Polyester Staple Fibre Process (PSF Mfg.

Plant)
Polyester Staple Fibre Process is broadly divided into three main sections of manufacturing
plant. They are CP, SPG & DL
 CP means continuous polymerization of raw material PTA (purified Terephthalic acid) &
MEG (Mono-ethylene glycol). Esterification and polymerization of PTA & MEG producing
polyester fibre.
 SPG where polyester polymer molt is converted to sold filaments for further process
 DL draw line is processing spun tow to maximum drawing extend up to 3 to 4 times
drawing for chain molecules orientation to get added strength to polyester fibre.
CP PROCESS

Esterifica

Polycond

CP: Continuous polymerization plant

There are two different silos for two different raw materials where MEG is solid powder type
and PTA is liquid. The ratio of mono ethylene glycol (MEG) to purified terephthalic acid (PTA) for
making polyethylene terephthalate (PET) resin is 30% MEG to 70% PTA. Each raw material is mix
in slurry mix preparation tank with standard ratio. One fixed mixing starrer is placed at the
centre of the tank vertically. CP capacity roughly 600 T/day
PTA/MEG slurry is prepared in slurry mix tank (1:2 mole ratio) and transferred to slurry feed
tank. Slurry is injected continuously into vapor separator. Here vapor Dowtherm heating is
provided for esterification, polymerization reaction vessels and all oligomer/polymer lines
H2O is removed from EG/water separation column and sent to operations Support Centre for
stripping off the low boilers
TiO2 slurry and catalysed glycol with Sb 2O3 & carbon if required is prepared and injected in
oligomer line. DEG is also injected for final product dye uptake per specification. After slurry
preparation (residence time 12/12 hrs) slurry fed to reactor vessel. After oligomer formation at
reactor, this oligomer fed to UPFF/Flasher.
UFPP vessel is combination of pre-heater, tray section, dome section which contains a big
bubble cap and loop seal for transferring material from UFPP to finisher. The main function of
UFPP is removal of glycol which is revolved during polymerization and thus building polymer
viscosity.
Next vessel is finisher where required viscosity of polymer is achieved. Finisher is horizontal
vessel with cage/screen type agitator both side of agitator shaft with glycol cooled double
mechanical seals. Finisher is connected with steam condenser through vapor line. Finisher
glycol circulating system with facility of filtration & cooling
Beneath the finisher polymer gear pump is provided for pumping polymer into polymer transfer
line connected to spinning department. This polymer transfer line consists of online viscometer,
diverter valves, booster pumps and manifold to carryout molten polymer to spinning line for
PSF production.
Esterification:
In the reactor -COOH group of PTA is reacted with -OH group of EG to form monomer and
oligomers. EG vapours & water are removed from vapour separator and are sent to separation
column where EG & water separated. The reaction between PTA and MEG occurs in two stages.
In the first stage one PTA molecule reacts with two MEG molecules to produce ester know as Di
Hydroxy Ethylene Terephthalate (DHET). This reaction is known as Esterification reaction and
water is the byproduct of this reaction. In the second stage ester formed (DHE) serves as
monomer and polymerizes to produce polymer known as Poly Ethylene Terephthalate (PTA).
The second reaction is known as Polycondensation reaction. In this reaction MEG is liberated.
Oligomer is pumped to UFPP through an oligomer filter. It is mixed with EF in 1:2 mole ratio in
slurry mix tank and pimped through slurry feed tank to reactor which comprises of heat
exchanger & vapour separator.
Polymerisation:
In UFPP oligomer is polymerised and EG is removed. The degree of polymerisation is increased
to 12 (approx.) EG liberated here is condensed in spray condenser. Pre polymer is sent to
finisher which is operated at 290°C.
The reaction in finisher proceeds at very high shear provided by specially designed screen type
agitators. EG liberated is evacuated out and is sent for recycling. Polymer coming out of finisher
has viscosity of 2500 poise and DP around 100. This polymer is then sent to spinning section for
polyester staple fibre manufacturing.
 PSF SPINNING

PSF spinning process is mainly converting

polymer melt to filaments through fine holes
spinnerets. Polymer melt can be feed directly
from CP to SPG by gear pump through
jacketed pipeline where hot Dowtherm oil is
used to maintain polymer molt temperature
(300°C) up to spinning manifold. Otherwise,
PET chips can be feed attached extruder
where solid polyester chips can be melted and
feed to spinning manifold. Polymer molt is
distributed to all 64 positions through
manifold. Metering pump is placed in every
position to control and measured quantity
polymer molt to spinning pack. This spinning
pack is used for filtration of polymer and
removal of polymer dusts, air bubbles and
unreacted monomer.

Spinneret is fixed bottom side of spin pack. Hot melt is passed through spinneret and become
solidify with diffuser child air (19°C). Here child air is flowing radically to all filaments without
any air turbulence. Chances of filament fusion is high here if non uniform flow child air within
diffuser chamber. Extra percussion is required for schedule change of spin pack and diffuser
within standard schedule. Then after filaments are chilled with cross flow cold air. By this
process liquid polymer molt converted to sold polyester filament. Spin finish is applied here for
further process without any static charge or less friction with machine parts.
All 64 positions tow materials are accumulated into a single tow by tie-in device. Then after
little drawing pushed it to spinning cans by take up spool roll.
Different spinnerets are used for different denier. Spinning parameters are depends on final
denier of the product
Spinning speed 1400 m/min
Spin block temp 287°C to 300°C
Through put depends on denier
Spinneret as per dinner. Fine holes for fine denier & vice versa
Melt DEG content 0.95
Melt viscosity 0.6 to 0.7 dl/g
Melt L Col ≥ 92 & b Col ≤ 1.0
 FIBER DRAWING/FINISHING LINE
Main units of fibre drawing line
PSF draw line composed of many modules synchronised with instrument drive as mentioned
below.
The main function of PSF draw line are
 Drawing with chain molecule orientation
 Crimping impression for making spun yarn
 Shrinkage ultimately
 Textile finish application &
 Cutting the tow band to fibre
 Can-type creel:
It is combination of spinning cans filled with tow with same type of material. More cans
are required for micro denier and less for courser denier. All cans contain 1 MT
materials. Regular supervision is always required for withdrawal of material from cans.

 Top guide creel:

Top guide ceramic rolls are guiding tow band down to draw line feed stand. It plays an
important role to process withdrawal of tow band from every cans.

 Bottom guide creel:

It is turning tow band 90° down to draw line and plays interphase top floor to bottom
floor

 Finger guide stand:

This stand is fixed many eyelet guides for each and every tow bands to separate and
uniform distribution of tow band to draw line rolls surface

 7 rollers tow guiding stand:

This is the first module of draw line beginning and important role of uniform feeding of
tow bands to all draw module

 Immersion bath:
This is water bath of rom temperature. The main function of this bath is to increase
cohesion of every filament of tow band for uniform drawing

 Draw stand I:
This first draw module of 7 steam heated rolls and one nip roll to hold tow band for
proper drawing. Main tow drawing almost ⅔ is taking place between draw stand I and
draw stand II.

 Draw bath:
Draw bath contains water with 80°C to 100°C temperature. Main function of draw bath is
to soften and playable two band to convert for drawing. Actually, drawing cannot be
possible if tow band is hard as it will be torn when drawing.

 Draw stand II:

It is intermediate draw module between draw stand 1 and draw stand 3. This module
contains 7 steam heated rolls for proper drawing and one nip roll to hold tow band for
proper drawing. 1st drawing is done here between draw stand 1 and draw stand 2

 Steam Chest:
To convert tow band softer and more playable live and coiled steam is used here. After
passing through this steam chest tow become soft and more playable for suitable
drawing.

 Draw stand III:

This is final draw module and 2nd drawing is done here between draw stand 2 and draw
stand 3. Here tow temperature reached up to 110°C. After this process final stage chain
molecules orientation taken place with increase of tensile properties. Actually, chain
molecules orientation converts from amorphous to crystalline state.
 Annealer:
This module contains 18 big diameter steam heated rolls for heat setting. All 18 steam
rolls are divided into three zones. 1 st zone temperature is between 110°C to 130°C. 2 nd
zone temperature is between 135°C to 175°C and 3 rd zone temperature is between 180°C
to 210°C. This heat setting is required to arrest further stretching of tow band. Means
there is chance to disturb chain molecule orientations from crystalline to amorphous
option without heat setting.

 Spin finish spraying machine:

As first stage spin finish is washed out at immersion and draw bath so again spin finish
application is done here for further smooth processing later state at textile process just
after annealer module.

 Roll-type cooler:
Just after annealer tow temperature is very high nearly 180°C. So, tow is moving here
within six cold rolls with atmospheric condition. And finally tow temperature reduced to
room temperature.

 Tow stacker:
Tow width is compressed here into three layer and finally tow width reduced to ⅓ to the
original width. This reduction is mainly looking to crimper width. Three layer of tow
band stacking done here.

 3 rollers dancing stand:

This dancing module is to imply tension to the tow band before crimper processing.

 Pre crimper steam chest:

Before crimper impression tow is requires to be softer and more playable. Hence pre
crimper steam chest is required to become tow softer and more lenient. Here 4.5 bar live
steam is sprayed on directly tow band.

 Crimper:
Crimper has box with upper plate and down plate. In action upper plate is open for tow
packed into the box and then upper plate push down the tow within the box for a while
and push forward tow band with zigzag impression. Flat fibre can not be mix-up with
cotton or viscose for making spun yarn. So, this impression is required for making spun
yarn.

 Tow stacker or spreading conveyor:

This device spread the tow over dryer belt horizontally for drying and final shrinkage.
This device is oscillating over dryer belt and spread the tow band uniformly on dryer
belt.

 Dryer:
The main function of dryer is drying the tow band before cutting and simultaneously
shrinkage of tow band too. Steam coil hot air is blown here to dry the tow band. 4.5 bar
steam line is connected to dryer. Here tow temperature is increased up to 100°C. dryer
zone is also divided into three zone according to temperature.
 Knot detector:
Tow knot is removed here before processing at cutter blade. Hence knot detector is
identifying the knot on tow and stop the cutter for removal it manually.

 Tow tension stand:

It implies tension on tow band to avoid loose tow inside cutter for uneven cutting. This
tension stand is very much required for required cutting length as per customer need.

 Cutter:
Cutter blades are placed vertically with equal distance as per cutting length. Different
cutter reels are used for different cutting length. Standard cutting length are 32 mm,
40mm, 44mm, 51mm etc.

 Baler
Baler plays an important role of packing the compressed bale with standard weight. PP
made top & bottom laminated waterproof capsule bags are used for bale packing. Every
baler has two boxes. One for packing the material manually and another one is polyester
cut fibre filling purpose.

Baler
Through conveyor belt bales are send to warehouse for storage stacking and send to customer
end through Lorry & tucks. Containers are used for ship export to foreign countries.