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MITSUBISHI Heavy Industries BOPP production plant of Age 1999 |
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AS
EXCLUSIVE REPRESENTATIVE FOR THIS PROJECT WE OFFER AS FOLLOWS: |
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MACHINERY AND
EQUIPMENT |
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1. One Biaxial Oriented Polypropylene Plant (BOPP) 6,300 mm width 250 meters p/min. MHI ,Mitsubishi Heavy Industries, Ltd, Age 1999 2,000 kg/hr max. Output
extruder capacity, 1, 700 kg per hour finished product rated capacity. |
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DESCRIPTION OF THE PROCESS Biaxially Oriented Polypropylene (BOPP), Plain or Composite film with 2 or 3 layers in B/A/A, B/A/B, B/A/C configuration. |
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(1) Resin to be used; (a) For base layer : Polypropylene homopolymer (b) For skin layer : Ethylene-propylene copolymer |
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(2) Film thickness range; (a) Plain film : 12 – 50 microns (b) Composite film : 15 – 40 microns |
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Production Capacity (On mill roll basis, Line capability) Typical capacity of mill roll film is shown as follows: Film Line Production capacity Annual capacity Thickness speed per one hour at 7000 net hours (Micron) (M/min) (Kg / h) (Ton / year) 12 200 816 5,712 15 250 1,275 8,925 20 250 1,700 11,900 30 166.6 1,700 11,900 40 125 1,700 11,900 50 76 1,292 9,044 Extruder Output : (1) Main Extruder : Max. Approx. 2,000 kg / hr (2) Satellite Extruder : Max. Approx. 180 kg / hr / set x 2 sets Max. Total: 2.000kg/hr General Specification (1) Dimension of Finished Film (a) Width : Max. 6,300 mm (b) Thickness Plain film : 12 – 50 microns |
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Composite film : 15 – 40 microns (2) Mill roll diameter : Max. 1,200 ø mm (3) Machine speed (a) Before orientation : Max. 60 m / min. (b) After orientation : Max. 260 m / min (4) Draw ratio (a) Longitudinal direction : 1 : 1 – 1 : 7 (b) Transverse direction : 1 : 7 – 1 : 10 (5) Operation side Film flows from left to right when standing at the operation side. (6) Dimension of BOPP LINE (Net machine size) (a) Total length : approx. 100 m (b) Width : approx. 13 m (c) Height : approx. 5.1 m |
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1.1. Polymer Receiving Area Polypropylene virgin pellets, reclaim pellets, and master batch pellets are unloaded into the receiving hopper and transferred to their respective silos by these equipments: Main Equipment: 1. Unloading hopper 1.5 cu. Meter 1 set 2. Rotary valve Capacity 10 tons / hour 1 set 3. Blower Roots type, 30 kW 1 set 4. Diverter valve Air operated Stainless cast iron 5 sets
1.2. Polymer Storing Area Raw materials are loaded and stored in their respective silos to ensure the continuous supply of polypropylene resins needed for the film production.
Main Equipment: 1. Storage silo for virgin pellet 50 cu. Meter 2 sets 2. Storage silo for reclaim pellet 50 cu. Meter 2 sets 3. Storage silo for master batch pellets 15 cu. Meter 2 sets |
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1.3. Mixing Area The silos for virgin pellets, master batch pellets, and reclaim pellets are connected with pneumatic conveying tube and the pellets are mixed in the tube during transportation. The screw feeder and rotary feeder control the mixing ratio of the different kinds of pellets. Then they are dried by a hopper drier.
Main Equipment: 1. Blower Roots type 15 kW 1 set 2. Rotary feeder Capacity 3 tons / hr 2 sets 0.6 tons / hr 2 sets 0.5 tons / hr 2 sets 3. Screw feeder Capacity 0.5 tons / hr 2 sets 4. Cushion chamber 100 liter 1 set 5. Rotary valve 3 tons / hr 1 set 6. Hopper drier 7 cu. Meter 1 set 7. Blower and heater Heater 110 kW Motor 30 kW 1 set
1.4. Raw Material Feeding Area After dried by the hopper drier, pellet materials are mixed with fluffs coming from edge trim crushing and feeding equipment and then sent to the feeding hopper mounted just above a main extruder. Main Equipment: 1. Blower Roots type, 18. 5 kW 1 set 2. Rotary valve Capacity 3 tons / hr 1 set 3. Cushion chamber 45 liter 1 set 4. Rotary valve Capacity 3 tons / hr 1 set 5. Feeding hopper with agitator 2.4 cu. Meter Motor 7.5 kW 1 set |
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1.5. Edge Trim Crushing and Feeding Area Film edges are slitted by the trimmer and are fed into the crusher through a conveying tube by a blower with suction filter. The conveying blower feeds fluff granulated by the crusher into the agitator hopper.
Main Equipment: 1. Blower Turbo type, 15 kW 1 set 2. Ejector Stainless steel 1 set 3. Crusher Capacity 350 kg / hr 1 set 4. Blower Turbo type, 15 kW 1 set 5. Cushion chamber 50 liter 1 set 6. Rotary valve Capacity 350 kg / hr 1 set
1.6. Auxiliary Raw Material Feeding Area This is a separate feeding system for the two satellite extruders. Raw materials and master batch are blended by automatic blender then delivered to the feeding hopper of the satellite extruder by means of auto loader. Raw materials without master batch are delivered to another satellite extruder by means of auto loader.
Main Equipment: 1. Storage hopper Capacity 1 cu. Meter 2 sets 2. Auto – loader Vacuum suction type 200 kg / hr 2 sets 3. Feeding hopper Capacity 0.2 cu. Meter 2 sets |
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1.7. Extrusion Area ( Tandem Extruder) The Tandem Extruder consists of two extruders coupled in a series. Each extruder has its own function: the Primary one is for melting, while the Secondary one is for metering, cooling and mixing.
1.7.1. Primary Extruder – Single Screw, 135Ø diameter, 68 kW Heater
Description Specification Model HME – 135 Screw Diameter 135 mm Screw Speed 30.2 – 393.9 rpm Screw L / D ratio = 20, including feed throat portion. Screw is special mixing type (HM screw). Material, Cr – Mo alloy steel. The surface is hard – chrome plated. Top of the flight is flame hardened. Cylinder Cylinder is made of nitrided steel and internal surface is honed. Drive Transmission Heavy duty helical gears and radial bearing are enclosed in the transmission which has its own integral case. Oil cooling unit including heat exchanger, pump, and strainer is provided, and oil temperature gauge and sensor of oil pressure are installed in the piping line. Feed Throat: Feed throat is made of cast iron and jacketed for water cooling. All resin – passage is hard – chrome plated. Heating and cooling unit Each zone of the cylinder is controlled for cylinder individually by resistance heating and water cooling system. Aluminum cast – in heater jacket. Cylinder: 5 zones Flange: 3 zones Drive Motor 550 kW DC motor. Speed: 115 – 1,150 rpm Constant Torque 1,150 – 1,500 rpm Constant Power
1.7.2. Secondary Extruder - Single Screw, 175Ø diameter, 107 kW Heater
Description Specification Model HME – 175 Screw Diameter 175 mm Screw Speed 11.6 – 152 rpm Screw L / D ratio = 20, including feed throat portion. Screw is conventional type. Material, Cr – Mo alloy steel. The surface is hard – chrome plated. Top of the flight is flame hardened. Cylinder Cylinder is made of nitrided steel and internal surface is honed. Drive Transmission Heavy duty helical gears and radial bearing are enclosed in the transmission which has its own integral case. Oil cooling unit including heat exchanger, pump, and strainer is provided, and oil temperature gauge and sensor of oil pressure are installed in the piping line.
Heating and cooling unit Each zone of the cylinder is controlled for cylinder individually by resistance heating and water cooling system. Aluminum cast – in heater jacket. Cylinder: 4 zones Flange: 1 zone Drive Motor 250 kW DC motor. Speed: 115 – 1,150 rpm Constant Torque 1, 150 – 1,500 rpm Constant Power
1.7.3. Connection Pipe The Primary Extruder is connected with Secondary Extruder by a connection pipe. Description Specification Material Carbon Steel Heating Resin Passage is chrome plated.
1.7.4. Satellite Extruders This extruder is equipped for skin layers of film. Description Specification Model ME – 90 Screw Diameter 90 mm Screw Speed 10.4 – 136 rpm Screw L / D ratio = 29, including feed throat portion. Screw is UB type (Barrier Screw). Material, Cr – Mo alloy steel. The surface is hard – chrome plated. Top of the flight is flame hardened. Cylinder : Cylinder is made of nitride steel and internal surface is honed. Drive Transmission Heavy duty helical gears and radial bearing are enclosed in the transmission which has its own integral case. Feed Throat: Feed throat is made of cast iron and jacketed for water cooling. All resin – passage is hard – chrome plated. Heating and cooling unit Each zone of the cylinder is controlled for cylinder individually by resistance heating and water cooling system. Cylinder: 5 zones Drive Motor 75 kW DC motor. Speed: 115 – 1, 150 rpm Constant Torque 1, 150 – 1, 500 rpm Constant Power 1.8. Filter Area The area wherein the melt pass through a screen pack and the solid and unmelted foreign materials are filtered out. It is being mounted between the extruder and the T-die.
1.8.1. Main Extruder Filter This screen changer is installed between the extruder and die. The contaminated screen pack can be changed. The multi-disc type filter, which has larger size of filtered area, is provided on the line of the main extruder. Description Specification Type Multi-disc type Filtering area 1.9 sq. meter Heating equipment Band Heater 4 zones A filter element including multi-discs, center pole and cap is provided as a stand-by preparation. A heating device for spare of multi-disc filter is provided.
1.8.2. Satellite Extruder Filter A cylindrical filter is used to filtrate the melt extruded into the satellite extruder. This filter has also the large filtrating area. Description Specification Type Cylindrical type Filtrating media Screen Filtrating area 254 sq. cm. Heating Electric heater : 4.2 kW 1 zone
1.9. Die Area The die converts a tube of molten polymer into a flat sheet by means of a manifold in shape of a “T”. It transfers the melted resin from the extruder in specified thick sheets to the casting roll. The satellite extruders also have their own channels that join the core sheet in the die assembly. Description Specification Type Three cavities T – Die with flexible lip Width of lip 920 mm Gap of lip 2.4 + 0.7 mm Gauge Adjustment Flexible lip can be adjusted with 31 heat bolts of push – pull type by manual operation and electrical heating by APC unit. Heating For heat bolt Sheath heater 31 zones For die body Aluminum cast – in heater 10 zones All resin passage is hard – chrome plated. Adaptor between the extruder and the die are provided. Heating For Main Extruder 5 zones For Satellite Extruder 3 zones x 2 units SEE EUROTHERM AUTOMATIC THICKNESS CONTROL MODEL 2004 UNDER 1.13
1.10. Casting Area After extrusion, Chill Casting is being achieved by rapid cooling of the molten web to the desired level of crystalline and by proper uniform pinning of the melt to the chill roll. The rollers and the water spray unit are so arranged that the sheet is cooled quickly and evenly from both sides and a uniformity of flat sheet can be obtained. A cooling roll, a water spray unit rolls, an air knife and a driving device are installed on the frame with wheels, which can be moved by a motor toward line direction along rails. Description Specification Machine speed 6 – 60 m/min. Cooling roll One 1, 300 dia. X 1, 300 L Hard – chrome plated, double shell type jacketed. Nip roll One 200 dia. X 1, 300 L Rubber covered, air operated. Guide rolls Five 200 dia. X 1, 300 L Hard – chrome plated. Take – off rolls One 300 dia. X 1, 300 L Hard – chrome plated One 200 dia. X 1, 300 L Rubber covered, air operated Air Knife The slot gauge of air is adjustable by means of the push – pull bolts. The position of air knife can be adjusted by handle. Slot length 1, 000 mm Blower 11.5 cu. m / min., 11 kW Driving device 5.5 kW I.M. with V.V.V.F. control (cooling roll). 1.2 kW I.M. with V.V.V.F. control (Take – off roll). Temperature control unit Control zone 2 zones Temperature range 20 – 80 deg C / 20 – 40 deg C.
1.11. Longitudinal Stretching Area (MDO) The Longitudinal Stretching Process (MDO) is by hot rollers using speed differential. During orientation, the film is heated to just below the melting temperature, then the crystals or spherulite which consists of long molecular chains are elongated and become to some extent, lined up in the stretch section. Without MD orientation the resulting film would lack stiffness and strength in that direction as well as being too easily extendible. The MDO is comprised of 3 sections of highly polished hard chrome plated roll rollers, which utilizes steam as heating medium. Description Specification Machine speed Low speed section 6 – 60 m/min Medium speed section 26 – 260 m/min High speed section 26 – 260 m/min Low speed section Preheating rolls Twelve 600 dia. X 1, 300 L One 180 dia. X 1, 300 L Stretching roll One 180 dia. X 1, 300 L
Medium speed section Stretching rolls Two x 180 dia. X 1, 300 L
High speed section Stretching roll One 180 dia. X 1, 300 L Heating – cooling rolls One 180 dia. X 1, 300 L Two 300 dia. X 1, 300 L Above rolls are hard – chrome – plated on the surface. Driving Device Low speed section 15 kW I.M. with V.V.V.F control Speed: 175 – 1, 750 rpm constant torque Medium speed section 37 kW I.M. with V.V.V.F control Speed: 175 – 875 rpm constant torque 875 – 1, 750 rpm constant power High speed section 37 kW I.M. with V.V.V.F. control Speed: 175 – 875 rpm constant torque 875 – 1, 750 rpm constant power
Temperature control unit Low speed section 6 zones Circulating medium: Steam Temperature range: 120 – 150 deg C Medium speed section 2 zones | ||
