Ashish Gaurav

Mechanical Engineering 0902840023 Final Year

Group (A)

Training Agenda
About the Company Unit Production (Fiber, Decron)

Introduction on Boiler
Type of Boilers Boiler Used in Industry Reference

Reliance Industries
Shri Mukes D. Ambani chairman & Managing Director
Shri Mukesh D. Ambani is a Chemical Engineer from the Institute of Chemical Technology, Mumbai (earlier the University Department of Chemical Technology, the University of Bombay). He has pursued MBA from Stanford University, USA. He joined Reliance in 1981 and initiated Reliance's backward integration journey from textiles into polyester fibres and further into petrochemicals, petroleum refining and going up-stream into oil and gas exploration and production. He created several new world-class manufacturing facilities involving diverse technologies that have raised Reliance's petrochemicals manufacturing capacities from less than a million tonnes to about twenty million tonnes per year.

The Company is
Largest producer of Polyester Fibre and Yarn 5th largest producer of Paraxylene (PX) 5th largest producer of Polypropylene (PP) 8th largest producer of Purified Terephthalic Acid (PTA) Mono Ethylene Glycol (MEG) The Company has the largest refining capacity at any single location

VISION
To establish a centre of excellence for Research & Development in PET homo and co-polymer fibres and resins through disciplined motivated and time bound execution of projects. To closely interact with the business group companies and technical groups for short, medium and long-term quality and process issues. To create, maintain and pursue strategic research alliance for top end research activities Achieve 'Global leadership in Polymers, Fibres and Resin businesses'

To closely interact with the business group companies and technical groups for short, medium and long-term quality and process issues. To thrive to become a catalyst to the growth of company's polyester business. To create an environment conducive to intellectual growth, efficient flow of information and accountability in order to achieve a productive and sustained phase of research activities.

MANUFACTURING FACILITIES
Naroda Patalganga Allahabad Dahej Hazira Nagpur Jamnagar Barabanki

SWOT ANALYSIS OF RIL

Strength Technological Skills Distribution channels Production Quality High resource & surplus Unique growth visibility Weakness Failure in Forward Integration Un-utilised high resource & surplus Opportunities Increase in demand in Chinese & Indian market Gas from KG basin Local Indian market visibility & growth

Threats Possibility of 100 % FDI Windfall taxes Competition Government Products Manufactured Polyester Staple Fibre Polyester and Tow
Trade name Recon (Darlene) Installed Capacity 41000mt/tons per annum

CONTINIOUS POLYMERISATION

MANUFACTURING PROCESS OF PLANT

Pure Terepthalic Acid (PTA), Mono Ethylene Glycol (MEG) and carbon black are the main raw materials for the manufacture of Dope Dyed Black Polyester Staple Fibre.
In CP, PTA and MEG in the form of slurry react with each other in a specially designed etherification vessel. The PTA powder is unloaded into Feed Hoppers and is pneumatically transferred to the storage silo under nitrogen atmosphere. PTA powder flows by gravity from the storage into the mass flow hopper, which provides a constant supply of PTA powder to the screw feeder. The screw feeder controls the PTA feed rate to the slurry mix tank. Glycol is also metered and added into the slurry mix tank. The PTA slurry from the feed tank is injected into etherification reactor with the help of slurry injection pump.

 For Semi dull production the product called oligometer is injected with delustrant TiO2 and catalyst.
For the production of Black Fibre, Carbon Slurry is injected into Oligometer in a highly controlled quantity. Further polymerisation takes place in prepolymeriser and finisher employing high temperature and vacuum.

CHIPS/FLAKES ROUTE In the expanded capacity, PET Chips/ flakes and Master Batch(MB) CHIPS are used for production of Black polyester staple fibre. Chips/Flakes &MB chips are bought from market. PET flakes dried in drier under vacuum using steam as heating medium. MB chips are dried in a tumble drier. PET flakes and MB chips are melted and extruded in extruders.PET chips/flakes melt is passed through a set of filters and MB Melt is then injected into the clean PET flakes melt. This polymer is spun in the spinning machine.

SPINNING The polymer is fed directly into the spinning machine by a screw pump and passed through manifolds, blocks, metering pumps and extruded through spinnerts.This process is known as melt spinning and the product after this is called filaments. The spun filaments are quenched with air and spin finish is applied on the emerging filaments. These are collected in cans. This product is called undrawn tow. DRAW LINE

The undrawn tow is drawn, heat set crimped and dried. Spin finish is applied to the tow. The emerging product is called crimpled tow. It is directly passed to cutter for staple cutting and packed as bale or collected in cutter boxes. For the production of polyester tow, the undrawn tow is drawn, crimped and dried. Finish is applied and is collected in tow boxes at tow pack station at the tow baler.

CUTTER BALER/ TOW BALER

The crimped tow is cut to required staple strength and packed in bales and polyester tow for worsted industry is directly packed into bales. During processing, in all sections strict control is maintained over all parameters to achieve product quality, material efficiency and safety requirements as detailed in procedures.

Boiler ?
Boiler is an apparatus to produce steam. Thermal energy released by combustion of fuel is used to make steam at the desired temperature and pressure. The steam produced is used for: (i) Producing mechanical work by expanding it in steam engine or steam turbine. (ii) Heating the residential and industrial buildings (iii) Performing certain processes in the sugar mills, chemical and textile industries.

Types of Boiler used in Industry

1. Fire Tube Boiler 2. Water Tube Boiler 3. Fluidized Bed (FBC) Boiler

Fluidized Bed Combustion (FBC) Boiler

Particles (e.g. sand) are suspended in high velocity air stream: bubbling fluidized bed Combustion at 840 950 C Capacity range 0,5 T/hr to 100 T/hr Fuels: coal, washery rejects, rice husk, biogases and agricultural wastes

Benefits: compactness, fuel flexibility, higher combustion efficiency, reduced SOx & NOx

Fluidized Bed Combustion

Working Process of Rice Husk Boiler Fuel used in this boiler

RICE HUSK BASED BOILER USED IN RIL (BMD)

Boiler Feed Water Treatment

Quality of steam depend on water treatment to control
Steam purity Deposits Corrosion

Efficient heat transfer only if boiler water is free from deposit-forming solids

Internal water treatment

Chemicals added to boiler to prevent scale

Different chemicals for different water types

Conditions: Feed water is low in hardness salts Low pressure, high TDS content is tolerated Small water quantities treated

Internal treatment alone not recommended

External water treatment:

Removal of suspended/dissolved solids and dissolved gases Pre-treatment: sedimentation and settling First treatment stage: removal of salts Processes

Ion exchange
Demineralization De-aeration

De-aeration
Dissolved corrosive gases (O2, CO2) expelled by preheating the feed water Two types:
Mechanical de-aeration: used prior to addition of chemical oxygen scavengers Chemical de-aeration: removes trace oxygen

Vent Spray Nozzles

Boiler Feed Water

Mechanical deaeration
Stea m

Scrubber Section (Trays)

O2 and CO2 removed by heating feed water Economical treatment process

Storage Section

Vacuum type can reduce O2 to 0.02 mg/l Pressure type can reduce O2 to 0.005 mg/l
De-aerated Boiler Feed Water

Reference
www.google.co.in/ www.ril.com/ www.wikipedia.org/ http://www.scribd.com/