A

REPORT

ON

SANGHI POLYESTERS

LTD.
BY

SURESH GANJI

(III B.TEXT. MMTT, DKTE’S ICHALKARANJI)

&

A AMARNADH

(II B.TEXT. MMTT, DKTE’S ICHALKARANJI)

Sanghi polyesters limited 1

 CONTENT

TOPIC PAGE NUMBER

1. Introduction & features of sanghi polyesters pvt. Ltd. 4
2. Introduction of polymer 5
3. Classification of polymers 5
4. Process flow 6
5. Raw materials and properties 7-10
 EG 7
 PTA 8
 TIO2 9
 SbO3 10
6. Polymerization 11-13
7. Process flow in poly department 14
8. Spinning department 15-24
 Functions 16
 Spinning process 16
 Chip spinning process flow 17
 Direct spinning process flow 18
 Burn out operation 19-22
 Finish oil flow 23
 Spinning process 24
9. Take-up 25
10. Quality control 26-31
 Textile lab 27
 Chemical lab 29
11. DT/DTY department 32
12. Packing department 35
13. Utility 36-42
14. Case study 43

Sanghi polyesters limited 2

INTRODUCTION

Sanghi polyesters limited 3

 INTRODUCTION

Sanghi polyesters limited is located in sanghi nagar, hayathnagar mandal,

ranra reddy district, Andhra Pradesh. It is 35 kms away from Hyderabad. It was
commissioned in the year 1992 in technical collaboration with KOHAP limited,
Seoul, Korea. Sanghi polyesters limited is a flagship company of sanghi group of
industries.
1. Sanghi polyesters limited
2. Sanghi spinners India limited
3. sanghi industries limited.
4. sanghi textiles limited.
5. sanghi zip fasteners limited.
6. sanghi threads limited.
7. sanghi filaments limited.
8. sanghi cements limited.

Besides these industries, sanghi plantation is also developed and well run by
Sanghi industries.

FEATURES OF SANGHI POLYESTERS LIMITED

1. it is an ISO 9002 & 14001 company since 1994.
2. it has been awarded “BRITISH SAFETY COUNCIL NATIONAL SAFELY
AWARD”, consecutively for six years. It has won the award for first time in
1992 i.e., in the first year of its operation.
3. it has the distinction of having the following for the first time in the country.
4. Zero wastage winders.
 No touch concept in POY manufacturing and handling by using fully
automated and integrated information systems.
 20 kg(POY) bobbins to reduce own time and wastage at customers end.
 Out line yarn quality control system.
 Palletized POY packing.
 Silo type fully automated warehouse.

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 INTRODUCTION

HISTORY OF POLYMER

 In 1932 W.C.H. Carothers of DUPONT research institute in the USA

established the theoretical basis for the melt spinning fiber manufacture.
 In 1941, J.R.Winfield and J.T.Dickson of CPA (carico printers
association), having the properties of fiber.
 In 1955, ICI (imperial chemical industry) in U.K. industrialized the new
product, leading to its top position in synthetic fiber today.

CLASSIFICATION OF POLYESTER IN FIBER

Polyester is the general classification of fiber of belongs together with nylon,

an artificial synthetic fiber, to condensation polymerization.
The general classification is as follows.
1. natural fiber : vegetable(cotton),
animal(wool, silk),
mineral (asbestos).
2. artificial fiber : inorganic fiber(aluminum thin fiber,
Glass wool
Regenerated fiber (rayan, artificial silk),
Semi synthetic fiber (acetate, rubber
chloride), synthetic fiber.
3. Polycondensation type : polyamide series (nylon), polyester
group.
4. Addition polymerization type : polyurethane & poly urea group,
polyethylene group, PUC group, Teflon,
acrylonitril, polypropylene groups etc.,

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 PROCESS FLOW

Raw material

↓
Polymerization

↓
Spinning

↓
Take-up

↓
Q.C.textiles

↓
DT/DTY

↓ ↓
Texurising draw texturising

↓ ↓
Q.C.textiles

packing ↓

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RAW MATERIALS AND THIEIR PROPERTIES

1. ETHYLENE GLYCOL

Chemically it is called as 1,2-dihydroxy ethane. It has the structure

HO-CH2-CH2-OH

The physical and chemical properties and the specifications required

for the industry are as follows:

ITEM UNIT SPECIFICATIONS

Appearance Colorless
Boiling point C 197
Melting point C -13
Sp.gravity 1.113-1.116
Firing point C 111.1
Ash content Ppm <=50
Mol. Weight 62.07
Acid content Wt% <=0.001
Moisture content Wt% <=0.005
DEG content Wt% <=0.1
Color Alphs <=5
Chloride content Ppm <=1.0
Fe content Ppm <=0.1
UV 20 NM % >=50
Penetration 250NM % >=80
275NM % >=90
Ratio
350NM % >=95
PURITY % >=99.5

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2. PTA
Common name : terepthalic acid
IUPAC name : p-pthalic acid benzene-1,4-dicarboylic acid

The physical and chemical properties and the specifications required

for the industry are as follows

ITEM UNIT PTA MTA

Acid value KOH mg/g 675 675
4-carboxy benzadehyde(CBA) PPM <=25 200-
250
Color b-value <=2 <=2
Alpha <=10 -

Sulphated ash Ppm 1-5 5-10

Slurry ability Poise <=50 <=50

Heat stability % >=90 >=90

Slurry stability % >=60 >=60

Cobalt content Ppm <=5 <=5

AcOH content Ppm None 500-

900
Bulk density G/cm3 0.85-0.95 0.8-0.9

Ahs Ppm <=20 -

Metal content Ppm <=15 -

Moisture Wt% <=0.5 -

Fe Ppm <=1 -

Avg. practical size Mic. 125-135 -

3.TITANIUM DIOXIDE

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 This is used as a pigment in the process in order to reduce the brightness of
polymer produced.
The physical and chemical properties and the specifications required for the
industry are as follows

ITEM CONTENT
Name Titanium dioxide

Mol.wt 75.9
Sp.gravity 4.26
Melting point 1820
Ratio of refraction 2.55
Coloring Extensive
Appearance Light grey white power
H2O <0.5%
Purity >98%
Incandescent wt% <0.8%
Dispersion in water >98%
Lactic acid insolubility >0.5%
SiO2 0.8 +/- 0.2%

AlO3 content 2.6 +/- 0.5%

P2O5 content <0.3%
Mn content >0.07%
Properties No reaction with metals, alkalis,
H2SO4, excessive strong H2SO4
causes reaction at high
temperatures.

4.ANTIMONY TRIOXIDE

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ITEM CONTENT
Name Antimony trioxide
Mol.wt 291.52 c
Melting Sublimates at 656 c at 1550 c sublimation
point
Appearance White powder of a white power
Color L>=80, a<=1, b<=3
Turbidity 5-15
Sp. Gravity 5.2
Purity 99.74-99.88%
Arsenic 0.05%
Lead 0.002-0.016%
Iron 0.001-0.003%
Sulphate 0.001-0.008%
Properties Insoluble in water, soluble in HCL KOH, tartaric acid,
acetic acid. Through insoluble in alcohol, light H2SO4,
light HNO3, when heated in red form turns into yellow
fluid, when cooled off crystallizes to white.

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Sanghi polyesters limited 11
 POLYMERISATION

POLYMERISATION

The PET polymerization can be produced in two methods.

 TPA method
DMT method

TPA METHOD

Esterafication step

TPA + EG ----------------> BHET + H2O↑

Polymerization step

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 BHET ----------> PET + EG ↑

REACTIONS
Esterification

HOOC—(C6H4)—COOH + 2HOCH2CH2OH
TPA EG

↓
2HOCH2CH2OOC-(C6H4)-COOCH2CH2OH
Bihydroxyethyl terephalate (BHET)
Polycondensation

n HOCH2CH2OOC—(C6H4)—COOCH2CH2OH

↓
HOCH2CH2O-{OC-(C6H4)-COOCH2CH2O}n-H +(n-1)HOCH2CH2OH

DMT METHOD

Esterification step

DMT + EG ---------------> BHET + METHANOL ↑

Polycondensation step

BHET--------------> PET +EG↑

After polymerization of PET will be transferred to the direct spinning or chip cutter.

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 Specification of chip cutter m/c:-

No. of m/C: 2
Cooling medium: water
Cutter type: rotary cutter
Production: up to 120 tones/ day
Chip size: min. 3 mm
No. of chips/gm: 20-25

PROCESS FLOW IN POLY DEPARTMENT

TPA unloading MEG unloading catalyst pigment

Transfer transfer preparation & & storage
preparation Storage

Slurry preparation

↓
Process chemistry

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 ↓
Esterification & distillation column

↓
EG recovery Poly condensation

↓
Chip cutting & storage

↓
Storage tank (silo)

SPINNING

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 SPINNING DEPARTMENT

FUNCTIONS

 Spinning department as a whole functions to produce quality yarn

with minimum waste and improved productivity and efficiency.
 Identification and segregation of non-conformity product in
consultation with concerned quality control department.
 Approval/rejection of raw materials/additives and various
consumables in consolations with concerned quality control
department.
 To implement production change programmes as per market demand
in consultation with production.

Spinning process

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 Polymerization

Polymer

Direct spinning cutter

Chips

Chip spinning process

CHIP SPINNING PROCESS FLOW

Storage tank

Wet chip silo

Crystallizer (primary heater)

Hopper dryer (secondary heater)

Storage dry chip silo

Extruder

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 Continuous polymer filter (CPF)

Manifold

Spinning beam

Spinning pump

Spin pack

Quenching chamber

Finish applicator

Take up winder (POY)

DIRECT SPINNING PROCESS FLOW

Polymerization

Polymer

manifold

Spin beam

Spinning pump

Spin pack

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 Quenching chamber

Finish applicator

Take up winder (POY)

BURN OUT OPERATION

The various operations involved in the burnout section are as listed below

 Used spin packs in disassembled state are brought to burn out from
spinning, all its parts are cleaned and dried, and spinnerets are checked for
their holes clarity under microscope. All the parts are then reassembled.
Packs, which could not be disassembled at spinning, are disassembled at
burnout.
 Polymer gear pumps and also oil gear pumps, or wear plates which are
removed from spinning due to some reasons, are disassembled at burnout,
cleaned and reassembled.
 Filter candles from spinning and polymerization are brought to burnout for
cleaning and inspection these candles are assembled and given for use.
 Finish oil emulsion preparation.
 Cleaning of finish tubes.

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  Hot water cleaning of finish systems.

The cleaning procedures for spinnerets, distributors, aluminum gasket,

and pack filter are as follows.

CLEANININ OF SPINNERETTES

 Clean the spinnerettes surface with nylon brush, if it was treated in fluidized
bed.
 Keep the spinnerettes inside the tank
 Take DM water in tank with the help of measuring bucket such that the
level in the tank is sufficient to immerse the spinnerets.
 Add uniclean in DM water to make 5-7% solution.
 Supply steam for heating the solution.
 Keep it for 2-3 hours.
 After treatment is over, close the steam valve and open the drain valve of a
tank to drain out the used uniclean solution in a separate drum. Keep this
drum with label used uniclean solution.

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  Close the drain valve and take fresh DM water in the tank open steam
supply valve and after half an hour close the steam valve. Open drain valve
to drain out hot water.
 Take DM water in a tub.
 Add labolene to DM water and agitate with hand.
 Take out the spinnerettes from the tank.
 Dip the spinnerettes clean with DM water and place on plastic trays.
 Treat the spinnerettes to ultrasonic.
 Dry the spinnerettes with air.
 Keep the spinnerettes in plastic trays.
 Inspect the spinnerettes under microscope.

CLEANING OF DISTRIBUTERS

Applicable to distributors treated in fluidized bed and salt bath.

Blow the air to distributors to remove the aluminum tri oxide particles.
Pack distributors’ needles in the NaOH tank in the NaOH room.
Take used uniclean solution in the tank such that level in the tank is
sufficient to immerse all distributors.
Open steam supply valve to the tank and close the lid of the tank.
After the 2-3 hours stop the steam supply and open the drain valve out the
used solution.

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 Close the drain valve and take fresh DM water up to the mark & open
steam supply valve.
After about half an hour close the steam valve and open the drain valve.
Take out the distributors and keep them on a trilly. Repeat the activities 2-7
times once again. clean the distributors with labolene.
 Give the ultrasonic treatment.

CLEANING OF ALUMINIUM GASKETS

Take tri chloro ethylene (TCE) in a plastic box.

Dip the gasket inside the TCE & cover the box.
Open the cover of the box & shake the gasket in TCE.
Take the gasket from the box.
Dry it with air, keep in a box on pack assemble take for use.

CLEANING OF PACK FILTERS

 Take TCE in plastic filters.
 Dip the filters in the box and cover the box.
 Keep the about 30 minutes in that condition.
 Open the cover of the box and shake the filter in TCE.
 Take out the filters from the box.
 Dry with process air.
 Keep the cleaned filters in the box on pack assembly table for use.

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SPIN FINISH EMULSION PREPARATION
Oil from drum is pumped into the measuring drums from there required oil
is pumped to the oil preparation tank and DM water is added and also
antiseptic oil is added.
The composition and properties of the finish oil and the bactericide are as
follows
 SPIN FINISH OIL
Composition:
 Electropoxylate fat alcohol derivatives (18-20%),it is harmful &
dangerous for the environment.
 Alkyl polyglycol ether(20-22%)
 Alkyl phosphorous acid (5-7%)

fire properties
It decomposes into CO, otherwise no extra precaution for fire
is required. It is not self explosive nor explosive.
 FORMALDIHYDE
It is a clear liquid, very pungent in odor, soluble in water. It boils at 96
c, highly flammable. Flash point is 60 c. auto ignition temperature is
300 c. it is neither explosive nor corrosive or oxidizing

FINISH OIL FLOW

Start

Oil preparation

Oil storing

GP-47 pump

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 Oil applicator

Bobbin winder

end

SPINNING PROCESS

CHIP SPINNING PROCESS

Wet polyester chips which contain moisture in them, are put through the
process of drying to remove the moisture content. The continuous dryer
performs the job of drying wet chips by means of a crystallizer and a hopper.
Dried chips are conveyed to the hopper above the extruders by air. Extruder
performs the duty of melting chips to the required viscosity and pressure. The
molten polymer flows through the continuous polymer filter and reaches the

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 spin beam. spin beam divides the incoming polymer in to various streams with
the help of manifold lines.

In order to maintain the fluidity of the polymer and to give the desired final
property of the yarn, these beams are continuously heated by means of a
vapors heating system from a dowtherm boiler.

Some time colored yarn is produced using dope dyed system, which with
the help of vibro feeder feeds the required set feed rate to produce different
types of shades and colors.

Polymer that has reached the individual position is then pumped through
the spin packs by means of a gear pump rotated by a driven motor; the delivery
quantity can be adjusted by changing the speed of these drives. Spin packs
contain filtration medium and spinnerete, through which the polymer is
extruded out. The polymer is solidified by cold air and spin yarn cohesiveness
and good antistatic properties. The yarn then goes to take up for winding.

DIRECT SPINNING
This process takes the polymer directly from the polymerization department
and it flows directly to the spin beams. After reaching the spin beams, the
process is same as the chip spinning. To maintain the pressure at the gear
pumps, sufficient main line pressure of polymer is maintained by means of a
booster gear pump.

TAKE UP
In take up, the yarn is wound on the paper tube with the help of winder through
a set of pigtail ceramic guides and transverse guides. Depending on the

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 required weight of the yarn to be wound on the paper tube is adjusted by
means of timer. Once this preset time is adjusted, the full bobbin automatically
comes down and the new empty paper tube automatically comes in the line to
wind on.
The bobbins are stripped for removing the top layer with the help of
identification stickers are put on the bobbin transported to packing after the
gradation.

SPINNING AND CONTROL ROOM

The whole operation of melting, filtration, quenching & emulation application

are carried out here. Process parameter setting and monitoring is performed
from the control room.
To spin yarn through spin beam the operations involved at spinning floor
are pack fixing and removal, spinnerete, wiping, quenching of filaments and
oil application etc.

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 QUALITY CONTROL

QUALITY CONTROL

TEXTILE LAB
FUNCTION OF THE DEPARTMENT
Fixing of specification and quality norms for final products as per the
customer specifications,
setting of process parameter norms in spinning and DT/DTY

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 Responsible for sampling procedure for testing of yarn and testing of
physical properties of yarn.
Monitoring of properties of yarn through stoical quality control method and
suggesting collective actions.
segregations and gradation of final products
Responsible for disposal of non conformity products
analysis of market compliant samples and suggesting corrective actions
Production planning and analysis of production and consumption rate
The deferent tests performed by the textile lab on the POY brought from the
take up section are as fallows

TEST PREFORMED LEVEL

Testing of denier of POY 1
Testing of % uster on 1
keisokki tester
Testing of c/s of yarn 1
Testing of draw force 1
Testing of % shrinkage in 2
boiling water
Testing of % uster on uster 1
tester 3
Testing of % elongation & 1
tenacity of POY
Testing of resistance of 2
POY spools

LEVEL CODE 1:

These are primary properties based on which nonconformity product is

identified, segregated, and graded as per the quality norms of POY. All
the properties are tested regularly as per the testing schedules.

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 LEVE CODE 2:

These are tests carried out to monitor the process and gradation is not
done based on these tests.

Apart from these tests performed on the POY the also does the following.
1. visual inspection station operations
2. Inspection labs control operations.
3. Testing of denier of texturized and flat yarn.
4. Testing of % hot crimp contraction.
5. Hose knitting of texturized yarn.
6. Testing of nips.
7. Testing of % elongation and tenacity of texturized and flat yarn.
8. Dyeing of knitted hoses.
9. Hose knitting of flat yarn.

The packing department will finally grade the material based on

physical checking of bobbins. However, they will not upgrade the
bobbins, which are already down graded, based on their physical
checking.

CHEMICAL LAB
 The Q.C. chemicals lab performs the job of testing raw
materials, additives, consumables, in process and final products
sample, water samples, distillation of chemicals and water, sample
collection etc.

RAW WATER ANALYSIS
SAMPLE NAME NAME OF ANALYSIS
Appearance

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 Acid value
% moisture content
Ash content
Solubility in 2N KOH
PTA
Iron content
A.P.H.A.
Partical size
Intrinsic viscosity
End group
BROUGHT OUT CHPS Ash content
Chips per gram
% DEG content
% PBT
Tone of dye
% dye variation
Filtration index
Appearance
A.P.H.A.
% moisture content
% acidity
Boiling range
Ash content
MEG Aldehide content
%DEG content
Density at 20 C
Chloride content
Fe content
U.V. transmittance

ADDITIVE ANALYSIS
SAMPLE NAME NAME OF ANALYSIS
Appearance
% purity
Turbidity
Solubility temp. in MEG
Sb2O3
Transmittance
Setting rate
Appearance

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 % loss in Wt at 100 C
TiO2 % loss in Wt at 800 C
% purity
Appearance
% moisture content
CONNING OIL PH of 15 % emulsion
Sp. Gravity
Viscosity at 38 C
Appearance
% moisture content
% acidity
Boiling range
DEG
Ash content
% purity
Density at 20 C
U.V. transmittance
Appearance
10% emulsion PH
Viscosity
Ionic nature
Acid value
SPIN FINISH OIL
Stability of 15 % emulsion
Refractive index
% moisture content
CONSUMABLE ANALYSIS
SAMPLE NAME NAME OF ANALYSIS
Appearance
TEG Refractive index
% moisture content
Boiling range
% moisture content
FURNANCE OIL Density
WTER SAMPLE ANAALYSIS
PH Silica
Conductivity Total dissolved solids
Total hardness Alkalinity to phenolphthalein
Calcium hardness Alkalinity to methyl orange
Magnesium hardness Sulphate

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Chloride Total suspended solids
Iron Chemical oxygen demand
Phosphate

DT/DTY DEPARTMENT

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 DT/DTY DEPARTMENT

FUNCTIONS OF THE DEPARTMENT

Four processes are involved in this department
Production flat yarn in draw twisting from POY, produced at spinning
stages.
Production of texturized yarn in draw texturizing from POY.
Rewinding of heat set material and shorts of draw texturized yarn or draw
twisted yarn.
Heat setting of draw texturising yarn as per requirements.

1. DRAW TEXTURIZING PROCESS

In this process strength ,bulk, greater absorbency is imparted to the
polyester filament yarn by the method of false twisting ( friction) & finally
wound onto paper tubes in the form bi-conical cheese. Polyester POY is used
as raw material. In this process POY is grown between two nips rollers
passing through primary heater. In primary heater mobilization of the
molecules in yarn takes place, at the time of drawing yarn is passed through

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 ‘cooling plate’ and ‘positorq spindle discs’ ,after primary heater molecules
are stabilized in cooling plate and bulk is imparted in to the yarn by false
twisting of yarn in passing the yarn through the secondary heater tubes.
Finally the yarn is wound on to the paper tubes after the application of coning
oil.

2.) DRAW TWISTING PROCESS

In this polymer POY is drawn into flat yarn & is wound on to cops.
Drawn into flat yarn & is wound on to cops, drawing is done in two stages. In
the first stage, nominal tension draw is kept in between feed roller and upper
hot godet yarn is set passing through slit heater. Then the yarn is wound o
cops by a ring and traveler winding system.

3.) HEAT SETTING

In this process, the yarn from one package is wound on paper tune and
made to a new package with or w/o the application of coning oil. Paper tubes
of the yarn package which has undergone the heat setting treatment and there
will be loss of coning oil in these packages, such packages are required on a
new paper tube with application of coning oil for improving the unwinding,
performance in the subsequent process. Less weight textured yarn packages
are rewound to make them big packages without the application of coning oil.

4.) REWINDING
In this process. The yarn from one package is wound on paper tube and
made to a new package is wound on paper tube and made to a new package
with or w/o the application of coning oil. Paper tubes of the yarn packages
which have undergone the heat setting treatment and there will be loss of
coning oil in these packages, such packages are required on a new paper tube
with application of coning oil for improving the unwinding, performance in
the subsequent process. Less weight textured yarn packages are rewound to
make them big packages without the application of coning oil;

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 PACKING DEPARTMENT

FUNTIOS OF THE DEPARTMENT

 Inspection and packing of the yarn breakages as per the gradation
 Weighing, sealing and stripping of he packed boxes.
 Wrapping and stripping of jumbo palettes.
 Stacking of the packed boxes on pallets and jumbo pallets.
 Transfers the pallets to warehouse, or specified area.
 Inspection of brought out items required for the department.

PROCESS DESCRIPTION
 Yarn packages are received from different production departments after
gradation through Q.C.(textiles)
 After physical inspection different yarn packages are packed in different
types of boxes/pallets.
 After weighing, these boxes/pallets are sealed/wreppes, strapped and
stacked on pallets.

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 This packed material is transferred or warehouse, or kept in a specified
area.

UTILITY

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 BOILERS HOUSE:
Boiler is used to make steam from water. In order to generate steam fast enough
to supply the requirement, most boilers have tubes, either fire tubes or water tubes,
and these provide s large area of heating surface.
The capacity and efficiency of a boiler varies largely, and is mainly dependent of the
requirement.
Fuel consumption can be reduced by preheating water, and air for the fire, with heat
from exhaust steam.
Considerable advantage is obtained from superheat. Since increased temperature is
needed to produce steam when the overlying pressure is high, early boilers could
barely keep high-pressure steam saturated, that is , free from condensed water vapor,
as it expanded and cooled while working through the engine, by passing steam
through tubes surrounded by fire, it can be superheated several hundred degrees.
Then its expansion while working the engine will not cause condensation and loss of
power. Since most water contains minerals. Which form scale in or around boiler
tubes, a water purifier may be needed.

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A boiler also needs an “injector” of some kind to force water in against backpressure
from steam.
Finally, every boiler needs a “water gauge”, to warn when water falls below a safe
level, and a “safety valve”. This usually has a spring which holds a valve closed
tightly against normal steam pressure.
If pressure rise unduly, it force the valve open, releasing steam and relieving the
excess pressure.
Modern boilers and engines use steam pressures of hundreds, of even thousands, of
pounds to the square inch.
Railroad locomotives and low-speed ship engines commonly use pressures from 250
pounds upward.
Large turbines, such as those in electric-power generating stations, use pressures of
from 1,400 to 2,000 pounds or more.
The boilers used in the polyester manufacture are fire tube type. they operate at a
pressure of 10.5 kg/cm^2, and produce steam at a temperature of 180-210 C . They
have a capacity of producing steam at a rate of 5 tons/hr. they are pressure atomizing
however the initial spark is produced from the two electrodes that are placed inside
the boiler, by passing 10,000 volts of current. The boilers burn furnace oil (calorific
value= 12,000 kcal/hr.) to get fire and heat. The water inside the boilers is always
maintained to a level of 60-80%. The furnace oil before entering the boiler is heated
in a oil pre-heater, where the oil passes through tubes, and the steam is on the shell
side. The temperature of the furnace oil in the service tank is maintained at 50-60 C
and after leaving the pre-heater, it has a temperature of around 230 C. the ratio of oil
to steam in the boiler is around 1:1
The heater used in the polyester industry are steam atomizing, and are used to
heat the Santo Thermo oil, which is used to maintain the temperatures in the reactors,
and polymer lines. The heater contains tubes through the oil is passing from the rear
end to the front when it is getting heated from 295 to 320 C. the feed to the heater is
furnace oil and air in the ratio of 1:16 and steam is supplied at a differential pressure
of two kg/cm2 (the pressure of steam being higher). The flue gases pass in the shell
side and the heater has 3 passes and 8 coils. The flue gases exiting the heater at a
temperature of 470 C and are used to heat the air in an air pre-heater. Where the air is
the tubes and the temperature of the air is raised from atmospheric to around 210C in

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the heater , the initial spark is given by the LPG gas, which is passed initially
between the electrodes at voltage of around 12,000.

DEMINERALISED WATER PRODUCTION

The process of producing demanerialised water can be easily understood in the step-
wise procedure detailed below.
 First water supplied by the tankers, which have hardness less than 300ppm,
is passed into filter water tank where any physical impurities are removed
off.
 The water from the filter water tank is passed into he SAC (strong acid
cation) tower. Where the hardness of water is reduced to zero. This tower is
almost half filled with hydrogen based resin and is periodically charged
with 5% HCI (originally 30% diluted to 5%). the water exiting the SAC
has a pH in the range of 3.5-7.
 From the SAC tower is passes into degasser tank, and a blower in the way
removes any CO2 gas produced in the SAC chamber.
 The water is next passed into a WBA(weak base anion),which contain
NaOH of 2% concentration

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  The water is now passed into a SBA (strong base anion), which contains
about 5% NaOH. The water exiting at this stage has a pH of 8.5-9.5
 The water at this stage is called boiler feed water, and the water from SBA
is partly sent into the boiler feed water storage tanks. The remaining water
is passed into a MB (mixed bed) tank. The mixed bed contains both the
acid and bade based resins and the water coming from the mixed bed is
called as DM (de mineralized) water.
 This water can be used for the chips cutting process. battery recharging,
finish oil preparation etc.,

PROCESS AIR PREPARATION

The process of preparing process air contains the air compressor and the air dryer.

AIR COMPRESSOR
This is a screw type two stage compressor, wherein the air from the
atmosphere is taken and first enters this low pressure stage where is compressed to a
pressure of about 2-2.5 kg/cm^2.in addition, the temperature rises to around 160-180
C. this hot air is then passed into the inter-cooler where the temperature is brought
down to around 40-70 c. then this air is pumped into the high-pressure stage where
the pressure of the air is increased to around 7-10.5 kg/cm^2, and the temperature
rises to around 160-220 C.

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AIR DRYER
The high-pressure air from the second stage of the compressor is then
pumped into the ‘air dryer’, which contains silica gel, and activated alumina, which
absorb the moisture content in the air. Now the temperature is atmospheric (40-50C)
this air is called the process air and is now sent to the process air storage tanks.

EFFLUENT TREATMENT PLANT

PURPOSE: to treat effluent up to the irrigation standards.

SCOPE: application to all effluent coming from process as well as various sections
of the plant.

ACTIVITIES

 Raw effluent is collected in two collections cum equalization tanks, after

removing the floating material.
 Pump raw water to flash mixer tank after neutralizing with lime/alum/HCL.
To adjust the pH and mixing a floating aerator for proper mixing.

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 Add lime/alum solution from the flash mixer from lime/alum tanks for the
formation of flocs. And allow the raw water to pass into clariflocculator.
 Transfer the settled sludge from clariflocculator to sludge drying beds. Allow
the overflow water to pass into aeration tank through the contact chamber, in
contact chamber, digested feed is added.
 The nutrients such as nitrogen and phosphate are dosed in the form of urea
and diammonuium phosphate into the contact chamber/aeration tank
according to raw B.O.D. values, when required.
 The overflow from aeration tanks enters the secondary clarifier.
 The settles biomass in secondary clarifier is pumped continuously to aeration
tank until the requires MLSS of 3000 MG/LT is achieved. The excess sludge
is pumped to sludge drying beds.
 The overflow of the secondary clarifier enters the final collection tank.
 At the outlet of the final collection tank the treated effluents meet the treated
effluent standards. For disposal as on land irrigation water
 The characteristics of the final treated effluent are as follows:

 pH  5.5-9
 Total suspended solids  <100mg/lt
 Total dissolved solids  <2100mg/lt
 BOD at 27 C  <100mg/lt
 COD^3  Max 300mg/lt

 From the final collection tank the treated effluent will be supplied for o land
irrigation purposes.

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 CASE STUDY
Study on effect of IV on tensile properties of POY & DTY

The polyester yarn can be produced in the form of colorless and also colored form.
The colored yarn can be produced by adding the coloring agents such that pigments
or dyestuff. This is called as a master batch method.
The master batched colored yarn is having the vary in the properties such
that tensile strength, elongation at break, breaks per tones etc.
These difference in the properties is due adding the coloring substance in polymer
molecular chains. The coloring substances are nothing but adding the impurities in
the polymer chain. This cause the reduce in the intensive viscosity, so these are act as
a week point and this will show the different properties with original properties.

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s. Color name POY DTY
no
date Line IV Draw Elong. Tencity Elong.
.
no. force % %
1 Black 19/06/07 7A-2 0.564 13.49 145.16 4.52 23.41
2 Black 20/06/07 7A-1 0.558 12.06 141.14 4.36 22.08
3 Holy violet 23/06/07 7A-2 0.577 10.96 144.06 4.01 24.61
4 Holy violet 24/06/07 7A-10 0.579 10.74 146.66 4.69 23.14
5 Blood red 24/06/07 7A-5 0.548 11.74 136.87 4.37 20.54
6 Blood red 25/06/07 7A-11 0.545 11.24 139.77 4.52 21.85

Intensive viscosity of chips

Dry chips - 0.620
Wet chips - 0.625
Intensive viscosity of FFY
For semi-dull - 0.598
Black - 0.560
Holy violet - 0.578
Blood red - 0.547

This reduction in the IV depends on loading ratio of the colored chips.

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