unit of 0.3 Mkcal/hr supplied by M/s. ISOTAX for Spandex Plant.
The requirement of Spandex Plant can also be met from the heating unit of Polyester Filament Yarn plant for which supply and return lines of hot fluid has been laid.

3.0 CENTRALISED WORKSHOP FACILITIES
To carry out minor repairs the following facilities have been provided to cater to the need of Plants.
 

SR. NO. EQUIPMENT DETAILS
1 LATHE MACHINE
MODEL
SUPPLY VOLTAGE
MOTOR,HP/KW
CONTROL VOLTAGE
RATED CURRENT

HMT
NH-22
415 V : 3 PHASE, 50 HZ
220 V WITH TRANSFORMER
23 A
2 DRILLING MACHINE
MAKE

MODEL
YEAR
TYPE
SIZE
SR.NO.


NILON M/C TOOLS
BHAVNAGAR
VIJAY
1992
A1
25 MM
1560
3 BENCH GRINDER
MAKE
WHEEL SIZE
MOTOR
SR.NO.
SPEED

PANCHAL ENGINEERING
7 INCH
1/2 HP, KW 0.37
L81
2350 RPM
4 CHAIN PULLY BLOCK 1/2 TON


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