This line uses polyester chips or bottle flakes as raw material to produce polyester fibers by means of drying, melting, filtering, spinning as well as quenching, oiling, feeding and filling with max. annual output of solid fiber of 15,000 tons.
This line consists of main production line, auxiliary production units and general utilities.
Specifications
Max. annual output: 15,000 tons per year (calculated as 1.56 dtex)
Denier of finished fiber: 6.67 ~ 16.7 dtex hollow fiber
Fiber types: hollow fiber
Spinning positions: 24
Spinning pitch: 650 mm
Specifications for spinneret: size Φ328 mm
Specification for metering pump: 70 cc/r
Mechanical speed for spinning line: 500-1500 m/min
Processing speed for spinning line: 500-1200 m/min
Max. mechanical speed for processing line: 240 m/min (based on the tension heat-setting machine)
Max. processing speed for processing line: 220 m/min
Max. draft denier: 200 × 104 dtex
Number of cans collected: 24
Package weight: 250-300 kg
Other specifications as per our attachments
Description Of Equipment And Process
General
Spinning equipment: HTM circulation system insulation enclosure, metering pump and its drive, spinning beam, quenching system, take-up machine, and can traverse mechanism
Auxiliary production units: disassembling, cleaning, assembling, preheating, ultrasonic cleaning of spin pack; spinneret detecting and sand preparation; finish oil preparation; air conditioning and ventilation; physical and chemical detection
General utilities: electric substation; water supply, compressed air system and others
Process Description
Spinning and taking-up: In the spinning plant, the polyester chips are melted and spun into tows.
The polyester chips or bottle flakes are carried into the screw extruder from the hopper after being dried. The melt coming out of the extruder goes into distribution pipes.
Two static mixers in the distribution pipes ensure even melt temperature uniformly and no invalid spaces.
Then the melt goes into spin beam in which the specially-designed distribution piping system guarantees the same dwell time for the melt to reach each spinning position.
The pin valve fixed before each spinning position ensures individual opening and closing of each spinning position.
After passing through distribution pipes, pin valves, and the metering pump, the melt flows into spin packs uniformly.
There are filter screen and filter sand inside the spin pack, which remove impurities from the melt. The melt becomes small stream after being extruded from the micro-holes of the spinneret.
The melt piping system and the spin beam are heated by HTM vapor from a HTM evaporator. The specially-designed vapor distribution system ensures uniform temperature on each spinneret.
This line has 3 spin beams, each having 8 spinning positions. That means there are 24 spinning positions altogether, with each spinning position fixed with a pin valve, a metering pump, a driving device and a spin pack.
In the quenching chamber, the melt stream is cooled and solidified by the uniform laminar cool air. Then the tow is carried to the take-up panel via the spinning tunnel.
On the take-up panel, the tow from each spinning position is finished by the spin finishes controlled by a static inverter, and then guided by a deflecting roller so that tows from 18 spinning positions become a bundle of tows. After the 6-roll draw-off machine controlled by inverters, tows go to the sunflower wheel and lay uniformly in the fiber can on the traverse mechanism.
A suction gun is used for tow string-up.
The spin finishes are supplied continuously to the oil preparation device of the take-up machine by means of an oil storage tank, an oil supply tank, an oil collecting tank and an oil input pump.
Automatic can-exchanging function is available for the traverse mechanism, so that regular can-exchanging can be realized automatically when the can is fully filled. The full can is carried to the creel frame by the fiber can transport cart.
Technological Description Of Auxiliary Process
Cleansing and preparation of spin pack: The spin pack, spinneret and metering pump are cleaned in a vacuum pyrolysis furnace. The spin pack changed from the spinning machine is disassembled immediately.
Then according to different types, they are put into different cleaning baskets which are sent by the hoist to the pyrolysis chamber of the vacuum furnace.
Then the pyrolysis chamber is closed and heated to 480 °C in two steps.
The mixture removed from the parts are collected by the collecting tank below the pyrolysis chamber. The smoke is condensed with steam when passing a suction device before it enters the vacuum pump. The pyrolysis chamber is vacated by a water-loop vacuum pump. After leaving the vacuum pump, the moist smoke enters a water-smoke separator device where the water flows into a sewer pipe and the effluent gas is exhausted into atmosphere by an exhauster after passing through an air pressure regulator and an activated carbon filter.
The spinnerets and the distribution plates are cleansed for the last time by an ultrasonic cleaning unit to remove remaining particles.
Finally all the cleaned parts must be dried by compressed air, tested and put into plastic bags as spares if they are qualified.
The cleansed pack parts, spinneret, filter screen, and the dried filter sand are put into the preheating furnace by the lifter to preheat as spares after they are assembled by the assembling tools.
Finish oil preparation system: The oil preparation system is used to produce finish oil of different density by mixing and diluting several kinds of oily mixture according to the different sections.
Before the finish oil is prepared, the selected ingredients are put into a metering and mixing tank at rather high concentration for premixing. The tank is fixed with steam-heated jacket to resolve cream matters.
The finish oil of higher concentration in the metering tank enters two oil mixing tanks by dead weight. Then it is diluted to required concentration by adding proportional dilution. During dilution, a stirrer is used to mix evenly the finish oil which is transported by the oil circulating pump to the oil storage tanks used for oiling at taking-up and the after processing line. The oil circulating pump is equipped with a mixture filter to remove impurities from the finish oil.
The finish oil in the storage tank drops to the places needing oiling by dead weight.
There is an oil feed tank between the storage tank and the taking-up where oiling is needed so that static head before the oil metering pump can be guaranteed. The feed tank is used together with an oil collecting tank, an oil transmission tank and an oil filter to form the oiling circulation system at taking-up.
