PP STAPLE FIBER ONE STEP PRODUCTION EXTRUSION LINE

PP STAPLE FIBER ONE STEP PRODUCTION EXTRUSION LINE

SATURN2505024

 

PP STAPLE FIBER ONE STEP PRODUCTION EXTRUSION  LINE

 

 

 EQUIPMENT CONFIGURATION AND QUOTATION

  1. General Description

This line is mainly used to produce PP staple fiber from the PP chips and powder. The finished product is PP staple fiber from 1.5 Den. to 15Den.

 

Technical Process

Pneumatic Raw Material Conveyer—Hopper—Screw Extruder—Filter—Melt Pipe—Spin Beam—Meter Pump—Spinning—Cooling Solidification—Oiling—Tow Guide—Stretcher—Hot Air—Stretcher—Stacker—Crimper& Oiling—Relaxing Heat Oven—Tow Guide Stand—Tension Device—Cutter—Pneumatic Conveyer—Baler

  • Main Technical ParameterScrew Extruder: 1set
  • Spinning Position: 6
  • Distance Between Adjacent Spinning Positions: 1100mm
  • Hole No. of Spinneret: 68000holes for 1.5 D-2D spinneret; 4.5D-8D 375000 holes;
  • Hole Type of Spinneret: Circular
  • Spinneret diameter: 630mm
  • Spinning Speed: 20-80M/min
  • Drawing Speed: 110M/min(max)
  • Draft Total Denier: 1400000D (Max)

 

The Structure and Main Parameter of Each Unit Machine

 

  1. Hopper with materialmixing system 1 set

This system is equipped with one main hopper and three masterbatch dosing system and mixing hopper group.

Three masterbatch dosing system and mixing hopper is controlled by 4 sets of inverters separately.

Synchronous with screw extruder main motor.

Each hopper equipped with alarm for low material level.

Each hopper bottom equipped with magnetic frame to avoid metal impurity flow into screw extruder.

  1. Screw Extruder:1 Sets

Specification of Screw: Dia.: 175; L/D: 30:1; with mixing nail at the meter zone.

Rotating Speed of Screw: 20-80rpm

Capacity: 600kg/hr(PP)

Power of Motor: 160KW

Speed Adjusting method: AC frequency conversion.

Heating Power: 118KW, totally 8heating zones, 7screw zones, 1 flange zone;

Equipped with stainless heat insulation cover.

  1. Filter 1 sets

Filtering Area: 3.5M2

Model: Horizontal double Switch

Max. Working Temperature: 25Mpa, two pressure checking points, one before filtering, one after filtering; one is for pressure self-control. One is for pressure indicating.

Filtering Precision: The buyer provides according to technical requirements;

Heating method: Electrical heating

Heating Media: Dowtherm oil;

Heating Power: 12KW

  1. Melt Pipe 1set

There is the static mixer inside the pipe. One purpose is to resolve the melt retain on inside of pipe, another is to make the melt mixed more evenly.

Thermal oil circulation layer is equipped outside with 2 temperature measuring point. One for temperature control and one for temperature display.

Heating Power: 40KW

  1. Spin Beam 1sets

Spinning Position: 1×6/set

Distance between two adjacent positions: 1100mm

Installation of Spinneret: Install from below, dolly type spinneret installation bed

Heating Method: Dowtherm oil

Heating Power: 68KW( each position heated and control separately)

Insultation material: aluminium silicate. Surface paint with high temperature resistance paint. Outside cover temperature ≦70℃.

Composition of Spinning Part: Spin beam, distribution plate, spinneret, filter net;

  1. Meter Pump Drive 6suit

Meter Pump Drive Consists of: Drive box, drive shaft, meter pump.

Power of Motor: 4KWsynchronous motor

Speed Adjusting Method: AC frequency conversion

Meter Pump Specification: 100cc/r

Six positions for each set.

  1. Central Blowingsystem: 6sets

Central Blowing Consists of: Blower, soft pipe, air transportation pipe, central blowing head

Working Process: the certain temperature cold air from the AHU is blown by the frequency controlled blower to meet the blowing speed requirement of central blowing. The air through the central blowing get through the tow to cool down it.

The quantity of the blower: 1 set/position;12 set in total.Power: 7.5KW; Speed Adjusting Method: AC frequency conversion.

Max. air volume: 3912m³X6,air pressure 4697pa.

Timing type: AC inverter.

Central Blowing Head: The blowing position is adjustable, the height of blowing also is adjustable.

  1. Oiling & Guiding Machine 1sets

Oiling type of Roll: double sides oilingwith double oil rolls;

Specification of Roll: ф110×600, surface coated withceramic.

Drive Type: each positionwith individual drive, power of motor: 1.1KW;

Speed Adjusting Method: AC frequency conversion;

Tow Guide Roller: Specification: ф118×600; Drive type; passive;

General Guide Roller: Specification: ф150×600; Drive Type: passive;

Oil Supply System: Oil tank, oil pump, oil pipe; the oil pump equippedwith  50L/min 3 phase pump, one in use, one stand by.

The surface of the frame: Stainless steel plate;

Spin Beam Frame: Main beam and main column adopt H type steel.

  1. First Stretcher 1 set

Drawing Roller No.: 7pieces; Specification: ф320×600， surface hard chromed.

Hard gear tooth, connect type for gear box and shaft: Tension jacket.

Press roller: 1 set. Specification：ф320×600

Bearing brand: Dalian metallurgy industries.

3mm mirror stainless steel plate for surface operation.

Lubrication System: Oil pump force lubricating;

The last two roller have anti-wrap equipment

Power of motor: 30KW ACvariable frequency motor.

Speed Adjusting Method: AC frequency conversion.

10.Water BathBox 1 set ( coiling heat steam)

Dimension: 2000×600mm

Material: Stainless steel

Way of liquid level control: by floating valve.

Automatic temperature control.

  1. Second Stretcher1 set

Drawing Roller No.: 7pieces; Specification: ф320×600

Hard gear tooth, connect type for gear box and shaft: Tension jacket.

Press roller: 1 set. Specification：ф320×600

Bearing brand: Dalian metallurgy industries.

3mm mirror stainless steel plate for surface operation.

Lubrication System: Oil pump force lubricating;

The last two roller have anti-wrap equipment

Power of motor: 75KW ACvariable frequency motor.

Speed Adjusting Method: AC frequency conversion.

  1. Steam Box 1 set ( coiling heat steam)

Dimension: 3000×600mm

Heating method: Steam with radiator, blower circulation.

Automatic temperature control.

  1. Third Stretcher 1 set

Drawing Roller No.: 7pieces; Specification: ф320×600

Hard gear tooth, connect type for gear box and shaft: Tension jacket.

Press roller: 1 set. Specification：ф320×600

Bearing brand: Dalian metallurgy industries.

3mm mirror stainless steel plate for surface operation.

Lubrication System: Oil pump force lubricating;

The last two roller have anti-wrap equipment

Power of motor: 110KW AC variable frequency motor.

Speed Adjusting Method: AC frequency conversion.

Max. Linear speed: 110M/min

  1. Pre-heat Steam Box 1set

Material: 2mm stainless steel

Spray: up and down cover balanced arrangement.

Pressure: 1.0MPa, working pressure≥0.3MPa

Specification: 2000×300

  1. Crimper1 set

Model: SZ655

Crimping wheel specification：ф200×200mm

Driving type： Individual

Driving power： 22kw AC variable frequency motor.

Timing type： A.C, inverter

Max. Linear speed: 110MM/min

Material of crimp roller: 4Cr13

This machine is equipped with steam heating box, fiber tow adjuster, oiling system.

16.Spreading Conveyor    1 set

Specification： 400mmX 35000mm

Driving power：1.5kw

  1. Relax and heating setter1 set

Working Width of chain plate： 1000 mm, material: stainless steel.

Effective length： 20000 mm

Section no.：10 sections with 4KW blower for each section.

Cooling section: 1 nos. Length: 3600mm, 2 sets of 5.5 kw blowers. 1set of 3kw Suction blower. 

Speed of chain plate ： 1—5 m/min

Heating media： STEAM

Exit part equipped with fiber guiding shelf.

  1. Tension Device 1 set

Tension Roller Specification: ф250×300; Drawing Power:1.5kw; 

Speed Adjusting Method: AC frequency conversion

Pressing Roller Specification:  ф200×300;  Hydraulic press type

Tension Roller Specification: ф120×300

Tow Guide Roller Specification: ф120×300

  1. Cutter 1 set

Model: CS-IIhorizontal type

Motor: 7.5 KW

Speed Adjusting Method: AC variable frequency conversion

Cutting Length of Fiber: 3-102mm, according to requirement.

  1. Pneumatic Convey System: 1 set

Including blower5.5kw, convey pipe.

  1. Baler 1 set

Singlechamber hydraulic type; weight of bale: 200KG.Installation power: 24.2kw.

  1. Electric control part
  2. Electric panel list

Spinning part control panelNo -control cabinet -Qty

1-Extruder driving  -1Set

2-masterbatch dosing system control panel -1set

3-Extruder heating (include connection box)-1Set

4-Gear pump driving (include operating box on the site)-1Set

5-Draw-off M/C control box-1Set

Draw line electric control box No -control cabinet -Qty

1-Draw line process step driving box（include operating box on the site） -4Set

2-Relax and heating setter control box-1Set

3-Cutter control box（include operating box on the site） -1Set

2Electric panel explanation

2.1 Extruder driving control box

This control box controls  driving of1Set Φ175extruder ，adopting melt-pressure display and alarm before filtrating, extruder motor is 160KW A.C inverter motor，the signals from post-pressure sensor to RKC-F900 adjuster，the adjuster adjusts the main signals of A.C inverter to alter the speed of extruder, and then the melt-pressure will be automatically controlled in closed loop，PID adjuster has manual andautomatic adjustment and they can exchange without disturbance，the mainframe inverter has interlock protection at failure，such as, if there were a blockage of filter, the pre-filtrating pressure would be above the setting pressure, then there is an alarm,the extruder motor will be stopped.  If there were a blockage of siphon (post-filtrating), the pressure of post-filtrating is above the setting pressure, and then alarm signal will control the extruder motor stopping swiftly. If there is shortage of material feeding, the post-filtrating pressure reduce, the PID adjuster will increase its output, thus the main signals of inverter increase, then the speed of extruder increase, the post filtrating pressure increase, finally to keep the post filtrating pressure stable to meet the requirement of spinning technology.

2.2 Extruder heating control box

This control box controls the heating of seven areas of 1sets extruder, flange area, filtrating area, syphon, spin beam. Heating power of seven areas is 12KW，flange area 12KW、syphon area 6KW、filtrating area 12KW, spin beam 56KW，adopting Japanese RKC temperature control instrument, solid relay，automatic air-switch, fast fuse to control the temperature of each zone.

2.3 Gear pump driving control box

This control box controls 6 Set gear pump driving motor, the motors are 5.5KW synchronousmotor，adopting6 Set 5.5KWSAMCOinverter to ensure the speed of each gear pump identical，there is a operating box in the spinning chamber to control the start and stop in time. There is one display instrument on the spot for each spin

pack.

2.5  Draw-off M/C control box 

This control box controls motors of oiling wheelsand oil pump: 1 Set0.55KW A.C. inverter, spin finish circling pump: 2Set A.C. 2.2KW inverter, 

2.6  Draw line process step driving box

This control box controls the running of three stretchers and crimper, adopting step driving、D.C altogether generatrix type，the first stretcher power:30KW, the second stretcher: 75KW，the thirdstretcher: 110KW inverter， 22kw for crimper. It adopt SAMMCO AC inverter and no-speed sensor vector control to assure the precision of draw ratio，adopting PLC and touch screen communication to control the given numbers. Conveyor motor: 1.5KW A.C inverte. normal A.C motor, spin finish cycling pump: 1.5Kw normal A.C motor.  Speed control among three stretchers、crimper、conveyor: speed chain control, draw ratio control is on the touch screen，speed up and down control by buttons. D.C generatrix adopts public brake unit and brake resistance. The lubrication pump has the protecting function of oil-supplying shortage.

2.7 Relax and heating setter control box

This control box controls the motor of chain plate conveyor ( 4KW)，adopting8 set blowermotor (each set 4kw) . The temperature control of each area of relaxes and heating setter is controlled by steam membrane valve aromatically.

  1. Electrical control panel detail explanation

3.1.All the control boxes adopt frame structure, surface plastic-spraying.

3.2. Main unit instrument: A.C contactor, Siemens 3TB and 3TF series; air-switch, Delix CDM10、DZ47 and DZ108 series，button、indicator light and knob, Jiangyin Changjiang LA38、AD11、LAY7 series，teperature control meter and pressure adjuster, RKC adjuster Japan; Fast fuse, Shanghai electric ceramic factory; other parts or apparatus, famous brand in domestic market.

3.3. The mark on the nameplate in control box adopts Chinese-English language.

3.4. In order to improve the ability to anti-jamming and easy to maintenance, double electric bridge frame is adopted on the site, i.e. the power cable and control cable is

  1. Engineering battery limit and supply scope
  2. Engineering boundary of supplier:

The supplier is responsible for the supply of equipment longitudinally from the feeding port of the vacuum dryer to the baler assembly and laterally from the first flange of the supplied line or the first piping connector.

  1. Engineering boundary of buyer

 

2.1Piping for general utilities: All kinds of pipes and their supports connecting to the first flanges or ports of the equipment supplied for water, finish oil, steam, compressed air air-conditioning. The installation support, hang frame and insulation material for the pipes, vacuum dryer etc.

2.2 Cables, bridges and auxiliary material from the power sub-station to the control cabinets of the equipment supplied and from the control cabinets to the IO point of the machine site.

2.3Auxiliary units, steel frame and other auxiliary material.

  • Engineering design division
  • Layout of equipment on each floor including loading
  • condition drawing of equipment foundation
  • Flow diagram of underground channel including width, depth, pipe support as well as embedded parts.

 

Draft for preparation of steel support structure for equipment as well as operation steel platform

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