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Neumag, PP BCF S5 Plant - Variomelt, 2009, 6 Positions, 15 Tons/Day, Tricolor

Neumag, PP BCF S5 Plant - Variomelt, 2009, 6 Positions, 15 Tons/Day, Tricolor

Description

  1. Overview
    1. Neumag model PP BCF S5 plant – Variomelt yarn extrusion machine
    2. Year: 2009
    3. Products: PP / nylon 6
    4. Machine configuration: 6 positions, 3 ends per position, tricolor
    5. Production capacity: PP 15 t/day and nylon 9 t/day
    6. Product specifications: PP 1600 – 3000 den and PA6 800 – 1600 den
    7. Includes Atlas Copco air compressors (3000 m³/h) and Trane chiller (150 TR)
  2. Condition
    1. Excellent condition
  3. Configuration Details
    1. 6 positions
    2. 1/3 colors
    3. 3 ends per position
    4. Total 18 ends
    5. 3 extruders
    6. Pitch 1400 mm
    7. Polymer: PP, PA6, MFI 18-25, RV 2.6-2.9
    8. Titer range: 1600-3000 den, 800-1600 den
  4. Production Capacity – PP (Approximate)
    1. Titer 1600 dtex (1440 den), 6 ends/pos, take-up speed 2720 m/min, capacity 470 kg/h (6 pos.), 11 t/day
    2. Titer 2000 dtex (1800 den), 6 ends/pos, take-up speed 2550 m/min, capacity 550 kg/h (6 pos.), 13 t/day
    3. Titer 2440 dtex (2200 den), 6 ends/pos, take-up speed 2550 m/min, capacity 672 kg/h (6 pos.), 15.8 t/day (reference working point)
    4. Titer 3000 dtex (27000 den), 6 ends/pos, take-up speed 2200 m/min, capacity 713 kg/h (6 pos.), 16.8 t/day
    5. Titer 3700 dtex (3000 den), 6 ends/pos, take-up speed 1670 m/min, capacity 668 kg/h (6 pos.), 15.6 t/day
    6. Based on 98% efficiency and 24 h/day utilization
    7. Based on 333 days/year utilization
    8. Production speed can vary due to polymer quality, masterbatch content and crimp level
  5. Production Capacity – PA6 (Approximate)
    1. Titer 880 dtex (800 den), 6 ends/pos, take-up speed 3000 m/min, capacity 286 kg/h (6 pos.), 6.8 t/day
    2. Titer 1220 dtex (1100 den), 6 ends/pos, take-up speed 2850 m/min, capacity 376 kg/h (6 pos.), 8.8 t/day (reference working point)
    3. Titer 1330 dtex (1200 den), 6 ends/pos, take-up speed 2805 m/min, capacity 402 kg/h (6 pos.), 9.4 t/day
    4. Based on 98% efficiency and 24 h/day utilization
    5. Based on 333 days/year utilization
    6. Production speed can vary due to polymer quality, masterbatch content and crimp level
  6. Personnel Requirement
    1. 1 shift leader (temporary, skilled) – additional plants can be controlled
    2. 2 plant operators (per shift, unskilled)
    3. 1 textile laboratory (temporary, skilled) – additional plants can be controlled
    4. 2 maintenance (temporary, skilled) – additional plants can be controlled
    5. For start-up training and commissioning, additional personnel is required
  7. Energy Consumption
    1. Only the consumption of the Neumag delivery volume has been considered (without chiller, without compressor station)
    2. Electrical power: 0.8 kWh/kg yarn
    3. Compressed air: 3.7 m³/kg yarn
  8. Space Requirement
    1. Approximately 11.0 m x 14.0 m x 14.0 m (height x depth x width)
    2. Including space for switch cabinets
  9. Raw Material Supply
    1. 1 chips suction conveying system for filling silo (for PP)
    2. 1 chips storage system (silo)
    3. 1 central chips conveying system for feeding 3 extruders (for PP)
    4. 3 metering and mixing devices, type gravimetric (for PP)
  10. Spinning Equipment – For 3 Spinning Positions
    1. 3 extruders for PP, throughput each 70 to 250 kg/h
    2. 3 gauge heads, stainless steel
    3. 1 polymer distributing pipeline for 6 positions (including melt flow changing plate type Variomelt)
    4. 1 spinning beam arrangement 1 x 3 pos., pitch 1400 mm (heating system: Dowtherm vapour)
    5. 18 spinning pumps, 3 x 10 cm³/rev.
    6. 108 spin packs, round design (54 in operation, 54 on standby)
    7. 108 spinnerets, profile: trilobal, number of holes to be specified at design meeting (54 in operation, 54 on standby)
    8. 6 quench air chambers
    9. 1 air supply/exhaust system for 6 positions consisting of: 6 monomer exhausting nozzles, 1 monomer exhausting pipeline, 6 interfloor ducts, 1 air washer for 6 positions, 1 feed air distributing duct, 1 set of fans (1x cooling drum, flue gas and tangling, 1x texturizing device)
    10. 1 Dowtherm system for 6 positions
    11. 1 Dowtherm vapour generator 60 kW
    12. 1 quench air unit for 6 positions, air volume 32,000 m³/h, temperature controlled
    13. 1 chilled water tank
    14. 1 chiller (cooling power depends on local conditions and must be stipulated during the design meeting)
    15. 1 steel frame for 6 positions (structure laid out for accommodating extrusion system, spinning beam, manifold and quenching system, including handrails and stairs)
    16. 1 spin pack mounting and transporting device
  11. Texturizing System – For 6 Texturizing Positions
    1. 1 draw texturizing machine, type S5, pitch 1400 mm, 6 positions
    2. 1 compressed air supplying unit, inlet pressure 10 bar (compressed air supplied by customer)
    3. 3 threading injectors with controller station and hoses (supply pressure 10 bar)
    4. 6 yarn exhausting devices with air mover
    5. 6 spin finish application systems, type pin preparation, 2 rows
    6. 1 set of pre-tangling devices for 6 pos., 3 ends/pos.
    7. 6 cam roll systems with drives
    8. 6 yarn cut-off devices
    9. 1 set of godets for 6 pos., inductive heating, max temp. 220°C consisting of: 6 inlet godets with idler rolls (unheated), 6 draw godets with idler rolls (heated), 6 godet duo I (heated), 12 draw-off godets with idler rolls (unheated)
    10. 6 texturizing units, type friction principle, 3 yarn ends, polymer PP (texturizing medium: air)
    11. 6 air heaters, heating power 2.6 kW per yarn end