NovaStar, NN238, SMS PP Spunbond Meltblown Nonwoven Production Line, 2400mm, 5000 Tons/Year (New)

Name: NovaStar, NN238, SMS PP Spunbond Meltblown Nonwoven Production Line, 2400mm, 5000 Tons/Year
Brand: NovaStar
SKU: G-3765

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Description

Process Flow
1. Additive (recycle edge)
2. Material → melting and extruding → filtering → metering → spinning → quenching → air-flow drawing
3. Material → melting and extruding → filtering → metering → spinning → hot air drawing → cooling → web forming → calendering
4. Material → melting and extruding → filtering → metering → spinning → quenching → air-flow drawing
5. → winding and slitting
Design Basis
1. SS system
  1. Raw material: polypropylene chips (melt index: 30-40 g/10 min, with variation not more than 1% for each batch; melt point: 166°C; ash content: <0.15-0.25%)
  2. Width of finished fabric: 2500 mm
  3. Single filament titer: 1.5-2.5 denier
  4. Annual output: 4300 tons (say 7200 hours per year, over 20 gsm)
  5. Web weight: 15-150 g per m²
  6. GSM variation: CV value less than 6%
  7. Extruder size: Φ130×32
  8. Flow rate of quenching air: approx. 2×20,000 m³ per hour
  9. Flow rate of suction air: approx. 2×35,000 m³ per hour
  10. No. of spin beams: 2
2. Melt blown system
  1. Melt index: 1200-1500 g/10 min
  2. Width of finished fabric: 2400 mm
  3. Annual output: 700 tons (say 7200 hours per year)
  4. Extruder size: Φ105×30
  5. Flow rate of suction air: approx. 35,000 m³ per hour
3. SMS system
  1. Width of finished fabric: 2400 mm
  2. Spec. of finished product: 20-150 g per m²
  3. Annual output: 5000 tons (say 7200 hours per year, over 25 gsm)
  4. Max. mechanical speed: 350 m per min
  5. Process speed: 20-300 m per min
  6. Installed power: approx. 1800 kW
Main Equipment
1. Spunbond section
  1. Material hopper: 2 sets
  2. Suction, dosing and mixing device: 2 sets
  3. Extruder: 2 sets
  4. Spinning machine: 2 sets
  5. Quenching and drawing system: 2 sets
  6. Edge recycle extruder: 1 set
  7. Web former: 1 set
  8. Winder: 1 set
  9. Slitter: 2 sets
  10. Steel frame for main machine: 1 set
  11. Electrical control system (excluding the cable and cable tray): 1 set
2. Melt blown section
  1. Storage hopper: 1 set
  2. Suction, dosing and mixing device: 1 set
  3. Extruder: 1 set
  4. Melt manifold: 1 set
  5. Die body (including spin pack): 1 set
  6. Electric (hot air) heating device: 1 set
  7. Movable steel frame: 1 set
3. Auxiliary equipment
  1. Pack oven: 1 set
  2. Pack ultrasonic cleaning machine: 1 set
  3. Lift for spin pack: 1 set
  4. Assembly and disassembly device for spin pack: 1 set
4. Utility equipment
  1. Chiller: 1 set
  2. Cooling tower for air-conditioner: 1 set
  3. Cooling tower for others: 1 set
  4. Air-conditioner: 2 sets
  5. Suction blower: 3 sets
  6. Cooling pump: 3 sets
  7. Chilling pump: 2 sets
  8. Compressed air system: 1 set
5. Spares (refer to VI spare parts): 1 set
Description of Units
1. Spun bond system
  1. Material hopper
    1. Efficient volume: 1 m³
    2. Main material: SS
  2. Suction, dosing and mixing device
    1. Function: chips are transported by a suction system from the ground to the dosing and mixing system on the third floor. Main material and auxiliary materials can be prepared as per a certain ratio. Dosing and mixing device, consisting of a main material tank, two auxiliary tanks, a mixing tank, a suction device.
    2. Technical data
      1. Adding ratio for additive I: 2-10%
      2. Adding ratio for additive II: 0.5-3%
      3. Max. feeding capacity for main material: 480 kg/hr
  3. Extruder
    1. Function: used to melt and extrude PP chips mixed with master batches and additives such as antioxidant, anti-pilling agent and flame retardant agent, including chip inlet, automatic temperature controls, cooling system and alarm system. Main drive employs A.C. frequency control. The temperature control for each zone adopts closed-loop system with West temperature meter, solid relay and PT100 platinum resistance.
    2. Technical data
      1. Screw size: Φ130×32, max. extruding capacity: 350 kg/h
      2. Rotary speed of screw: 20-70 r/min
      3. Dragging power: 90 kW
      4. Heating power: 84 kW
      5. No. of heating zones: 7
  4. Spinning machine
    1. Function: the melt coming from the extruder becomes filaments in the spinning machine, which consists of melt manifold, filter, metering pump and its drive, spin beam, monomer suction and spin pack. It has automatic heating and insulating system, pressure indication and control system behind filter screen and one static mixer in the melt manifold.
    2. Technical data
      1. Output: 2250 t/a
      2. Single filament titer: 1.5-2.5 denier
      3. Melt pre-filter
        
        Type: cylinder
        
        Filtering precision: 60 µm
        
        Diameter of screen: Φ149 mm
      4. Metering pump and its drive
        
        Metering capacity: 200 cm³/r
        
        No. of pump: 1 set
      5. Monomer suction device
        
        Motor power: 2.2 kW
        
        Total air pressure: 1160 Pa
        
        Suction volume: 2476 m³/h
      6. Spin pack
        
        Material of spinneret and distribution plate: SUS431 heat-resistance SS
        
        Holes no. of spinneret: approx. 12,950
        
        Diameter of spinneret hole: Φ0.5 mm
        
        L/D ratio: 5
  5. Quenching and drawing system
    1. Function: used for the cooling and drawing of filaments, including quenching chamber, upper drawing channel, lower drawing channel, and diffusion channel. Double-side symmetric quenching is employed, and the gap of the lower drawing chamber can be regulated as per the process requirements.
    2. Technical data
      1. Nominal working width: 2500 mm
      2. Quenching air volume: 20,000 m³/h
      3. Pressure: approx. 2500 Pa
      4. Effective working width of quenching chamber: approx. 2850 mm
      5. Effective working height of quenching chamber: approx. 600 mm
      6. Effective working width of upper drawing channel: approx. 2850 mm
      7. Effective working width of middle chamber: approx. 2850 mm
      8. Effective working width of lower drawing channel: approx. 2850 mm
  6. Web former
    1. Function: used to supply carrier for the drawn fiber webs, including a drive system for web forming belt, a suction channel device, a sealing device, an automatic correcting device, belt tensioning device, a frame and a pre-pressing roller, oil furnace and web support roll.
    2. Technical data
      1. Max. mechanical speed: 350 m/min
      2. Process speed: 20-300 m/min
      3. Air permeating ratio of web forming belt: approx. 8000 m³/h·m²
      4. Belt width: approx. 3000 mm
      5. Main drive: dragging power: 37 kW, A.C. frequency speed regulation
  7. Kuster calendar (buyer’s scope of supply)
    1. Function: used for bonding formed webs by pressure and heating.
    2. Technical data
      1. Process speed: 20-300 m/min
      2. Working width: 2800 mm
      3. Roller type: engraved upper roll and plain lower roll
      4. Drive method: individual motor for each roll
  8. Winder
    1. Function: used for winding the calendered webs on rolls. Including two plain rolls and two pneumatic rolls.
    2. Technical data
      1. Max. mechanical speed: 350 m/min
      2. Process speed: 20-300 m/min
      3. Working width: 2800 mm
      4. Max. winding diameter: 1200 mm
      5. A.C. frequency motor