Professional Documents
Culture Documents
REPORTFILE
REPORTFILE
A
REPORT ON SUMMER TRAINING
AT
VARDHAMAN YARNS AND THREADS LTD
INDEX
1. Qualities of Yarn
2. Department
3. G.T.S
4. Linking
5. Mercerization
6. Scouring
7. Bleaching
8. Dumper
9. Hydroextractor
10. Steam drier
11. R.F. Drier
12. Berta hydroextractor
13. Roll Dyeing
14. Cabinet Dyeing
15. HT/HP Package Dyeing
16. P.T.S
17. Boiler
18. About project
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Dyeing Dyeing ↓
For Examining
LINKING
The objective of linking process is to make all the thread to be
processed in rope form to facilitate further process. Here 2 T shaped
pole is used link all the threads with each other by tying and knotting
them.
Linked material is used in kier boiling and then processed as per
requirement.
Care should be taken during linking such that the material is properly
linked otherwise the rope form of material could break thereby
affecting the production rate and time.
MERCERISATION
Introduction:-
Mercerisation was discovered by John Mercer in England and thus
the process is named after him. Mercerisation gives cotton a silky
lustre, and is the foundation of many improved and beautiful finishes.
Sewing and embroidery cotton yarns are mercerised in the hank form
with tension. Stretched yarns can be mercerised without tension.
Objective:-
Rotating poles
Caustic bath
Water bath
Squeeze roller
Washing tube
Washing frame
Hood
Motors
Parameters:
QUALITY: 12/30
Dia setting 2210 mm
Pre tension(-1%) 2190 mm
Shrinkage(-4%) 2120 mm
Lye tension(2%) 2255 mm
Final tension(2.5%) 2265 mm
Limit Switch setting 2275 mm
QUALITY: 12/36
Dia Setting 2220 mm
Pre tension(-1%) 2200 mm
Shrinkage(-4%) 2130 mm
Lye tension(0%) 2220 mm
Final tension(2.5%) 2230 mm
Limit switch setting 2240 mm
6/40G 34 200
12/30G 24 350
12/36G 24 250
3/40 CHROMA 8 1000
3/60 CHROMA 8 1000
4/20 CHROMA 8 1000
3/16 CHROMA 8 1000
3/50 CHROMA 16 500
3/34 8 1000
2/30G 16 500
2/25 16 500
Precautions:
The workers should wear masks to avoid inhaling fumes.
The workers should make use of gloves while loading or
unloading material.
There should be equal loading of material on the pole.
All holes of the washing pipes should be open.
CHEMICAL TESTS
EXPERIMENT 1.
AIM: To calculate gpl of caustic solution.
APPARATUS: pipette,burette and flask
CHEMICALS USED: HCL(1N), Phenopthalein and caustic
solution.
PROCEDURE:
Caustic sample was collected from the center lye tank
1 ml of this was taken along with 50 ml of soft water in a
conical flask.
1-2 drops of phenopthalein indicator was added to this
solution. The solution turned pink.
It was then titrated against 1N HCL.
The end point of reaction was when the solution turned
colourless.
CALCULATIONS:
Burette reading:7.2 ml
Caustic gpl=7.2 X 40=288 gpl
RESULT:
The caustic gpl was found to be 288 gl which is normally in the
range of 280-320 gpl.
EXPERIMENT 2.
AIM: To calculate the caustic retention of mercerised
sample(3/50)
APPARATUS: Pipette, burette,flask,heating apparatus
CALCULATIONS:
Sample weight(after titration)=4.7
Burette reading= 2.6 ml
Caustic retention% =(N X 40 X B.R.)/(sample wt X 10)
=(1 X 40 X 2.6)/(4.7 X 10)
=2.21%
EXPERIMENT 3
AIM: TO CALCULATE THE BARIUM ACTIVITY
NUMBER(12/36 M).
APPARATUS :BURETTE,PIPETTE, CONICAL
FLASK,MEASURING CYLINDER.
CHEMICALS: Barium Hydroxide(0.25N),
HCL(0.1N),Phenopthalein.
PROCEDURE:
CALCULATION:
BAN=[ (Blank B.R.- Mercerised B.R.)/(Blank B.R.-
Unmercerised B.R.)] X 100
=[(8.5-6.9)/(8.5-7.3)] X100
=133
EXPERIMENT 4
AIM: TO CALCULATE THE SHRINKAGE OF THE
UNMERCERISED SAMPLE WHEN INTRODUCED IN
CAUSTIC SOLUTION.
Objectives:-
To make the yarn highly hydrophillic.
To remove impurities such as oils,waxes, gum,husk as far
as possible.
To increase absorbancy of textile materials without
physical and chemical damage.
To produce a clean material by adding alkali.
To make the product ready for further processing.
During the process of scouring the following reactions takes
place:-
Chemicals :-
Caustic Soda:- The caustic soda reacts with vegetable
oil in the material and forms soluble sodium salts of
fatty acid which can be removed. It also swells and
dissolves the motes( cellulose of low crystallinity).
Klennox Baspaste:- This is the scouring agent which is
responsible for saponification of oils.
Soda ash:- Soda ash provides an alkaline medium for
the scouring process.
KLERIX PER:- This is sequestering agent or chelating
agent and is used to remove hardness of water.
POLYAX TDS:- This is the non- ionic soap.
Scouring Recipie
MLR:- 1:4
S. Chemical Kier Kier2
No. used 1
1. Caustic lye 6 gpl 6gpl
2. Soda ash 0.8% 1.6%
3. Scouring 0.4% 0.8%
agent
4. Non ionic 1% 2%
soap
5. Sequestering 0.35% 0.7%
agent
Machine Operations.
Manual loading of hanks in the form of layers (20min)
Cold water filled (12 mins)
Cold water drained (4.5 mins)
Hot water added.The temp. reaches 60-65oC.(18-20 mins).
Addition of caustic at around 60oC
At 70 0 C, all other chemicals are added.
The scouring process continues for around 4 hrs. It takes 2 hrs to
reach 117o C and the temp. is maintained at 117oC for another 2
hours.
At 90oC , the vent valve is closed.
After 4 hours the caustic solution is drained and the temperature is
allowed to come down.
At 90oC hot wash is done for 1 hr and drained
1st cold wash (0.5 hrs)
2nd cold wash(0.5 hrs)
3rd cold wash (0.5 hrs)
Material unloaded.
CHEMICAL TESTS
Experiment 1- To find caustic gpl in scouring process.
Apparatus:- Burette, pipette, and conical flask.
Procedure:
BLEACHING:-
After scouring all the impurities are removed from cotton except
natural coloring matter. To decolorise this matter bleaching of
cotton goods is performed with various oxidizing agent . Agents
like sodium hypochlorite or bleaching powder or sodium chlorite
are used.
Objective
To increase the absorbency of material
To produce uniform and permanent whiteness.
To remove the residual impurities of cotton yarns.
Sodium hypochlorite is the strongest oxidising agent because it
is capable of giving oxygen at room temperature. It is also
economical in use.
Recipie:-
Sodium hypochlorite:-1.6 gpl
Sodium thiosulphate:- 10 kg
Fincon ADA( liquid alkali):- 2.5 kg
HCl:- 4gpl.
When cotton goods are to be bleached they are scoured or
kier boiled and then uniformly packed into cylindrical or
rectangular vessel which may be made of wood ,cement
lining stainless steel. The vessel has a perforated false
bottom with an outlet of a tank below of a similar
capacity. The liquid in the pump is made up to the desired
conc. of available chlorine with sodium hypochlorite. It is
then pumped up and spread through the sprinklers ,over
the top of the cotton goods, through which it percolates to
find its way ultimately back into the pump.
Bleaching liquor:- 1.5 gpl of available chlorine.
Temp :- room temperature.
pH:- 10-11
CHEMICAL TESTS:-
Experiment:- To calculate gpl of HCl
Apparatus:- Burette ,pipette and conical flask.
Procedure:-
DUMPER MACHINE
Objective of dumper machine:- The bleached material which
is not to be dyed in subsequent processes is sent to the dumper. It
makes the material whiter and softer.
CHEMICALS USED AND THEIR RECIPE
Recipie for dumper m/c for 400 kg material.
Fresh bath Standing bath
Sara whitecoloring 100 gm 90 gm
powder
Skaywhite HCE liq. 1200 gm 1100gm
Softner Quantity( Mercerised material)
Non ionic Softner 4.5% 4.5%
Emulsion 1% 1%
Mild acid 0.25gpl 0.25gpl
Softner Quantity ( Soft material)
Non ionic softner 4.5% 4.25%
Emulsion 1% 1%
Mild acid 0.25gpl 0.25gpl
Process:-
The material is passed through the dumper machine in 6 cycles.
The material is d through optical whitening agents for 4 cycles and
is passed through softner for 2 cycles. Each cycle takes around 5-6
mins .The treatment leaves the material whiter and softer . The
material is passed through the machine in rope form . It dips in the
optical whitening agent or softner and then through squeezing
rollers which extracts excess liquids from the material. The
material ,on reaching the other side is again passed through the
same machine.
The theory behind the process is as follows:-
According to light theory,when any two complimentary colours are
mixed ,a neutral colour like white is produced. Optical brightening
agents are violet and the cotton is yellowish due to presence of
natural impurities. Violet and yellow form a pair of complementary
, which when combined result in a neutral white colour.Thus ,a
white material is obtained.
MACHINE DETAILS
The capacity of the machine is 3000 litres. But 2400 litres is
filled for a lot size of 400 kg.
The top roller is made of vulcanized rubber and bottom roller
of ebonite.
The rotation of motor is bi directional
2 winches are used for the operation.
HYDROEXTRACTOR:-
Objective:- The basic objective of hydroextractor is to remove the
moisture from the wet hanks coming from the dumper, bleach line or
from roll dyeing machines.
MACHINE DETAILS:-
The complete lot is not loaded in one go; instead the material is
loaded intermittently . First, some material is loaded and the
machine is run for some time .This makes the material recede
back thus making way for more material to be loaded. After the
entire material is loaded in this manner ,the machine is
continuously run for 30 mins.
Each machine consists of 3 shock absorbers which absorb the
effect of vibrations occuring due to rotation of machine at high
speed. If the vibrations exceed beyond a safe limit ,the machine
touches the feeler of the shock absorbers which ultimately stop
the machine automatically.
Hand brake:- The hand brake is provided so as to gradually
bring the machine to a stop. The machine runs at a high speed so
as to be stopped gradually.
STEAM DRIER
Objective of steam drier:- The material from the hydro extractor
is transferred to the steam drier where it is dried completely.
R.F. DRIER
Introduction:
In radio frequency drying systems, RF generates an alternating
electric field between two electrodes. The material is dried in
packages form. It is placed on a conveyor belt. When the belt moves
forward , materials come in between electrodes where the water
molecules continuously re-orient themselves to face opposite poles
much like magnets would move in alternating magnetic field. This
causes the complete removal of water.
By means of radio frequency waves, heat develops inside the material
in a quantity that is proportional to the water dispersed in it. In fact
water molecules subject to an electric field are polarised in the
direction of the electric field: in an alternate electric field, each field
displacement corresponds to an inversion of the polarisation direction.
Water molecules in an alternated electric field, each field
displacement corresponds to an inversion of the polarisation direction.
Water molecules in an alternated electric field are forced to displace
by oscillating with the same frequency of the field, thus dissipating
energy by effect of molecular friction.
BERTA HYDROEXTRACTOR
Machine Capacity Rpm
Machine 1 36 packages 1470
Machine 2 48 packages 1440
coil.
The tank is fitted with a temperature indicator and control sensor.
There is an array of SS rollers /poles which are fitted on a suitable
frame.
The roller can rotate both sides direction (clockwise and
anticlockwise direction ) with the gear arrangements .The machine is
fitted with a stop /start system to control the roller movement.
The hanks loaded on rollers can be lowered in the tank or lifting out
by lifting or lowering frame with the help of hydraulic system. The
speed (rpm) of roller can be varied by changing the gears and
rotation cycles are controlled by timers which change the direction of
movement of motors .
The dyeing vat has the filling and draining facility of dye liquor . The
dyes and chemicals are added directly into the dye vat.
22 7 70 84 105
23 3 30 36 45
24 3 30 36 45
25 1 10 12 15
26 1 10 12 15
27 1 10 12 15
PROCESS FLOWCHART
Hot wash (10 min. In 1:10 MLR)
↓
Drain
↓
Dx treatment (10 min.in 1:12 MLR)
↓
Color solution supplied and Run 15-20 mins at 50-600C.
↓
Salt 10 minutes at 40°C
↓
Salt 10 minutes at 60°C
↓
Soda ash at 60°C
↓
Shade checking
Shade matching
Drain
↓
Ricofix-NF dye fixer
↓
Drain
↓
Softener
↓
Drain
↓
Unloading
Drain
Dyefix (Ricofix-NF )
Drain
Softener
Unloading Drain
● No. Of machine : 4
● Speed= 600 rpm
● Pressure = 2.5 kg/cm2
●MLR = 1:12 to 1:15
Machine details:
● It is a fully closed chamber.
● Main dyeing vessel made of stainless steel.
● Carrier for loading of hanks with stainless steel sticks for loading of
hanks.
● An internal axial pump or an external pump for liquor circulation.
● An indirect heating system, steam circulated in coils for heating
purpose.
● An addition tank with injector pump for colour addition manually.
● Preparation tank.
● An internal or external sampling device.
Process flowcharts :
Loading
↓
Hot wash
↓
Drain
↓
Water filling
↓
Caustic addition, 5 min. l/O, 5 min. O/l flow of liquor
↓
Hydro
↓
Colour supply within 45 min.
↓
Hold for 20 min.
↓
Temperatures raise up to 60°C
↓
Sodium thiosulphate addition
↓
20 min. Hold
↓
Sample checking
Ok Not match
Drain
↓
Cold wash
↓
Soda ash+ Peroxide treatment at 50-55°C for 20 min.
↓
Drain
↓
Cold wash
↓
Soaping at 90-95°C for 10-15min.
↓
Cold wash
Unloading
Dyeing process flowcharts :
Loading
↓
Water filling
↓
Add chemicals+Run
↓
H2O2+HPS+Base Past+F Bol at boiling temperature for 20 min.
↓
Drain
↓
Water filling
↓
Hot wash with RJK at 60°C for 20 min.
↓
Drain
↓
Water filling
↓
Salt+DS Run at R.T for 30 min.
↓
Colour supply within 45 min. & run at 60°C for 20 min.
↓
Soda ash supply within 25 min. & run for 30 min.
↓
Caustic soda supply within 20 min. & run for 1 hour.
↓
Drain
↓
Water filling
↓
Cold wash for 5 min.
↓
Drain
↓
Water filling
↓
Green acid at R.T run for 20 min.
↓
Drain
↓
Water filling
↓
PCS at boiling temperature for 30 min.
↓
Drain
↓
Water filling
↓
Drain
↓
Water filling
↓
Dye fixer + green acid at R.T for 30 min.
↓
Drain
↓
Water filling
↓
NIAS+Emulation +Green acid 1046 at 40°C for 30 min.
↓
Drain
↓
Unloading
Water filling
↓
Hot wash at 80°C for 15 min.
↓
Drain
↓
Water filling
↓
Treat with RJM+RJK at 60°C for 20 min.
↓
Drain
↓
Unloading.
● Neutralisation Process Flowcharts :
Loading
↓
Water filling
↓
Hot wash at 85°C for 15 min.
↓
Cold wash for 5 min
↓
Hcl treatment at R.T for 20 min
↓
Drain
↓
● Recipe :
● Chemicals for polyester dyeing :
1. Dye : As per shade
2. Stock solution (or, Green acid, Dispersing agent
Sequestering agent)
● Chemicals for reduction clearing
1. Sodium dithionite (Hydros)
2. Sodium hydroxide/Sodium carbonate
3. Thinowax WS
BOILER
1. Specifications :
● Make by : CATHER VESSEL LTD (CVL)
● Production : 8.3 Ton/hr.
● Pressure : 10.54 kg/cm2.
● Type : BI – Drum tube Boiler.
● Fluidised Bed combustion boiler.
● Raw material (Fue) : Rice Husk.
2. Air and Fuel Gases System :
● FD ( Forced Draft ) fan.
● PA ( Per Air ) fan.
● ID ( Induced Draft ) fan.
● Air pre heater.
● Spark pre heater.
● Boiler furnace.
● Bag filter.
● Stalk.
3. Fuel supply system :
● Rice Husk.
● Vibrator & Conveyer belt.
● Hopper.
● PA fan.
● Fuel nozzle.
4. Steam Supply System :
● Steam drum.
● Steam main head.
5. Bed material :
● Size : 2.36 mm – 0.85 mm.
● Composition : Almina 35-45 % , Silica 55-65 %.
● Fusion temperature – 1400°C.
6. Furnace :
● Bed size : 1350 × 2828 mm2.
● Bed hight : 700 mm.
● Heat input : 5684211 kCl/hr.
7. Heating Surface :
● Water fall : 86 m2.
● Bed coil : 30
● Bank tube : 166
8. Light up of Boiler :
● Whenever the boiler is started charcoal, kerosene & bed
material is used.
9. Features of Boiler :
● Super heated steam is produced here with temperatures of
800-850°C .
● In Boiler house steam having pressure of 10.54 kg/cm2 . But
in various department steam is required for lesser pressure
generally of 3.5-4.5 kg/cm2. Therefore PRV (Pressure
reducing valve ) is mounted.
● Steam reaches of various department of 30°C lesser Temp.
● In furnace for continuity of firing oxygen is supplied of 8 %
rate.
● 23-24 ton per day fuel is used .
● 6 Kg steam is used to dye 1 kg material.
● TRAP System is used to utilise maximum amount of steam.
● GCV (Gross Calorific Value) in KCl
Rice Husk 3400-3500
Coal – 4000
LPG Gass – 10000
10. Problems Occur During Operations :
● Start – up failure .
● Clinker formation.
● Choking.
● Adequate temperature not achieved.
● Lesser steam.
● Jerking feeder.
● Back flow of air throw.
● Leakage of steam.
● Scale formation.
● Bursting of pipe line.
Conclusion :