INTRODUCTION
Ibrahim Fibres Limited
(IFL)Polyester Plant is for the
continuous production of Poly
Ethylene Terepthalate (...
PLANT CAPACITY & START UP
There are two polyester plant i.e.
IFL-I having two lines of Polymer melt. Line
#14 and Line #...
DCS SYSTEM
Both plants are equipped DCS
system of Fisher –Rosemount named
as “provox” .
But DCS system of IFL-I Polyeste...
Polymer Process
TOPICS
Raw material and Specification.
Catalyst and Titanium Di Oxide .
Paste Preparation.
Esterificat...
RAW MATERIAL AND SPECIFICATION
Basically two raw materials are
used for the production of fibers.
 PTA (Pure Terepthalic...
RAW MATERIAL AND SPECIFICATION
PTA (PURE TEREPTHALIC ACID)
 PTA is one of basic raw material used for
the production of ...
RAW MATERIAL
 PTA SUPPLIERS

 BRAND COUNTRY
 ICI England
 PPTA Pakistan
 Siam Mitsui Thailand
 Amoco Japan
 Inter ...
RAW MATERIAL
 PACKAGING.
Jumbo size bags of capacity 1000~1100 kg
PTA
Containers of capacity 22.0 tons of PTA
RAW MATERIAL
MEG ( MONO ETHYLENE GLYCOL )
MEG is crude oil ( (Refinery Product ) it is liquid
and transparent in nature ...
RAW MATERIAL
MEG ( MONO ETHYLENE GLYCOL )
 MEG SUPPLIERS
 BRAND COUNTRY
 Mobil Saudi Arabia
 Equate Kuwait
 SABIC Sa...
RAW MATERIAL
ADDITIVES
CATALYST ( Antimony Triacetate)
TDO (Titanium Dioxide)
RAW MATERIAL
CATALSY SUPPLIERS
 BRAND COUNTRY
Elf Atochem America
Polytrade A-42 Germany
RAW MATERIAL
 TITANIUM DIOXIDE ( TDO)
Nearly all synthetic fibers are transparent or
translucent with glossy luster , wh...
RAW MATERIAL
TDO SUPPLIER
BRAND COUNTRY
Sachtleben Hombitan Germany
Titanium Dioxide
PACKAGING
TDO comes in bags of dif...
RAW MATERIAL
 PRODUCT TYPE AND TDO FEEDING
CONCENTRATIONS
 Two type of product are being made on the basis of TDO
additi...
PASTE PREPRATION
PASTE PREPRATION
PTA
MEG AND EGR
COLUMN EG
CATALYST
PASTE TO ES-I
MAIN PROCESS
 There are two Esterification reactors. Here the
raw material react and form monomer (BHET).
And water, Este...
During Esterification reaction water formed which
mixes with EG vapors. Composition The vapors
formed from ES-I and ES-II ...
ESTERFICATION REACTION:ESTERFICATION REACTION:
2 MEG + PTA → BHET + 2 H2 MEG + PTA → BHET + 2 H22 OO
Bis Hydroxy Ethylene
...
PASTE FROM PASTE TANK
VAPORS TO PROCESS
COLUMN
OLIGOMER TO ES-II OLIGOMER TO ES-II
LINE # 14 LINE #15
ES-1 REACTOR
HEATING SYSTEM OF ES-1
LIQUID & VAPOR HEATING SYSTEM.
THERE ARE TWO HEATIING SYSTEMS FOR THE
ES-1
LIQUID HEATING WITH S...
POLYMERIZATION
The conversion of a particular compound
to a large , multiple of it’s monomer
(itself )
There are two typ...
1- ADDITION POLYMERIZATION
The Polymerization reactions through
which the molecular formula of the
repeating unit is ident...
2- CONDENSATION POLYMERIZATION
The Polymerization reactions in which
monomer are joined together into bigger
molecule by c...
CONDENSATION POLYMERIZATION
REACTION
2 MEG + PTA BHET +2 WATER
BHET + BHET n PET + ( n -1) MEG
Mono Ethylene
Glycol
Pure T...
POLYCONDENSATION
PREPOLYMER REACTOR -1 ( PP-1)
TOTAL VOLUME
Monomer / Oligomer
from Es-II (14/15)
Product to PP-II
Vapors ...
POLYCONDENSATION
HEATING ARRANGEMENT
1. HTM IN COILS (THREE IN NOS.)
2. DOWTHERM IN JACKET
POLYCONDENSATION
PREPOLYMER REACTOR -II ( PP-II)
POLYCONDENSATION
STAGE II REACTOR
PRE POLYMER FROM
PP-I
Product to DRR th...
POLYCONDENSATION
LEVEL TRANSMITTER
RADIO ACITVE TYPE
Co60
HEATING ARRANGEMENT
DOW THERM IN THE JACKET
POLYCONDENSATION
DISC RING REACTOR ( DRR)
FINAL
POLYCONDENSATION
DISK RING REACTOR
(DRR)
PRE POLYMER FROM
PP-II
Product to...
DISC RING REACTOR ( DRR)
The main function of the final polycondensation stage is
to complete the reaction to the final po...
SPINNING &
FIBRE LINE
SPINNING
Polymer MeltPolymer Melt
(from Polymer Plant)
Distribution ManifoldDistribution Manifold
Spinning BeamSpinning Be...
DISTRIBUTION MANIFOLD
 All Polymer Melt lines are HTM jacketed.
 Distance from distribution valve to each spinning posit...
Melt From POLY
DN 2 X 98/350
DN 2 X 60/250
7537-M01
355mm
7537-M01
355mm
7537-M01
355mm
7537-M01
355mm
7537-M02
225mm
DN 9...
SPINNING BEAM
 Spinning Beam is heated with HTM (Dowtherm) vapors and is insulated.
 Vapor inlet is from top and condens...
EXTRUSION
 Polymer melt from distribution manifold is directly supplied to motor operated
metering pumps (total 32 in num...
High Throughput, Same Take-up Speed Low Throughput, Same Take-up Speed
Fine Denier
Coarse Denier
Draw
Zone
SPINNERET HOLE ...
QUENCHING & OILING
 Filament quenching is done with double filtered quench air at 20.5°C and 85% RH
at approx. 1750 m3
/h...
SPINNING WALL
 Filaments from the quench chamber pass through a slub catcher, thread-oiler,
ceramic V-guide, suction & cu...
CAPSTAN UNIT
 Capstan Unit consists of six (06) + one (01) Godets (rollers) and a set of two
Sunflower Wheels, in series,...
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Poly & sfl

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Poly & sfl

  1. 1. INTRODUCTION Ibrahim Fibres Limited (IFL)Polyester Plant is for the continuous production of Poly Ethylene Terepthalate (PET), Staple Fibres or Textile grade Chips.
  2. 2. PLANT CAPACITY & START UP There are two polyester plant i.e. IFL-I having two lines of Polymer melt. Line #14 and Line # 15 total capacity (186 tons/ day, 93 tons / day for each line). Start up line # 14 / 15 occurred on 26, FEB. 1997 / 29 DEC, 1997. IFL-II having single line for Polymer melts i.e. line # 17 , design capacity 400 tons / day it started on 02 June, 2002.
  3. 3. DCS SYSTEM Both plants are equipped DCS system of Fisher –Rosemount named as “provox” . But DCS system of IFL-I Polyester Plant has been replaced with latest system Delta – V on MAY 2008.
  4. 4. Polymer Process TOPICS Raw material and Specification. Catalyst and Titanium Di Oxide . Paste Preparation. Esterification. Polymer and Polymerization Polycondensation.
  5. 5. RAW MATERIAL AND SPECIFICATION Basically two raw materials are used for the production of fibers.  PTA (Pure Terepthalic acid). MEG (Mono Ethylene Glycol).
  6. 6. RAW MATERIAL AND SPECIFICATION PTA (PURE TEREPTHALIC ACID)  PTA is one of basic raw material used for the production of Poly Ethylene Terephthalate (PET) . It is white color powder with small particle size.
  7. 7. RAW MATERIAL  PTA SUPPLIERS   BRAND COUNTRY  ICI England  PPTA Pakistan  Siam Mitsui Thailand  Amoco Japan  Inter Quisa Spain  Kasie Bakeri Indonesia  T-Kong America  Samsung Korea  Lotte Pakistan
  8. 8. RAW MATERIAL  PACKAGING. Jumbo size bags of capacity 1000~1100 kg PTA Containers of capacity 22.0 tons of PTA
  9. 9. RAW MATERIAL MEG ( MONO ETHYLENE GLYCOL ) MEG is crude oil ( (Refinery Product ) it is liquid and transparent in nature . SPECIFICATIONS Formula HO-CH2-CH2-OH Molecular weight 62.07 Appearance Colorless / Transparent liquid
  10. 10. RAW MATERIAL MEG ( MONO ETHYLENE GLYCOL )  MEG SUPPLIERS  BRAND COUNTRY  Mobil Saudi Arabia  Equate Kuwait  SABIC Saudi Arabia
  11. 11. RAW MATERIAL ADDITIVES CATALYST ( Antimony Triacetate) TDO (Titanium Dioxide)
  12. 12. RAW MATERIAL CATALSY SUPPLIERS  BRAND COUNTRY Elf Atochem America Polytrade A-42 Germany
  13. 13. RAW MATERIAL  TITANIUM DIOXIDE ( TDO) Nearly all synthetic fibers are transparent or translucent with glossy luster , which is undesirable in most of the applications . TDO has proven to be most efficient agent for delustering or matting for these fibers. TDO is white color powder and in the process we use in the form of slurry prepare in MEG .
  14. 14. RAW MATERIAL TDO SUPPLIER BRAND COUNTRY Sachtleben Hombitan Germany Titanium Dioxide PACKAGING TDO comes in bags of different packaging i.e. 25/500/1000 kg .
  15. 15. RAW MATERIAL  PRODUCT TYPE AND TDO FEEDING CONCENTRATIONS  Two type of product are being made on the basis of TDO addition i.e. bright and semi dull. But other product can be made on the basis of TDO feeding concentration detail is as under.  Super bright contains TDO 0.010 wt. % of PET  Bright contains TDO 0.030 wt. % of PET  Dull contains TDO 0.500 wt. % of PET  Semi dull contains TDO 0.300 wt. % of PET
  16. 16. PASTE PREPRATION PASTE PREPRATION PTA MEG AND EGR COLUMN EG CATALYST PASTE TO ES-I
  17. 17. MAIN PROCESS  There are two Esterification reactors. Here the raw material react and form monomer (BHET). And water, Esterification reaction takes place at elevated temperature i.e. 255 ~ 258 0 C, and pressure 0.39 ~ 0.15 bar. Temperature, pressure ,E / T ratio , residence time ( level ) , agitation are the main controlling parameters for controlling the Esterification reaction.  About 91 ~ 93 % reactions completes in estreification reaction -1. ESTERFICATION
  18. 18. During Esterification reaction water formed which mixes with EG vapors. Composition The vapors formed from ES-I and ES-II led to process column for separation of water and & EG . The column is operated at atmospheric pressure .The low boiler water will leave at the top of the and after condensation led to sever , EG will be collected at the bottom of the column with 96 % purity and will used again in paste preparation , ES & ES-II .  The heating media used for both Esterification reactor is called Santotherm ( in liquid form ) in coils & Dowtherm ( in vapor form ) in jacket of the reactors . ESTERFICATION
  19. 19. ESTERFICATION REACTION:ESTERFICATION REACTION: 2 MEG + PTA → BHET + 2 H2 MEG + PTA → BHET + 2 H22 OO Bis Hydroxy Ethylene Tere Pthalate
  20. 20. PASTE FROM PASTE TANK VAPORS TO PROCESS COLUMN OLIGOMER TO ES-II OLIGOMER TO ES-II LINE # 14 LINE #15 ES-1 REACTOR
  21. 21. HEATING SYSTEM OF ES-1 LIQUID & VAPOR HEATING SYSTEM. THERE ARE TWO HEATIING SYSTEMS FOR THE ES-1 LIQUID HEATING WITH SANTOTHERM IN COILS VAPOR HEATING WITH DOWTHERM IN JACKET.
  22. 22. POLYMERIZATION The conversion of a particular compound to a large , multiple of it’s monomer (itself ) There are two types of polymerization
  23. 23. 1- ADDITION POLYMERIZATION The Polymerization reactions through which the molecular formula of the repeating unit is identical with that monomer , no by product is formed .e.g. Polyethylene etc.
  24. 24. 2- CONDENSATION POLYMERIZATION The Polymerization reactions in which monomer are joined together into bigger molecule by condensation also producing some small molecule as a by product is called condensation polymerization e.g. PET( Poly Ethylene Terepthalate) MEG is produced as by product
  25. 25. CONDENSATION POLYMERIZATION REACTION 2 MEG + PTA BHET +2 WATER BHET + BHET n PET + ( n -1) MEG Mono Ethylene Glycol Pure Terepthalic acid Bis Hydroxy Ethylene Terepthalate Poly Ethylene Terepthalate Mono Ethylene Glycol Temperature +pressure Temperature +Vacuum +Catalyst
  26. 26. POLYCONDENSATION PREPOLYMER REACTOR -1 ( PP-1) TOTAL VOLUME Monomer / Oligomer from Es-II (14/15) Product to PP-II Vapors to vacuum system
  27. 27. POLYCONDENSATION HEATING ARRANGEMENT 1. HTM IN COILS (THREE IN NOS.) 2. DOWTHERM IN JACKET
  28. 28. POLYCONDENSATION PREPOLYMER REACTOR -II ( PP-II) POLYCONDENSATION STAGE II REACTOR PRE POLYMER FROM PP-I Product to DRR through Pre polymer pumps and filter Vapors to jet system
  29. 29. POLYCONDENSATION LEVEL TRANSMITTER RADIO ACITVE TYPE Co60 HEATING ARRANGEMENT DOW THERM IN THE JACKET
  30. 30. POLYCONDENSATION DISC RING REACTOR ( DRR) FINAL POLYCONDENSATION DISK RING REACTOR (DRR) PRE POLYMER FROM PP-II Product to Staple fiber through Pre polymer pumps and filter Vapors to jet system
  31. 31. DISC RING REACTOR ( DRR) The main function of the final polycondensation stage is to complete the reaction to the final polymer target . The reactor consist of a horizontal cylindrical vessel provided with built in chamber and a horizontal agitator having many disc rings. The disc rings are arranged in each of these chambers These rings are used to lift up the product from the chambers and form a thin film which enables the excess glycol (MEG ) produced in the reaction set free. Due to the fact the EG is withdrawn immediately under vacuum and polycondensation reaction proceed in the forward direction
  32. 32. SPINNING & FIBRE LINE
  33. 33. SPINNING Polymer MeltPolymer Melt (from Polymer Plant) Distribution ManifoldDistribution Manifold Spinning BeamSpinning Beam (Spin Pumps & Spin Packs) Quenching & OilingQuenching & Oiling Tow FormationTow Formation (Capstan Unit) Tow Collection &Tow Collection & StorageStorage (CTR & Tow Cans) Spinning Wall Extrusion
  34. 34. DISTRIBUTION MANIFOLD  All Polymer Melt lines are HTM jacketed.  Distance from distribution valve to each spinning position is almost equal.  20 Static Mixers are installed to ensure proper mixing and breakup of boundary layer.  Melt Transfer line contains a Heat Exchanger which can heat or cool the melt, as required.  Heat Exchanger & Transfer line is heated with liquid HTM (Santotherm) to maintain the polymer in molten form.
  35. 35. Melt From POLY DN 2 X 98/350 DN 2 X 60/250 7537-M01 355mm 7537-M01 355mm 7537-M01 355mm 7537-M01 355mm 7537-M02 225mm DN 98/200 DN 98/200 DN 60/100 DN 60/100 DN 60/100 M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M 6000 mm 6000 mm DN 2 X 60/250 TR 37-01 TI 37-01 TR 37-05 TI 37-05 PI 37-01 PR 37-01 PR 37-02 PI 37-02 PR 37-04 PI 37-04 PI 37-03 PR 37-03 TR 37-07 TI 37-07 TR 37-06 TI 37-06 POLYMER DISTRIBUTION (MANIFOLD)POLYMER DISTRIBUTION (MANIFOLD)
  36. 36. SPINNING BEAM  Spinning Beam is heated with HTM (Dowtherm) vapors and is insulated.  Vapor inlet is from top and condensed HTM is removed by gravity, from the bottom.  Spinning Beam is in four (04) portions, each containing eight (08) positions.  Temperature of Spinning Beam is maintained at approximately 290°C.  Spinning Beam consists of Spin Pumps and Pack housing.  There are a number of thermo-wells at different locations of each Spinning Beam for temperature measurement.
  37. 37. EXTRUSION  Polymer melt from distribution manifold is directly supplied to motor operated metering pumps (total 32 in number per line)  Metering pumps are gear pumps having a step down gear box after the motor. The coupling contains a metallic shear pin to avoid damage to the motor / gear box in case of jamming of pump.  Gear Pumps are enclosed inside the HTM-heated Spin Beam.  There is no valve in the melt line but an air jet is provided on the un-jacketed line for freezing of polymer as and when required.  The through-put of the metering pump is controlled through inverter driven motor speed.  Spin Packs are installed directly under the metering pump (spin pump) and extrude polymer melt through a spinneret.
  38. 38. High Throughput, Same Take-up Speed Low Throughput, Same Take-up Speed Fine Denier Coarse Denier Draw Zone SPINNERET HOLE OUTLET VARIATIONSPINNERET HOLE OUTLET VARIATION
  39. 39. QUENCHING & OILING  Filament quenching is done with double filtered quench air at 20.5°C and 85% RH at approx. 1750 m3 /h per position flow.  Quenching is radial after a 50 mm Draw Zone, in which the filament is drawn up to 120 times.  Exhaust air after quenching is removed to the atmosphere following a scrubbing process to remove monomer particles.  Filament oiling is done in two stages, Ring Oiler and Thread Oiler. In both oilers 0.3% conc. Aqueous solution of Spin Finish Oil is used.  Oiling is done to minimize friction and neutralize static electric charge.  Excess Spin Finish Oil is recycled back into the system.  The resulting spun tow contains around 30% moisture and 0.09% OPU as a result of this two stage oiling.
  40. 40. SPINNING WALL  Filaments from the quench chamber pass through a slub catcher, thread-oiler, ceramic V-guide, suction & cutting device and drip detector before passing around a free-moving deflector roller.  The slub catcher presses the filaments against the thread oiler and removes any slubs in the sliver.  The thread oiler provides surface moisture and lubrication to the sliver.  The ceramic V-guides increases the compactness of the sliver by converging the filaments into a narrow band.  The suction & cutting device ensures safe & smooth operation in case of interruption. During position cutting, it provides ease and safety of operation.  The drip detector removes and provides information of drips in the sliver.  The deflector roller changes the direction of the slivers towards the Capstan Unit by merging them into a single tow band
  41. 41. CAPSTAN UNIT  Capstan Unit consists of six (06) + one (01) Godets (rollers) and a set of two Sunflower Wheels, in series, to form the tow band.  All seven (07) Godets are directly driven by individual motors, but a single inverter, and have the same ‘rpm’.  The first four (04) Godets are hard chrome plated and smooth. The next two Godets are ceramic coated and axially grooved, while the seventh Godet is also ceramic coated but without grooves.  The first Godet has an outer diameter of 236.5 mm and each successive Godet is larger in diameter by 0.5 mm. The seventh Godet has a diameter of 240 mm. This successive increase results in continuous increase in surface speed. Sunflower Unit  Each Sunflower wheel is ceramic coated and has 80 teeth. However, the intake-side wheel is 165 mm in diameter while the discharge-side wheel has a diameter of 125 mm. Its function is to compact the tow and to feed the tow in the can.

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