G-0784 RIETER FDY EXTRUSION EQUIPMENT FOR POLYPROPYLENE YEAR 1996/98

REFERENCE  NUMBER:  G-0784

RIETER FDY  EXTRUSION EQUIPMENT FOR POLYPROPYLENE YEAR 1996/98

 

1. Machine m26/39:

Year 1996

For 1 fdy spinning line with 2+4 positions, each position with 4 ends

Product:  fdy-yarn on bobbins

Raw material:  pp, dried filament grade chips

Yarn count range:  150 – 400 dtex

Winder speed for target:  4000 m/min

 

Machine technical data:

Position gauge:  800 mm

Spinning pump capacity:  4x10 ccm/rev

Spinneret size diameter:  95 mm

Quench width:  670 mm

Quench length:  1700 mm

Number of spin-finish pumps per position:  1

Capacity of spin-finish pump:  4x0.05 ccm/rev

Number of winders/position:  1

Type of winder:  riemat a6-094

Number of packages/winder:  4

Maximum package diameter:  420 mm

Package stroke:  190 mm

Package weight at 280 mm package diameter:  approx. 6.2 kg

 

Detailed technical specifications:

Extruder for 4 positions Year 1998:

 

1 extruder type e1. 105-30m:

-nominal extruder capacity:  max 275 kg/h for pp

-operational extruder capacity:  max 248 kg/h for pp

-screw diameter:  105 mm

-l/d ratio:  30

-barrel with:

                electrical ceramic heaters

                7 heating zones, each zone equipped with one 2xpt100

                heating zone capacity approx. 58 kw

                inlet zone, water cooled

                nozzle for nitrogen purge

                insulation

-screw with torpedo mixing head

-reduction gear, including belt transmission to motor

-dc motor, rated power approx. 95kw

-extruder frame

 

1 extruder measuring head, dowtherm vapour heated

-measuring head comprising:

                coarse filter

                insulation

-double pt100, one each for melt and dowtherm vapour temperature

-pressure sensors for melt pressure, one in front and one behind the coarse filter

 

1 melt distribution system, dowtherm vapour heated

-melt distribution system comprising

                main product pipe between extruder, measuring head and melt distributor.

 

Extruder for 2 positions Year 1998:

1 extruder type e1. 60-30

-nominal extruder capacity:  max 275 kg/h for pp

-operational extruder capacity:  max 248 kg/h for pp

-screw diameter:  60 mm

-l/d ratio:  30

-barrel with

                electrical ceramic heaters

                6 heating zones, each zone equipped with one 2xpt100

                heating zone capacity approx. 17 kw

                inlet zone, water cooled

                insulation

-screw nitrited with maddock mixing head

-reduction gear, including belt transmission to motor

-dc motor, rated power approx. 22kw

-extruder frame

 

1 extruder measuring head, electrically heated year 1998

-measuring head comprising:

                insulation

Double pt100, one each for melt and dowtherm vapour temperature

                                pressure sensors for melt pressure

                burst disc for power switch-off at overpressure.

 

1 melt distribution system, dowtherm vapour heated

-melt distribution system comprising

                main product pipe between extruder, measuring head and melt distributor.

 

1 riebeam bottom loading spinning beam year 1998

-beam comprising:

                welded-in pump blocks with bolted pump adapter plate

                silumin insulation blocks

                melt distribution pipes with polished inner surfaces

                efficient vapour heating on all sides of spin pumps

                optimized heat condustion to the spinnerets

                1 freezing valve upstream of each spinpump

                2 pressure sensors for measuring the melt pressure in front and behind the spinpump

                (2 per line)

                heating box, completely insulated

                heating by dowtherm vapour

                1 double pt100 for measuring and controlling the heating box temperature

Designed as follows:

-bottom loading of rieter quickfit spinpacks

-design temperature 320°c

-maximum allowable working pressure: 300 bar for melt pipe and 2.57 bar for jacket

 

Dowtherm evaporator and components for heating system:

-electrically heated, total capacity approx 25 kw

-shut-off valves

-drainage valves

-dry protection sensor

-magnetic controlled level gauge

- vent system on top of measuring head.

 

Poy spin packs, type rieter quickfit:

-max pressure in the spinpack:  350 bar

-design temperature:  320 °c

-spinneret outside dimensions:  95 mm

-bottom loading design

-bayonet locking, insert and tighten by turning 90°

-self sealing system

-sand or metal powder filtration, 3 cm filling depth

-wire mesh filters

 

Spin pumps with motors and gears:

Gear pumps, 4-fold

Capacity 4 x 6 ccm/rev

Each spin pump system comprising

Individual drive motor with flange connection to the reduction gear

Hollow gear shaft for installation of spin pump shaft

Shaft with shear pin protection

Reduction ratio 1:80

Pump speed:  8-30 rev/min

Motor type:  synchronous ac-motor

Rated power:  500w at 50 cps

 

Quench air cabinets bsk 670/1700:

Each cabinet comprising:

-rigid cabinet made from welded sheet metal, painted, side walls made from alu sheet metal

-air rectifier consisting of different layers of perforated metal sheets, rectifiers removable to the front for cleaning.

-1 perforated hinged door

-air inlet duct flanged with counter flange, comprising air flow regulating flaps

-interfloor filament duct, length 2000 mm

-alu chutes for start-up

-nozzles for connection of differential pressure gauge.

 

Spinning vapour exhausts:

-exhaust hood per spinning position for removal of spinning vapour

-hood designed as follows:

                made from stainless steel

                air flow regulation flap

                hood removable for cleaning

 

Take-up frames, type riedraw 1:

Welded steel frame, housing all drawrolls, compressed air supply pipes for the aspirator units and the yarn waste pipes within the fdy take-up unit.

Per position:

                4 inlet yarn guides

                4 spin finish application nozzles

                1 yarn cutter / aspirator unit

                1 spin finish pump

                4 centring yarn guides

                4 intermingling units

                rolls as described further

                1 automatic winder riemat a6-094

 

Drawrolls year 1998:

Mono 1 with 1 rievap 32 dual shell drawroll, type j7/32-40, ot40

Speed range:  750 to 4000 mpm

Roll diameter:  190 mm

Working width:  250 mm

Temperature range:  45-250°c

And 1 bearing separator roll, type srd60 hard chromium plated

 

Duo 1 with 2 rievap 32 dual shell drawroll, type j7/32-60, ot40

Speedrange:  1000 to 6000 mpm

Roll diameter:  190 mm

Working width:  250 mm

Temperature range:  45-250°c

 

Duo 2 with 2 rievap 32 dual shell drawroll, type j7/32-60, ot40

Speedrange:  1000 to 6000 mpm

Roll diameter:  190 mm

Working width:  250 mm

Temperature range:  45-250°c

 

Duo 3 with 2 cold draw roll units each type j7/45-55

Speedrange:  1800 to 5500 mpm

Roll diameter:  150 mm

Working width:  180 mm

 

Automatic and wasteless winder riemat a6-094

Spindle driven

Number of ends per winder:  4 ends

Yarn count range:  15 to 1000 dtex

Take up speed:  2500 to 5500 m/min

Chuck length:  900 mm

 

190 mm stroke, 420 mm outside package diameter

Package volume:  24.7 dm³

Tube bore:  94 ±0.2 mm

Tube outside diameter:  106 ±0.4 mm

Tube length:  225 ±0.5 mm

 

Oil-mist lubrication unit:

Compressed air distribution station

Mobile aspirator guns with hoses

Electrical control equipment

-for electrical power

                general:  3 x 380v/50hz plus ground wire

                euro-standard:  3x400v 50 or 60hz plus ground wire

                maximum voltage variation ±10% measured at terminals of cabinets

                maximum frequency variation:  ±2%

 

Process control system (cif):

                fully integrated control system to control and monitor the entire spinning line.

                the central monitoring unit si linked to the plc of the spinning section and the plcs of each spinning position.

 

Drive and heater control year 1998:

 

Spinning section:

Speed adjustment for the extruder motor is done via a dc-convertor

To achieve a constant pressure at the extruder outlet, the output of the pressure controller is transmitted to the dc-converter to adjust the extruder speed.

The feedback of the actual extruder speed is done by a tacho generator mounted on the extruder motor.

One common frequency inverter supplies the synchronous ac motors for the spin pumps.

According to process conditions, the plc transmits the setpoint to the inverter.

All motors are equipped with an overload protection.

Solid state relays heat each extruder zone and spinning beam.

Each extruder zone and the spinning beam represent an independent control loop.

 

Take-up section:

The inverter unit is a processor-controlled static frequency inverter for powering the 3-phase motors.

All inverter units in a position cabinet are supplied with approx 570v dc from a common rectifier.

 

Heating system:

The heating unit rhu is processor-controlled.

The power supply is taken straight from 3-phase 380/400v which powers the cabinet.

The inductor is fitted inside the draw roll.

The rhu switches the current on and off in this inductor. While current flows, a voltage is inducted into the

Rotating draw roll.

This sets up a short-circuit current in the draw roll, thereby heating the roll unit.

 

2. Machines m27/ 28 / 30 year 1998:

For 3 fdy spinning lines each with 2 positions, and each position with 4 ends

Product:  fdy-yarn on bobbins

Raw material:  pp, dried filament grade chips

Yarn count range:  150 – 400 dtex

Winder speed for target:  4000 m/min

 

Machine technical data:

Position gauge:  1000 mm

Spinning pump capacity:  4x7.5 ccm/rev

Spinneret size diameter:  95 mm

Quench width:  470 mm

Quench length:  1200 mm

Number of spin-finish pumps per position:  2

Capacity of spin-finish pump:  4x0.16 ccm/rev + 4x0,05 ccm/rev

Number of winders/position:  1

Type of winder:  riemat a6-094

Number of packages/winder:  4

Maximum package diameter:  420 mm

Package stroke:  190 mm

Package weight at 280 mm package diameter:  approx. 6.2 kg

 

Detailed technical specifications:

 

1 extruder type e1. 60-30m

-nominal extruder capacity:  max 80 kg/h for pp

-screw diameter:  65 mm

-l/d ratio: 30

-barrel with:

                electrical ceramic heaters

                7 heating zones, each zone equipped with one 2xpt100

                heating zone capacity approx. 22 kw

                inlet zone, water cooled

                nozzle for nitrogen purge

                insulation

-screw with torpedo mixing head

-reduction gear, including belt transmission to motor

-dc motor, rated power approx. 22kw

-extruder frame

 

1 extruder measuring head, electrically heated:

-measuring head comprising:

                coarse filter

                insulation

-double pt100, one each for melt and dowtherm vapour temperature

-pressure sensors for melt pressure, one in front and one behind the coarse filter

 

1 melt distribution system, dowtherm vapour heated:

Melt distribution system comprising:

                main product pipe between extruder, measuring head and melt distributor.

 

1 riebeam bottom loading spinning beam:

-beam comprising:

                welded-in pump blocks with bolted pump adapter plate

                silumin insulation blocks

                melt distribution pipes with polished inner surfaces

                efficient vapour heating on all sides of spin pumps

                optimized heat condustion to the spinnerets

                1 freezing valve upstream of each spinpump

                2 pressure sensors for measuring the melt pressure in front and behind the spinpump

                (2 per line)

                heating box, completely insulated

                heating by dowtherm vapour

                1 double pt100 for measuring and controlling the heating box temperature

Designed as follows:

-bottom loading of rieter quickfit spinpacks

-design temperature 320°c

-maximum allowable working pressure: 300 bar for melt pipe and 2.57 bar for jacket

 

Dowtherm evaporator and components for heating system:

-electrically heated, total capacity approx 18 kw

-shut-off valves

-drainage valves

-dry protection sensor

-magnetic controlled

-level gauge

-vent system on top of measuring head.

 

Poy spin packs, type rieter quickfit:

Max pressure in the spinpack:  350 bar

Design temperature:  320 °c

Spinneret outside dimensions:  95 mm

Bottom loading design

Bayonet locking, insert and tighten by turning 90°

Self sealing system

Sand or metal powder filtration, 3 cm filling depth

Wire mesh filters

 

Spin pumps with motors and gears:

Gear pumps, 4-fold

Capacity 4 x 7.5 ccm/rev

Each spin pump system comprising

                individual drive motor with flange connection to the reduction gear

                hollow gear shaft for installation of spin pump shaft

                shaft with shear pin protection

                reduction ratio:  1:80

                pump speed:  8-30 rev/min

                motor type:  synchronous ac-motor

                rated power:  500w at 50 cps

 

Quench air cabinets bsk 470/1200

Each cabinet comprising:

-rigid cabinet made from welded sheet metal, painted, side walls made from alu sheet metal

-air rectifier consisting of different layers of perforated metal sheets, rectifiers removable to the front for cleaning.

-1 perforated hinged door

-air inlet duct flanged with counter flange, comprising air flow regulating flaps

-interfloor filament duct, length 2000 mm

-alu chutes for start-up

-nozzles for connection of differential pressure gauge.

 

Spinning vapour exhausts:

-exhaust hood per spinning position for removal of spinning vapour

-hood designed as follows:

                made from stainless steel

                air flow regulation flap

                hood removable for cleaning

 

Take-up frames, type riedraw 1:

Welded steel frame, housing all drawrolls, compressed air supply pipes for the aspirator units and the yarn waste pipes within the fdy take-up unit.

Per position:

                4 inlet yarn guides

                2 spin finish application nozzles per end

                1 yarn cutter / aspirator unit

                2 spin finish pump

                4 centring yarn guides

                4 pre-intermingling jets

                4 intermingling units

                1 additional operator panel between duo1 and duo 2.

                rolls as described further

                1 automatic winder riemat a6-094

 

Drawrolls:

Mono 1 with 1 rievap 32 dual shell drawroll, type j7/32-40, ot40

Speedrange:  750 to 4000 mpm

Roll diameter:  190 mm

Working width:  250 mm

Temperature range:  45-250°c

And 1 bearing separator roll, type srd60

Hard chromium plated

 

Duo 1 with 2 rievap 32 dual shell drawroll, type j7/32-60, ot40

Speedrange:  1000 to 6000 mpm

Roll diameter:  190 mm

Working width:  250 mm

Temperature range:  45-250°c

 

Duo 2 with 2 rievap 32 dual shell drawroll, type j7/32-60, ot40

Speedrange:  1000 to 6000 mpm

Roll diameter:  190 mm

Working width:  250 mm

Temperature range:  45-250°c

 

Duo 3 with 2 cold draw roll units each type j7/45-55

Speedrange:  1800 to 5500 mpm

Roll diameter:  150 mm

Working width:  180 mm

 

Automatic and wasteless winder riemat a6-094:

Spindle driven

Number of ends per winder:  4 ends

Yarn count range:  15 to 1000 dtex

Take up speed:  2500 to 5500 m/min

Chuck length:  900 mm

 

190 mm stroke, 420 mm outside package diameter

Package volume:  24.7 dm³

Tube bore:  94 ± 0.2 mm

Tube outside diameter:  106 ± 0.4 mm

Tube length:  225 ± 0.5 mm

 

Compressed air distribution station:

Mobile aspirator guns with hoses

Electrical control equipment

For electrical power

                general : 3 x 380v/50hz plus ground wire

Euro-standard: 3x400v 50 or 60hz plus ground wire

Maximum voltage variation ±10% measured at terminals of cabinets

                maximum frequency variation: ±2%

 

Process control system (cif):

Fully integrated control system to control and monitor the entire spinning line.

The central monitoring unit si linked to the plc of the spinning section and the plcs of each spinning position.

 

Drive and heater control:

Spinning section.

Speed adjustment for the extruder motor is done via a dc-convertor.

To achieve a constant pressure at the extruder outlet, the output of the pressure controller is transmitted to the dc-converter to adjust the extruder speed.

The feedback of the actual extruder speed is done by a tacho generator mounted on the extruder motor.

One common frequency inverter supplies the synchronous ac motors for the spin pumps.

According to process conditions, the plc transmits the setpoint to the inverter.

All motors are equipped with an overload protection.

Solid state relays heat each extruder zone and spinning beam.

Each extruder zone and the spinning beam represent an independent control loop.

 

Take-up section:

The inverter unit is a processor-controlled static frequency inverter for powering the 3-phase motors.

All inverter units in a position cabinet are supplied with approx 570v dc from a common rectifier.

 

Heating system:

The heating unit rhu is processor-controlled.

The power supply is taken straight from 3-phase 380/400v which powers the cabinet.

The inductor is fitted inside the draw roll.

The rhu switches the current on and off in this inductor.

While current flows, a voltage is inducted into the rotating draw roll.

This sets up a short-circuit current in the draw roll, thereby heating the roll unit.

 

HOURLY PRODUCTION:

FOR 150 DENIER @ 3500 MPM WINDER SPEED, THE HOURLY PRODUCTION IS 3.5 KG/BOBBIN.

AS THERE IS 4 ENDS PER POSITION, THIS MEANS 14 KG/HOUR/POSITION

M26/39 ARE OF 2 + 4 POSITIONS; HENCE M26 = 28 KG/HOUR AND M39 = 56 KG/HOUR

M27/28/30 ARE OF 2 POSITIONS EACH, HENCE 28 KG/HOUR EACH.

(AS PER OUR PEOPLE AT THE EXTRUSION PLANT, THEY WERE RUNNING TRIALS TO PRODUCE THE 150 DENIER @ 4000 MPM WINDER SPEED)

 

FOR 300 DENIER @ 3600 MPM WINDER SPEED, THE HOURLY PRODUCTION IS 7.2 KG/BOBBIN.

AS THERE IS 4 ENDS PER POSITION, THIS MEANS 28.8 KG/HOUR/POSITION

M26/39 ARE OF 2 + 4 POSITIONS; HENCE M26 = 57.6 KG/HOUR AND M39 = 115.2 KG/HOUR

M27/28/30 ARE OF 2 POSITIONS EACH, HENCE 57.6 KG/HOUR EACH.

 

FOR 600 DENIER @ 2200 MPM WINDER SPEED, (SPEED LIMITATION DUE TO EXTRUDER CAPACITY) THE HOURLY PRODUCTION IS 8.8 KG/BOBBIN.

AS THERE IS 4 ENDS PER POSITION, THIS MEANS 35.2 KG/HOUR/POSITION

M26/39 ARE OF 2 + 4 POSITIONS; HENCE M26 = 70.4 KG/HOUR AND M39 = 140.8 KG/HOUR

M27/28/30 ARE OF 2 POSITIONS EACH, HENCE 70.4 KG/HOUR EACH.

 

MACHINE HAS BEEN PARTIALLY DISASSEMBLED (EXTRUDERS AND SPINBEAMS HAVE BEEN TAKEN DOWN TO GROUNDFLOOR) REST OF THE EQUIPMENT STILL TO BE DISASSEMBLED