About Afroze Textile Industries (Pvt):AFROZE TEXTILE INDUSTRIES (PVT) LTD. is in Karachi, Sindh, located in LA-7/1-7, Block-22 F.B.

It has been serving in the field of textile in Pakistan for three decades with an ever improving quality of product.

There are several aspects of Afroze Textile progress which can be examined to evaluate this industry ,which are:

1. Management2. Products and Production and capacity3. Certifications4. Machines and plants5. Environmental report6. Exports7. awards

MANAGEMENT:The AFROZE TEXTILE INDUSTRIES is lead by a very intellectual and well reputed management:

Mr.mehboob alam lari

Mr.feroze alam lari

Mr.afroze alam lari

PRODUCTS:Its products can be divided into three major categories:

TOWEL BEDDING CURTAINS

While it’s processing includes:

TOWELS 150000 lbs/dayQUILT COVERS 10000 sets/dayBED SPREADS 1000 sets/daySHOWER CURTAINS 6000 pcs/dayAPROMS 6000 pcs/dayTABLE COVERS 8000 pcs/dayBED SETS 15000 sets/dayCOMFORTERS 8000 sets/dayLINED CURTAINS 3000 pairs/dayKITCHEN TOWELS 60000 pcs/dayJERSEY BED SETS 12000 sets/day

EXPORTS:AFROZE TEXTILE has a very high demand of its products in Pakistan as well as other world

countries like:

United States of America AustraliaCanada New ZealandUnited Kingdom BrazilNetherland FranceGermany South AfricaIreland United Arab Emirates

1998-1999 $ 62 million1999-2001 $ 70 million2001-2002 $72 million2002-2003 $ 75 million2003-2004 $85 million2004-2005 $100 million2005-2006 $125 million2007-2008 $135 million

STEAM BOILERSTEAM BOILER:

There are two steam boilers of DESCON; one is 8 TPH, and other is 15 TPH.

CIMME air blower (22 K, 50 amps), MONARCH burner (2100-6400 KW at 380-600 milibar gas pressure)

BOILER’S SPECIFICATION: The boiler here is fire tube; i.e. fire heats the hollow tubes form one end that is then

transfer heat to water surrounded. The boiler here is three pass i.e. its tubes are looped and give exhaust on the opposite

end to the economizer; this helps in utilizing heat in an effective way. The fire tubes are of stainless steel.

PLANT CAPACITY:23 tons per hour of steam can be produced in this plant at Afroze. The steam is at 160-170 deg C

saturated, 8 bar of pressure is obtained at the final product.

REQUIREMENT:At Afroze they mostly require steam at 10-13 TPH which is sufficiently fulfilled by these two

boilers.

FEED WATER:For the high efficiency and long life of the boilers the feed water for the boiler should be of very

low TDS and 0 hardness to avoid scale build up in the boiler inner surface that can increase the fuel consumption of the boiler.

1. TDS should be 40-50ppm; here we are getting 1200 TDS due to RO inefficiency.2. Hardness should be 03. pH should be 7-7.5

For this purpose factory has intelligently utilized its condensate return 60% from various processes like (caustic condensate return, dryers return) at about 90-95 deg C ,which heats up the 40% + 60% mixture in feed water tank to 80-85 deg C. Advantage: this helps in saving fuel as well as the condensate return water has 0 TDS and o hardness and 7 pH

ION EXCHANGE PLANT:For the very pure and required quality of boiler water here at Afroze they have an ion exchange

plant that replaces the hardness ions of Ca and Mg with Na ions using the resin beads of sodium zolite.

PROCESS: WATER FEED; water is fed into the boiler through 80 HP pumps which is at 80-85 deg C into the

economizer. ECONOMIZER; water in the economizer is heated using the exhaust combustion gases at 240

deg C of the boiler to enhance the plant efficiency, to the 90-95 deg C.

BOILER; Water from economizer is fed into the boiler where it is heated to the 160-170 deg C and converted to saturated steam of 8 bar gage of pressure.

HEADER; It is the steam distribution center ,it has one-one line of feeding steam of boiler and one-one line of steam feed to the wet processing plants in the Afroze textile industries.

HMI; Electronic control panel in the boiler hall haves all the necessary boiler safety and boiler reading displays.

BLOW DOWN:This is the boiler maintenance perimeter in which a scheduled scaled water flush is carried that

is kept building on the lower boiler surface to ensure no scaling in the boiler ,water is kept feeding during the blow down to ensure a minimal safe water level in the boiler.

1. Blow down is triggered when the TDS level in water exceeds 3500 ppm of TDS and it runs for 15-18 sec with an alarm.

2. Operator has to check the TDS of drained water to measure the TDS level and then if necessary operator manually blows down all the increased scaling in the boiler by manually adjusting water flushing out with water feed.

3. It can run for 30-90 secs.

CHEMICALS USED: Hard water builds up scale of Ca and Mg which effect heating mechanism so soft water should

be used. Soft water is fed into the boiler which is acidic in nature and can corrode the boiler from inside

and weaken it.

Phosphates-dispersants, polyphosphates-dispersants (softening chemicals): reacting with the alkalinity of boiler water, these products neutralize the hardness of water by forming tricalcium phosphate, and insoluble compound that can be disposed and blow down on a continuous basis or periodically through the bottom of the boiler.

Natural and synthetic dispersants (Anti-scaling agents): increase the dispersive properties of the conditioning products. They can be:

o Natural polymers: lignosulphonates, tanninso Synthetic polymers: polyacrilates, maleic acrylate copolymer, maleic styrene copolymer,

polystyrene sulphonates etc.

Sequestering agents: such as inorganic phosphates, which act as inhibitors and implement a threshold effect? Oxygen scavengers: sodium sulphite, tannis, hydrazine, hydroquinone/progallol-based derivatives, hydroxylamine derivatives, hydroxylamine derivatives, ascorbic acid derivatives, etc. These scavengers, catalyzed or not, reduce the oxides and dissolved oxygen. Most also passivate metal surfaces. The choice of product and the dose required will depend on whether a deaerating heater is used.

Anti-foaming or anti-priming agents: mixture of surface-active agents that modify the surface tension of a liquid, remove foam and prevent the carryover of fine water particles in the steam

COSTING:1. 1 ton steam require 75 m3 N gas2. 1 m3 N gas is of 16.48 RS3. 1120 liter of water to produce 1 ton of steam4. Cost: 1556 RS/ton

OIL BOILERCOMPANY:Inenieurtechnic company oil boiler is used with Weishaupt burner and cimme air blower.

Oil used:At afroze we use mineral oil for the oil, heat flow system from oil boiler; the oil is the product of shell petroleum AV POLYSOFT HLC heat transfer oil.

Oil boiler specs:Flow rate= 200m3/hr

Max pressure= 10 bar

Max test pressure= 21.4 bar

9 KW air blower.

PROCESS: The oil boiler is supposed to provide high temperature of about 250-300 deg C. Heated mineral oil is supplied to AROLI and THERMOSOL machines High temperature pumps are used to drive the oil form boiler to the machines.

EFFICIENCY: Oil has good capacity to hold the heat and mostly the oil is heated in the boiler so the boiler not

needed to work at very high loads. Oil does not evaporate so oil needs refilling very rare in 2-3 years.

HOT OIL TRANSFER: Insulated SS pipes are used for the oil transfer from the boiler to the machines. High temperature resistant bearings are used in the high temperature fluid pump. Bearing is of category c4.

REVERSE OSMOSIS PLANT (RO)REQUIREMENT:

At Afroze textile the requirement of RO feed water is about 500,000 gallons.

PLANT CAPACITY:The RO plant at Afroze is capable of producing 100000 gallons due to the limited use of RO feed

water to the steam boiler, cooling tower and chemicals.

FEED WATER:Plant can deal with the max TDS of 12000-16000ppm, but here the well water feed has 2500-

3500ppm.

PRODUCT QUALITY:Product water should not have 40-50ppm of TDS, 7-7.5pH and hardness of 2-3.

But the final product is obtained at 400ppm due to very high demand of water and less time for treatment.

WATER SOURCE: At Afroze, they have 4 x 130-150 feet deep at about 3500-4000ppm TDS.

PROCESSES: BOD, COD in well water is killed by the chlorination. Then this water is treated with ACF to remove smell, color, and chlorine. DMF; One design brings the water in the top of a container through a "header" which distributes

the water evenly. The filter "media" start with fine sand on the top and then graduating coarser sand in a number of layers followed by gravel on the bottom, in gradually larger sizes. The top sand physically removes particles from the water. The job of the subsequent layers is to support the finer layer above and provide efficient drainage.

ACF; Activated carbon works via a process called adsorption, whereby pollutant molecules in the fluid to be treated are trapped inside the pore structure of the carbon substrate. Carbon filtering is commonly used for water purification, in air purifiers and industrial gas processing, for example the removal of siloxanes and hydrogen sulfide from biogas.

CARTRIDGE FILTERS; - Applications: drinking water, boilers, washing machines, pre-filtration in water treatment, sea water desalination, process water, chemical processes... Filtration range: 0.5 - 150 micron

REVERS OSMOSIS VESSELS; there 6 three stage RO vessels at Afroze that use reject of one another and provide more efficient RO filtration for an optimum and large product.

CHEMICALS USED: BIOSIDE; Non-oxidizing, non-ionic biocides can be used either on line or as part of a cleaning

program to control biofouling in reverse osmosis (RO) membranes. When used as an on-line

treatment, the biocide should be dosed prior to the RO system to control bio-growth in the membranes.

ANTI SCALANT; range of liquid antiscalant/dispersants for membrane separation systems. These formulations are designed to inhibit scale while also dispersing colloidal particles. The inhibition and dispersant properties help extend RO system run times, reduce cleaning frequencies and increase the overall productive life of the RO elements

INSPECTION: pH meter is used to check the final pH of product which should not be more than 7-7.5. EDTA sol is used through titration to calculate the amount of TDS in product water.

COMAPANIES CONTRIBUTED: Filmtech membrane (USA) for RO. Norit activated carbon for ACF.

WASTE WATER TREATMENT PLANTPLANT CAPACITY:At Aforze the water treatment plant is one of a kind 500000 gallons processing plant.

FEED WATER:The feed of WWTP is the waste water of wet fabric processing machine of the Afroze textile that is stored in the 4 feed tanks underground.

PRODUCT QUALITY:The product of WWTP is safe for the environment and seawater inhabitants and it is approved by EPA at Afroze.

PROCESS:CHEMICAL DOSING;

1. ALUM; the principal advantages of pre-polymerized inorganic coagulants are that they are able to function efficiently over wide ranges of pH and raw water temperatures. They are less sensitive to low water temperatures; lower dosages are required to achieve water treatment goals; less chemical residuals are produced; and lower chloride or sulfate residuals are produced, resulting in lower final water TDS. They also produce lower metal residuals.

2. POLYMER; Polymers are a large range of natural or synthetic, water soluble, macromolecular compounds that have the ability to destabilize or enhance flocculation of the constituents of a body of water.

D.A.F; The WPL DAF is a purely physical process which operates on a simple design philosophy. Incoming effluent may require pre-treatment as necessary; for example the addition of chemical coagulant(s) and/or flocculent(s) may be required with associated mixing and

coagulation/flocculation stages. Adjustment of pH may also be necessary to ensure optimum operating conditions.

The incoming effluent enters the flotation vessel where it comes into contact with recycled, treated effluent (sometimes termed ‘white water’). The percentage of the total effluent flow into which air is dissolved under pressure and subsequently recycled will be determined by several factors. Increasing the pressure within the vessel where the air is being dissolved ensures that a higher concentration of air dissolves into the liquid phase than is possible at atmospheric pressure.

SLUDGE REMOVAL:The removed flocculated impurities from the DAF are stored in a sludge storage tank that is then used for fertilization.

FLUSHING:Then the treated water is drained with no toxicity.

Power House:PLANT MANUFACTURER:

Orient Energy System (Contractor). 3 JENBACHER ENERGIE generators of (1MWatt) power rating.

1. JGS 320 jenbacher 1064 KWatt2. 2 x JMS 320 jenbacher 1006 KWatt

Outsource plant operation and management provided by Orient Energy System.

PLANT CAPACITY: Three megawatt can be delivered from this plant Water recovery is provided to the customer from the two 1006KWatt generators.

PLANT OPERATION: Maximum load at AFROZE TEXTILE IND. Is in between 2.2-2.6 MWatt. 90 to 95 degC water is recovered from the two heat recoveries for the cost saving and

fabric processing in factory. It is designed to run 24/7, while the minors (engine maintenance of low level) and

majors (engine maintenance of high level).

ENGINE OPERATION:Engine type J 320 GS-C121Working principle 4-StrokeConfiguration V 70°No. of cylinders 20Bore mm 135

Stroke mm 170Piston displacement lit 48, 67Nominal speed rpm 1.500Mean piston speed m/s 8, 50Filling capacity lube oil lit 370Filling capacity water lit 150Length mm 3.320Width mm 1.358Height mm 2.065Weight dry kg 5.000Weight filled kg 5.500Moment of inertia kgm² 8,61Direction of rotation (from flywheel view) leftFlywheel connection SAE 18''Radio interference level to VDE 0875 NStarter motor output kW 9Starter motor voltage V 24

Exhaust gas dataExhaust gas temperature at full load °C 487Exhaust gas mass flow rate, wet kg/h 5.655Exhaust gas mass flow rate, dry kg/h 5.225Exhaust gas volume, wet Nm³/h 4.398Exhaust gas volume, dry Nm³/h 3.882Max.admissible exhausts back pressure after engine mbar 60

Output / fuel consumptionISO standard fuel stop power ICFN kW 1.095Mean effect. Press. At stand. Power and nom. speed bar 18, 00Fuel gas type Landfill gasBased on methane number MZ d) 100Compression ratio Epsilon 11, 80Min./Max. Fuel gas pressure at inlet to gas train mbar 80 - 200 c)Allowed Fluctuation of fuel gas pressure % ± 10Max. rate of gas pressure fluctuation mbar/sec 10Maximum Intercooler 2nd stage inlet water temperature °C 50Spec. fuel consumption of engine kWh/kWh 2, 43Specific lube oil consumption g/kWh 0, 30Max. Oil temperature °C 90Jacket-water temperature max. °C 95

WATER CIRCUITS:1. Closed jacket water circuit to maintain engine block at 65 deg C, which is at about 70-80deg C.

This also maintains lube oil temp at 90 deg C.2. An open circuit that is connected to cooling tower and into the heat exchanger where jacket

water circuit loses its heat.3. Customer’s water is heated through the heat recovery from exhaust gases, that heats the water

at 90-92 deg C, then the customer heats it through steam at 98 deg C

Air Compressor:

Types of Compressors: There are 2 Types of Compressors

Dynamic Compressor (Centrifugal Compressor, Axial Compressor) Positive Displacement Compressor (Reciprocatory Compressor/Rotary Compressor). Rotary

Compressors (screw compressors) are used in Afroze Textile Industry. Compressors in Afroze Textile Industry:

There are 5 compressors in Afroze Textile Industry.160 KW 110 KW 45 KW 2 X 37 KW

Filters: Two Filters are used, oil filter and air filter.

Process: Compressor intakes air through duct from the atmosphere and then air is filtered with the help

of screw rotating on the principle of Archimedean screw generate, pressure. While oil is used as a lubricant in screw, cooling of high temperature in motor, due to friction. Screw rotation of 160KW compressor is 1400rpm. Then, oil is cool by the help of oil cooler. Then air moves to Oil separator where oil and air gets separated and air with moisture from all working compressor collects at Dryer where moisture in air is removed.

Pressure Requirement: At Afroze maximum pressure requirement is 8 bar pressure.

1. Usually machines are designed at 4 bar pressure.2. Mainly pneumatic padders require high pressure but not always and pressure level can

vary between 0.5-8 bars in these padders according to their application. Dry Air Usage:

Dry air mostly used for Pneumatics:1. Pneumatic valves operations for computer guided and automatic working

environments.2. For pneumatic padders, almost used in all wet processing machines as squeezing and

cloth feeding.3. Pneumatics control panels.

SINGEING AND DESIZING

Definition: Removing the fluf and puff from the fabric is called singeing Removal of Starch is called desizing.

Details: Machine Company: German Osthoff Running Load: 10-12 KW Maximum Load: 16-17 KW Compensator is used which synchronizes and maintain speed of motor with the help of drives of

motor. At the start of machine, Torque load is provided as per controlled by driver.

Process: Roll is unroll It passes through rollers where blower removes fluff. Then it passes through the burner where puff is removed and carbon with the help of blower. Washing with water with desizer, these are enzymes that convert starch into glucose. Then with the help of Padders water is removed from the cloth and it is then rolled and ready

for the next process of Bleaching.

BLEACHING MACHINEDefinition:

To remove the color from, as by means of chemical agents or sunlight. To make white or colorless.

Process: 3 X PRE WASHING CHAMBERS; The feed fabric is full of glucose due to the action of

enzyme over the starch in it, therefore it is passed through these three washing chambers which have cross rolls, this helps in increase of washing time at 90-95 deg C of hot water.

BLEACHING CHAMBER (IMPECTRA); Now the bleaching chemicals (H2O2, NaOH, stabilizer, wetting) are applied on the fabric and then the fabric is passed through the rubber + ebonite padders which squeeze out extra amount of bleaching chemicals and then the fabric enters steamer.

STEAMER; in the steamer fabric rolls in through 12-15 cross rolls at the steaming temperature of 102 deg C and offload in cluster over the bed roll which keeps the cloth in for exact 18-20min of reaction time and then the fabric is neutralized.

NEUSTRALIZATION; In this chamber cloth is flushed with acetic acid and then washed and squeezed in the two ebonite hard padders for drying on the steam rolls.

4 X POST WACHING CHAMBERS; in these chambers the bleaching chemicals are washed away from the cloth as well as the acid neutralization product.

Mercerizing MachineDefinition:

It improves the fabric dye absorption affinity, SHINING AND LUSTRE and makes the fabric ready for dyeing process.

Process: After bleaching Process, fabric is brought to mercerize machine where it enhance the fabric

ability to add capacity for dyeing. First fabric is moved to wetting chamber. Where strong lye of caustic soda is added on the fabric. The concentration of caustic soda is 28

Be°. It is showered on the fabric. It is then moved to padder, after that due to shrink/creased in the fabric it is then moved on pin

wheel which opens the crease of the fabric. And then it moves to washing area. Fabric is washed in water, just after applying of acetic acid with fabric in order to neutralize the pH, fabric is washed again.

With the help of hydraulic padder(squeezes 50% of moisture) it is moved towards the dyer, where fabric gets dry.

CAUSTIC RECOVERY UNIT (CRU)PLANT TYPE: It’s a three stage plant for maximum recovery; it takes weak lye at 6-7 Baume from the mercerizing machine.

REQUIREMANT: we need 24-26 baume of caustic for the mercerizing process.

The marketed feed is 48 baume which is diluted to give 24 baume caustic to the machine

60% of caustic is recovered here.

PROCESS:The weak lye is reconcentrated by water evaporation. The Caustic Soda Recovery System is based on the natural circulation evaporation. The heating steam is condensed on the outside of the tubes and heats the lye inside. The lye boils up in the heating tubes, the mixture of lye and vapor flows into the laterally arranged separator, where the vapor is separated from the circulating lye. The vapor is used as heating steam in the next stage. A partial vapor flow is used to pre-heat the weak lye. The separated lye flows back to the evaporator through a return pipe. A swirl droplet separator integrated into the separator prevents the alkaline liquid from being carried over into the vapor phase.

The evaporation plant is driven by the pressure gradient between the stages. The highest pressure is in the first stage. The last stage operates under a vacuum maintained by a steam jet vacuum ejector (v) with an after-condenser (ac), or by a liquid-ring-pump. In the first stage (1) live steam generates vapor which flows as heating steam into the second stage (2). The heating steam condensate from the first stage flows back to the boiler. The vapor from the second stage heats the third stage (3). The vapor from the last stage (here the 3rd stage) is condensed with cooling water in condenser (c). So cooling water becomes hot water by utilizing waste heat from the last stage

CONCLUSION:1. We had a great learning and training experience at Afroze Textile Industries for our

academic program of MECHANICAL ENGINEERING at DHA SUFFA UNIVERSITY.

2. We physically visited industrial utilities like steam boiler, RO plant, oil boiler, WWTP, air compressor, chiller plant which work on those basic thermodynamics principles and laws which we have studied in theories, working on them physically on the industrial scale was really so demanding for us.

3. We had a real world working and have work from, experiences which we had never been exposed to, in our isolated academic life at university.

4. We learned the coordination in planning of production order of different buyers to make the buyers happy and how to take the necessary steps in modifying the machines to cover any halts in the machines during a run.

5. We learned that how mechanical engineers do take actions in maintaining a harmonious flow in the production line by the properly govern the maintenance of machines and by designing new efficient plants and by modifying the existing plants to reduce the time consumption, cost, break downs of the production line.

6. They also increase by the same way the quality, and more diversified product which can change the market.

7. We learned how to work in a team and how to work under the higher authorities.

SUGGESTIONS:

WATER SUPPLY: We saw that Afroze has to depend upon the water tankers a little bit which are expensive,

not a true solution, dealing with them is nasty.1. We suggest that they should consider reconfiguring the waste water plant RO, which

has the water storage capacity of 500,000 gallons, this will eventually be good for environment, production, and profitable I guess.

BOILER WATER: Feed water to the boiler which is treated with RO and resin is still carrying TDS above 3500ppm which requires very frequent blow downs in the boiler, this increase power losses, time and money losses.

1. We suggest that RO plant should be rebooted with more effective maintenance and running conditions, by making use of that WWTP RO plant in conjunction with this we think it’s possible.

ENERGY CRISIS:In spite of having fully owned 3MWatt power plant Afroze is still facing power shutdown on Sundays due to N.Gas strike by the govt. this cause an effective loss to the production and profit of the industry.

1. We recommend the industry to install solar panel and wind turbine on the roofs and make use of it in conjunction with N.gas power plant.

2. We also recommend that industry should encourage the govt. for the use of thar coal in producing energy for the betterment of this sector.

3. We also recommend that industry should overcome power losses in terms of power efficient machines and good lubrication and insulations of machines.

MAINTENANCE:We observed that good repair and fabrication is done at the Afroze workshops but machines and plants are not wisely maintained, which causes continuous malfunctioning and acquiring repair.

1. We recommend that for proper maintenance workers and operators of related machine or plant, should be given proper teaching for one day once three-four months to overcome new problems and their solutions.

2. We recommend that machines and plants parts of expected maintenance should be arranged always in stack for the nonstop production.

3. We recommend that bearings, gear boxes, greasing, oiling, and walls and gauzes cleansing should be well managed since these things can drastically improve the machine’s life also influence production and shut down of process is rear.

SAVE PAPER:We have seen that the paper is so extensively used in the industry for even very short lived

instructions and maintenance documents, and even very much unimportant multiple copies of even the little issue are made on the papers.

1. We recommend that the IT system should be empowered in the factory to communicate and keep record of everything; this will help save the paper.

2. We know that some documents need to be on paper and paper is also more secure than online form so print only selected documents , rather printing pages of various unwanted documents.

APPENDIXSTEAM BOILER 14/8/2014-15/8/2014

OIL BOILER 16/8/2014

RO PLANT 17/8/2014-19/8/2014

WWT PLANT 20/8/2014-21/8/2014

AIR COMPRESSOR 21/8/2014

POWER HOUSE 22/8/14-26/8/14

CAUSTIC RECOVERY PLANT 26/8/2014

CHILLER 27/8/2014

SIENGING / DESIZING 27/8/2014

BLEECHING 28/8/2014

MERCERIZING 29/8/2014

MECHANICAL PARTS STUDY 30/8/2014

We were also having time sittings in electrical and mechanical workshops where we learned the working on lathe, grinders, welding and electrical windings of motors.

We also had worked on the gear box project, but due to the time constraints and unavailability of gears we had to postpone that project.

References:http://en.wikipedia.org/wiki/Media_filter

Read more: http://www.lenntech.com/systems/sediment/cartridge/cartridge.htm#ixzz3Byqo4ay3

http://www.reverseosmosischemicals.com/reverse-osmosis-chemicals/ro-membrane-biocides-disinfectants

http://www.wpl.co.uk/?page=IndustrialWastewaterTreatmentPlants

http://www.iwawaterwiki.org/xwiki/bin/view/Articles/CoagulationandFlocculationinWaterandWastewaterTreatment

Read more: http://www.lenntech.com/applications/process/boiler/boiler-water-treatment.htm#ixzz3C5LSsxYQ