IIP201 Core Industry Internship & Colloquium report

For

Morarjee Textiles Ltd.

(an Ashok Piramal Group company)
Supervised by
Ms. Shweta Bodkhe
Mr. P. Babu
Submitted by

Ajay yadav (2016meb1145)

Indian Institute of Technology Ropar
 Contents
IIP201 Core Industry Internship & Colloquium report ................................................................................. 1
Brief information about the organization ................................................................................................... 3
Project work ................................................................................................................................................ 4
Maximizing the efficiency of the boiler plant by use of WPH ..................................................................... 4
Objective: ............................................................................................................................................................ 4
Assumptions: ....................................................................................................................................................... 4
Method used: ...................................................................................................................................................... 4
Calculations: ........................................................................................................................................................ 8
Observational training............................................................................................................................... 11
Overview of processes in the industry:............................................................................................................. 11
Spinning process: .............................................................................................................................................. 12
Humidification plant ..................................................................................................................................... 13
Need for conditioning ................................................................................................................................... 15
Yarn conditioning plant ................................................................................................................................. 15
Air compressor .................................................................................................................................................. 16
Boiler ................................................................................................................................................................. 18
Process: ......................................................................................................................................................... 19
DM(demineralization) Plant .......................................................................................................................... 19
Boiler ............................................................................................................................................................. 19
Preparatory process for weaving: ..................................................................................................................... 23
Post weaving processes .................................................................................................................................... 24
Effluent treatment plant ................................................................................................................................... 26
 Brief information about the organization
Manufacturing Facilities - Fabric
Morarjee has an integrated manufacturing plant at Nagpur in Central India. The plant is equipped to produce
premium shirting and high fashion printed fabric for clients across the globe. To cater to the changing demand
and requirements of the fashion industry, Morarjee believes in investing in product development and
technology up-gradation.
Manufacturing Facilities - Garments
To meet the growing demand for quality shirts and dresses, Morarjee established a subsidiary company;
Integra Apparel and Textiles Pvt. Ltd, in Bangalore, India. Integra specializes in products ranging from woven
shirts for men to intricately embellished dresses for women. The other products on offer include different
washes, embroideries and panel prints that employ the latest techniques.
Manufacturing Facilities-Shirting

Morajee is the first company in India to have successfully entered a joint venture with an Italian company for
setting up a yarn dyed shirting fabric unit at Nagpur, India.
The division specializes in color woven high end premium shirtings with fine yarn counts upto 180/2. The
products are manufactured using the latest dyeing and finishing facilities and are in accordance with the Oeko-
tex standard as well as national and international standards of full quality control assurance, at all times. This
division is also equipped with advanced equipment for testing yarn, fabric and chemicals in accordance with
international testing standards.
Manufacturing Facilities-Voiles

Morarjee caters to the Middle East and African Subcontinent along with the conversion centers in Europe and
Far East for its traditional ensembles. Morarjee imports the best of raw material for spinning its fine count
yarns and has mastered the art of giving special finishes to products through A.G.Cilander of Switzerland,
producing world-class cotton rich fabrics for these regions. Our designers work on African & Middle Eastern
designs to create thobes best suited for the African palate. Constant innovation breathes a new life into this
traditional garment
Corporate profile

Morarjee is a leading player in premium cotton shirting fabric and high fashion printed fabric globally.
Morarjee has a 49% stake in Just Textiles Ltd. which is currently engaged in processing various fabrics installed
at its factory in Ambernath, Mumbai. Morarjee counts most of the popular international and domestic brands
as it clients, across 20 coutries. Dunhill, Zara, Esprit, Hugo Boss, Next, Paul Smith and Zodiac are some of its
customers. In the domestic market, Morarjee caters to popular brands like Louis Philippe, Van Huesen and
Zodiac.
 Project work
Maximizing the efficiency of the boiler plant by use of WPH
The boiler plant generates low pressure steam to meet the various requirements for the textile plant. Coal
is burnt to produce heat which is used to heat the water for steam production. The flue gases generated
play a very important role in the heating process by convection. Still as the gases make their way out of the
boiler they are still at a very high temperature and this heat energy can be further exploited.
Though it cannot be used to heat the water to steam, still it can exploited to heat the air supplied to the
combustion bed for combustion and the other part can be used for preheating the water that arrives at the
boiler. So we will look at how tapping out this heat can prove very helpful increasing the boiler efficiency
and cutting costs.
WPH (water preheater)

The water preheater serves similar purpose as air preheater with water replacing air.
Water preheater is a heat exchanger that uses flue gas and water.

Objective:
To calculate the power conserved by the water preheater.

Assumptions:
 Shell and tube type heat exchanger(1 shell pass 2 tube pass)
 Heat transfer takes place by convection
 Carbon dioxide is the major component of flue gas

Method used:
THE LOG MEAN TEMPERATURE DIFFERENCE METHOD

represents rate of heat transfer between the two fluids

is the overall heat transfer coefficient
is the surface area of the tube inside the shell where heat exchange takes place
is the correction factor

is the log mean temperature difference, which is the suitable form of the
average temperature difference for use in the analysis of heat exchangers. Here ∆T1 and ∆T2
represent the temperature difference between the two fluids at the two ends (inlet and outlet) of
the heat exchanger. It makes no difference which end of the heat exchanger is designated as the
inlet or the outlet
1 shell 2 tube pass heat exchanger
 Correction factor (F) used for shell and tube pass heat exchanger

The correction factor F for common cross-flow and shell-and-tube heat exchanger configurations is given in
above figure versus two temperature ratios P and R which are defined as

where the subscripts 1 and 2 represent the inlet and outlet, respectively. Note that for a shell-and-tube
heat exchanger, T and t represent the shell- and tube-side temperatures, respectively, as shown in the
correction factor charts. It makes no difference whether the hot or the cold fluid flows through the shell or
the tube. The determination of the correction factor F requires the availability of the inlet and the outlet
temperatures for both the cold and hot fluids.
 Calculation of overall heat transfer coefficient
(U):

In the analysis of heat exchangers, it is convenient to

combine all the thermal resistances in the path of heat
flow from the hot fluid to the cold one into a single
resistance R, and to express the rate of heat transfer
between the two fluids as

When the wall thickness of the tube is small and the

thermal conductivity of the tube material is high, as is
usually the case, the thermal resistance of the tube is
negligible and the inner and outer surfaces of
the tube are almost identical (Ai=Ao=As).

is the equation we will use in our calculation;

Where i and o subscripts refer to inner and outer surface
of the pipe.

Calculation of convective heat transfer coefficients ( )

Flow in smooth tubes is fully turbulent for Re

10,000. Turbulent flow is commonly utilized in practice because of the higher heat transfer coefficients
associated with it. As it will turn out later flow in our case is turbulent. For fully developed turbulent flow in
smooth pipes the following equation holds true
(0.7<Pr<160 and Re>10000)
Where n=0.4 for heating and 0.3 for cooling of the fluid flowing through the tube. This equation is known as
the Dittus–Boelter equation.
Then h can be calculated using
 Calculations:
Data used:

Where subscripts are w-water, f-flue gas, i-inlet, o-outlet

Diameters of the tube are:

Length of shell L=2m

Diameter of the shell is:

Coal consumption rate

Calorific value of fuel used is

Water flow rate

Rate of generation of flue gas:

Calculation of theoretical combustion air:

Calculation on weight basis:
Let the ultimate analysis of a coal sample is as follows:
Carbon: 73%; hydrogen: 4.5%; oxygen: 5.9%; nitrogen: 1.5%; sulphur: 5% ; water: 2.1%; ash: 8%
Oxygen required for burning of carbon, hydrogen and sulphur are as follows:
Basis: 1 kg coal burned
C: 0.73 × 2.667 kg = 1.9469 kg of oxygen
H: (0.045 × 8) - 0.059 = 0.301 kg of oxygen
(1 kg of hydrogen consumes 8 kg of oxygen and 0.059 kg of oxygen is initially present in coal which should
be subtracted from the total required oxygen)
S: 0.05×1 kg = 0.05 kg of oxygen
Total oxygen required to accomplish the complete burning = 1.9469+0.301+0.05 = 2.298 kg
Ash generated per kg of coal
Coal converted to flue gas
Oxygen converted to flue gas
Total flue gas generated per kg of coal
Hence flue gas generation rate
Calculating
 Average temperature of water inside tube
Average temperature of flue gas inside shell
Taking the water and flue gas properties at this average temperature:
Water properties:

Volume flow rate of water

Speed of water in tubes

Using and
And ; the value of convective heat transfer coefficient can be calculated for the inner surface of the
tube i.e.

Flue gas properties:

Assuming carbon dioxide to be major component properties calculated for CO2

Calculating hydraulic diameter for shell(D h ) and

; d=tube diameter

Volume flow rate of flue gas

Velocity of flue gas in shell

 Using and
And ; the value of convective heat transfer coefficient can be calculated for the outer surface of the
tube i.e.

Calculating the overall heat transfer coefficient (U):

Calculating the Correction factor (F):

From the graph given in the Correction factor (F) section,

Calculating the net heat transfer:

Rate of fuel saved:

Fuel saved per day(24 hours)=1.146 tonnes

Coal cost per tone=2674 rupees
Money saved per day=3066 rupees
Coal consumption rate of boiler= 1166 tonnes per month

References

Heat and mass transfer, Cengel and Ghajar;

NPTEL pdf for coal combustion;
 Observational training
Overview of processes in the industry:

preparatory
spinning preparatory dyeing
for weaving

final final grey

weaving
inspection processing inspection

packaging
and delivery
 Spinning process:

blow room carding draw frame lap former

ring frame speed frame draw frame comber

yarn
link coner packing
conditioning
 Humidification plant
Spinning requires ideal conditions of temperature and relative humidity. The H-plant takes up this job.
3 dampers-fresh air, recirculation and exhaust dampers-are installed to regulate the incoming and outgoing
air from the plant. The fresh air damper allows air inside. It then passes through a sprinkler room where a
water pump and sprinklers and deployed. The sprinklers spray water which greet the incoming air and the
air is washed. Then air passes through the eliminators and makes its way past the supply fan-that creates
the pull on air- through the air tubes to the spinning plant where the required air temperature and humidity
is maintained. A sensor is placed that measures these values and provides feedback to the system. At the
floor small holes called trunches are present that take in the waste air and send it to the rotary filter that
traps in the waste cotton and the clean air moves past the return fan to the dampers. As per the
requirements the air leaves through the exhaust damper or re-circulates by the recirculation damper or a
combination of both the dampers is employed.

Humidification plant requirements

Sr No. description unit blowroom carding preparatory spinning linkconer TFO

1 Supply fan Cum/hr 75000 105000 180000 820000 240000 300000
2 Return fan Cum/hr 180000 180000 174600 780000 190000 285000
3 Relative % 65 55 55 50 60 65
humidity
4 Room
temperature
a Maximum Celsius 34 37 37 39 35 34
b minimum Celsius 26 26 26 26 26 26
 H-plant process

fresh air
spray room supply fan
damper

spinning
trenches ducting tube
plant

exhaust
rotary filter return fan
damper

recirculation
damper
 Recycling plant

The waste cotton is trapped in the rotary filter and sucked in by the waste collector. Four types of wastes
are produced: Flat, licker in, carding and combing wastes.
These wastes are collected from their respective rotary filters and sent to their respective silos via ducts.
Below these silos is a recycling machine called vertical bale press that compresses the wastes into bales that
are reused.
The bale press deals with one silo at a time so that the wastes do not mix. Also the quality of bale produced
varies with the type of waste used. Each silo has a sensor installed in it to check the level of waste inside it.
As the waste crosses the peak level a the sensor sends a signal and the silo opens up its contents to the bale
press.

Need for conditioning

Moisture in atmosphere has a great impact on the physical properties of textile fibers and yarns. A high
degree of moisture improves the physical properties of yarn and it helps the yarn to attain the standard
moisture regain value of the fiber.

Yarn conditioning plant

After yarn making is complete, it is sent to the yarn conditioning plant for some final touches and packed
and delivered.
During purchase the moisture content in raw cotton is about 8 to 9% but at the end of yarn spinning
process it get reduced to 5%. Yarn conditioning is a process to regain the moisture of yarn at the end before
selling to customers. Yarn conditioning simultaneously work as heat setting that provides flexibility, better
performance in onward process for all types of yarn.
 Air compressor
Air compressor is used for supplying compressed air to the spinning department, airjet looms, and other
processing machines. Compressed air is also used for cleaning purposes.
Three types of air compressors are present:
Centrifugal compressor
Screw air compressor
Reciprocating air compressor
Centrifugal compressor

Centrifugal Compressor is a machine in which a particular gas or 16apour is compressed by a radial

acceleration by an impeller with the help of a surrounding case. It can then be arranged multistage for
greater proportions of compression. The compression is largely influenced by a centrifugal pump.
Screw air compressor

A rotary-screw compressor uses a rotary-type positive-displacement mechanism. They are commonly used
to replace piston compressors where large volumes of high-pressure air are needed, either for large
industrial applications or to operate high-power air tools such as jackhammers and impact wrenches.
Rotary-screw compressors use two meshing helical screws, known as rotors, to compress the gas. In a dry-
running rotary-screw compressor, timing gears ensure that the male and female rotors maintain precise
alignment.
Reciprocating air compressor

A reciprocating compressor is a positive-displacement compressor that uses pistons driven by a crankshaft

to deliver gases at high pressure. The intake gas enters the suction manifold, then flows into the
compression cylinder where it gets compressed by a piston driven in a reciprocating motion via a
crankshaft, and is then discharged.
Compressor operation in plant

Screw air compressor provides for the air requirements of the spinning plant. The compressor is monitored
regularly and readings are taken after every 2 hours. It is a two stage screw compressor i.e. air is
compressed in two stages. Water cooling is done in between the stages. Air passes through air dryer before
being sent to the compressor. The compressed air is then sent to the pressure gauge where it is stored and
then moved to the air distribution header which controls the transport of air to the required machines.

Centrifugal compressor and screw air compressor are used in a combination to provide for the pressurized
air requirements of the remaining plant. Reciprocating compressor is used as safety in case a compressor
stops working or is unable to meet the industry requirements.
 Parameters for screw compressor used in spinning plant:

Sr parameter Set point Unit Measured value

No.
1 Set point load 7 Kgf/cm2 6.8
2 Set point unload 7.7 Kgf/cm3 7.5
3 Discharge pressure 8.5 Kgf/cm2 7.3
4 Discharge temperature Celsuis 35
5 Stage 1 discharge temp <226 Celsuis 204
6 Stage 2 inlet pressure 1.73-2.75 kgf/cm2 2.1
7 Stage 2 discharge pressure 2.75-8.66 Kgf/cm2 7.3
8 Stage 2 inlet temperature Celsuis 36
9 Stage 2 discharge temperature <252 Celsuis 185
10 Bearing oil temperature <77 Celsuis 57
11 Bearing oil pressure >2.31 Kgf/cm2 4.4
12 Inlet vacuum <0.048 mmHg 0.02
13 Air dryer dew point Celsuis 6.3
14 Dryer temperature Celsuis 33.4
15 Refrigerant discharge presssure <280 Kgf/cm2 250
16 Refrigerant suction pressure >60 Kgf/cm2 62

As we can see the measured values are offset from the actual values.
 Boiler
Coal handling plant

Coal is dropped in the hopper where a conveyor belt system transports it to a screening machine that
separates the fine particles from the coarse ones before sending them to the screw feeder. The coarse
particles are sent back for size reduction.
Air preheater

The air preheater or APH uses the outgoing flues gases to heat the incoming air for combustion. It has a
heat exchanger type structure that heats the air.

Control room

All the processes going on in the boiler plant are monitored in the control where two different control
systems have been deployed for water boiler and the thermopac. Here we can regulate the parameters of
the various processes by turning the knobs and monitoring the real time values on the monitor screen
Screw feeder

It is used to regulate the fuel supply to the fluidised bed.

Air preheater

Air preheater is a heat exchanger that uses heat from the flue gas to heat the incoming air and facilitates
combustion.

Water preheater

The water preheater serves similar purpose as air preheater with water replacing air.
Water preheater is a heat exchanger that uses flue gas and water.
FD fan

Fd fan is installed below the air preheater where it pumps in fresh air into the air preheater. This ensures
proper air supply to the furnace by maintaining a pressure draught. It is driven by a motor.
ID fan

ID fan serves similar purpose as the FD fan i.e. to create a draught pressure in the boiler system except that
is placed under the chimney. The draught pressure ensures that the flue gases make the way comfortably
out of the chimney and continue to go up.
Fluidised bed

It is where the screw feeder sends the coal for combustion. A bed of sand is made upon which sits the
incoming coal. Below the bed are nozzles that blow air into the bed and set the hot environment that sets
the coal ablaze.
 Bag house filter

A baghouse filter is an air pollution control device and dust collector that removes particulates or gas
released from commercial processes out of the air.

Demineralization plant(DM plant)

Demineralization is the process of removing mineral salts from Water by using the ion exchange process.

Process:

DM(demineralization) Plant
Soft water is pumped to a muitigrade filter which removes the suspended particles. Then it goes to the
activated carbon filter that further cleans it. then it goes to the strong acid cation tank where it is influxed
with hydrochloric acid for neutralization. Then it goes to the degasser tank where two blowers are at work.
Then it is pumped to strong base anion tank where caustic soda neutralizes the excess acid inside. Then it
goes to a mixed bed unit where both HCl and caustic soda are mixed with it. An air blower blows air into
this unit. Finally the treated water leaves it and the pH booster tank further checks it pH value before it
makes it way to the boiler feed tank.

Boiler
Water from demineralization plant is pumped into the water feed tank. The water preheater treatment is
carried before this where used flue gases exchange some waste heat with the incoming cold water.
Sometimes soft water or recycled water from ro plant is used as a replacement for dm water in case of
emergency. The water is pumped from the feed tank to the boiler where heat is exchanged from the
burning coal as water passes through the heat exchanger tubes.
At the bottom lies the fluidised bed where coal from the screw feeder sits on sand. Below it are the nozzles
that blow hot air into the bed. Forced draft fan pumps in fresh air into the air preheater where it extracts
the remaining heat from the used flue gases before they are sent to the bag house filter. The hot air makes
it way through the nozzles into the bed. Combustion takes place and flue gases are generated. The heat of
radiation and convection vapourises the water flowing in the tubes.
The steam is transported to the various required operations like dyeing, bleaching, calendaring etc. And the
flue gases pass through wph, aph, baghouse filter finally to the chimey where induced draft fans suck them
out of the chimney.
Pressure gauge is attached in the boiler to measure the water pressure and a secondary pressure gauge is in
place if the primary gauge fails. Similarly a temperature gauge is present as well.
The sand in bed helps in combustion of coal.
 Processes in
Boiler plant

Water from DM Water preheater Boiler tank

plant

Steam generated Boiler (heating by

and sent to textile burnt fuel and
plant flue gases
produced)

Coal from coal Screw feeder Flue gases

handling plant generated

Sand for making Boiler combustion Combustion takes

combustion bed bed place

Air is pumped in by Air preheater

forced draft fan(FD
Fan)
 Flue gases Air preheater Water preheater
generated in boiler

chimney Bag house filter

Boiler specifications:

Sr specification unit magnitude

No.
1 Pressure of steam Kgf/cm2 8
2 Temperature of steam Celsius 170
3 Max evaporation rate Tonnes/hr 12
4 Efficiency of boiler 80
5 Quality of steam 0.98
6 Feed water temperature Celsius 60
7 Flue gas mean temperature Celsius 220
8 Chimney height m -2 to -3
9 Draught in furnace mmWC
10 Coal grade used G8 to G9
 Flow of water in boiler

DM plant feedwater water

water pump preheater

textile boiler boiler

plant tubes tank
 Preparatory process for weaving:

drawing winding

weaving
preparatory
processes

warping
direct warping sizing
sectional warping

Warping process

Cheese/cones are set on a warping machine to wind the predetermined length and number of yarns onto
the predetermined number of warping beams under constant tension.
Winding process

The winding process involves rewinding the finished yarn onto bobbins into the cheese or cone according to
its purpose
Drawing process

To prepare for setting beams on a loom, warps are routed in the order of droppers, healds and guide bars.
Sizing process

The warping beams of the required number of warps of the final textile are piled up for rewinding on beams
after sizing and drying.
 Post weaving processes

RF drying calendaring

sanforizing
stentering
cloth
processing

Stentering process

Stentering is a mechanical finishing process of textile. It is done for the stretching of fabric by the stenter
machine. In other words we can say stentering is done for gripping the edges of a moving web to support
the web during heating and stretching operations.

Calendaring process

Calendering of textiles is a finishing process used to smooth, coat, or thin a material. With textiles, fabric is
passed between calender rollers at high temperatures and pressures. Calendering is used on fabrics such as
moire to produce its watered effect and also on cambric and some types of sateens.

In preparation for calendering, the fabric is folded lengthwise with the front side, or face, inside, and
stitched together along the edges. The fabric can be folded together at full width, however this is not done
as often as it is more difficult.The fabric is then run through rollers that polish the surface and make the
fabric smoother and more lustrous. High temperatures and pressure are used as well. Fabrics that go
through the calendering process feel thin, glossy and papery.

Sanforizing

Sanforizing is a mechanical finishing process of treating textile fabrics to prevent the normal dimensional
alternation of warp and weft. It is also called anti-shrinkage finishing process. It is a process of treatment
used for cotton fabrics mainly and also for some other textiles made from natural and synthetic fibres. It is
a method of stretching, shrinking and fixing the woven cloth in both length and width, before cutting and
producing to reduce the shrinkage which would otherwise occur after wash.
 RF drying

Here water content from fibres, yarns and fabrics are removed through Radio Frequency. Apart from textile
industry this process is used in paper industry, foundries, Chemicals, pharmaceuticals and ceramic industry.
In radio frequency drying system alternating electric field between two electrodes is created by RF
generator. The material to be dried is put acrossed between the electrodes, where the alternating energy
causes polar molecules in the water to continuously re-orient them to face opposite poles - much the same
way magnets move in an alternating magnetic field. This movement causes the friction and due to this
water in the material to rapidly evaporate throughout the material.
 Effluent treatment plant
The waste water from the unit 1&2 is sent to the water treatment plants. Two effluent treatment plants are
present. Physical, chemical and biological treatment methods are employed.
Plant 1 treates wastewater and sends it to the CETP department. Plant two on the other hand treats
effluent using reversre osmosis process and the recycled water is sent back to the plants for reuse.
Effluent treatment plant 1process

equalization pH correction flocculation

flash mixer
tank tank tank

parallel plate bacterial pH correction

tube settler
settler treatment tank

treated water
CETP
tank

Effluent treatment plant 2 (reverse osmosis) process

screening boilogical pH correction

filter tank tank

reverse
settler tank oxidation tank
osmosis plant