Polyplex

Training Report – 12th July

Submitted by :-Piyush Lawania

Executive Trainee

BOPET Plant BOPET Plant input consists of two :-1. Main Line/ Melt handling Layer B2. Co-extruder/ Extrusion system Layer A At the main Line/ Layer B the melt from the poly-condensation

flows through a melt pump to a single filter & Afterward through the 2nd part of the melt pipe to the die.

At the co-extrusion/ Layer A, the co-extruder supplies the melt through a single screen changer & a melt pump to a single filter. The filtered melt will be transported to die.

Safety – First concern Since Dornier installed all the equipment of the line so there are

certain instruction which has to follow for safety purpose. Operate line only within the limits specified in the order

confirmation. Dornier is no longer liable for defects of the product if we use the

spare parts other than the DORNIER or other than recommended. There are certain protection symbols which has to know :- Danger (Red in color) :- Will cause serious injury/death. Warning(Orange in color) :- Could cause injury. Caution(Yellow in color) :- Result in minor or moderate injury. Caution without signal :- May result in property damage. Notice(Blue in color) :- Indicate information which relate to the

safety of personal.

Functional Description1. Main Extrusion – Melt pump2. Main Extrusion – Single Filter3. Main Extrusion – Melt Pipe4. Main Extrusion – Melt Pressure & Temperature Sensor5. Co-Extrusion – Coextruded with vacuum degassing 6. Co-Extrusion – Measuring head7. Co-Extrusion – Screen Changer8. Co-Extrusion – Melt Pump9. Co-Extrusion – Single Filter10. Co-Extrusion – Melt Pipe11. Co-Extrusion – Melt pressure & temperature12. Die Unit13. Thermo Oil Heating Station14. Operator Panel

Poly condensation ( melted bright chip) is input for the Main extrusion.Next we will briefly give the step by step flow of the melt in Main

Extrusion.

Melt Pump – Used for metering & conveying the melt & ensure uniform pressure.

Single Filter (for filtration of hot melt) – It is connected to melt pipe system & heated with thermo oil. In this melt enters the filter at bottom & is pressed through filter disc. This melt is filtered & enters the filter stacks through its holes. The clean melt emerges through the melt outlets.

Main Extrusion

Melt Pipe (Transports the hot melt) – The melt pipe parts are heated with thermo oil & therefore double walled melt flows at inner & thermo oil at outer jacket. Vent Valve are used to bleed thermo oil circuit, if necessary.

Melt pressure & temperature sensor – Along the melt handling line several melt pressure & temperature sensors are installed. They monitor & control the parts of melt handling system & give feedback to control system.

e.g. if PM2 pressure before the filter and PM3 is the pressure after the filter then difference between the PM2 & PM3 gives the indicator for filter insert. We can easily know the pressure & temperature by these sensors.

Co-ExtrusionIn co extrusion, input is 30%silica, 50% arema and 20% bright chips Co-extruder with vacuum degassing – In this we have motor

which drives the gear box by security clutch(use to protect the gearbox against overload) and then extruder does it function. Oil supply unit is connected to the gearbox, water tempering unit is connected to the extruder to cooled down the heat at extruder and Vacuum unit which used to remove dust, dirt etc.

Measuring Head – Measuring head is mounted at extruder exit of co-extruder. It is used to maintain the uniform pressure because it may be possible that pressure is not continuous after the extrusion.

Screen Changer – It is used at start up & during operation to protect the melt pump from getting damaged by coarse particle.

Melt pump - Used for metering & conveying the melt & ensure uniform pressure.

Single Filter (for filtration of hot melt) – It is connected to melt pipe system & heated with thermo oil. In this melt enters the filter at bottom & is pressed through filter disc. This melt is filtered & enters the filter stacks through its holes. The clean melt emerges through the melt outlets.

Melt Pipe – The melt pipe of the co-extrusion/Layer A transports the hot melt to the die. The melt pipe parts are heated with thermo oil & therefore double walled melt flows at inner & thermo oil at outer jacket. Vent Valve are used to bleed thermo oil circuit, if necessary.

In order the flow direction the melt passes following parts :-

Melt Pressure & Temperature Sensor :- Along the co-ex line several melt pressure & temperature sensors are installed. They monitor & control the parts of the extrusion system & give feedback to the control system. This is used as indicator for condition of screen at screen change, indicator for pressure built up at melt pump etc.

Die Unit :- It provides the melt stream which is cast into roller. The complete die unit Consists of three parts.

Distribution block (Layer ABA)– Connected to the melt pipes on both sides. It distributes the melt flows into the required pattern for production & supplies to the feed block with three individual melt stream.

3 Layer Feed Block – The feed block assembles & laminates the 3 layers as they are supplied from the distribution block.

Extrusion Die – Melt enters at top of die & leaves it through the die tip.

Thermo Oil Heating Station – The thermo oil heating units are used to heat up the thermo oil for the corresponding melt- pipe parts of the melt handling system, the co-extrusion system, the filter s & the melt pumps.

Operator Panel – All the parameters are senses by sensors and display on the panel so operator can easily understood what should going in the plant.