05-12-2012, 03:54 PM
VOCATIONAL TRAINING REPORT BASED ON SUMMER TRAINING 2012 FROM PASUPATI ACRYLON LIMITED
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PASUPATI ACRYLON LIMITED-AN OVERVIEW
INTRODUCTION:-
PasupatiAcrylon Limited started commercial operation in the year 1990. The plant was set up in technical collaboration with SNIA BPD, renowned Fiat group of Italy.
Pasupati was designed for a rated capacity of 15000TPA. By means of various innovative modifications and debottlenecking the capacity has been enhanced to 30,000 MT. Now with the installation of an additional spinning line the capacity has been further enhanced to a level of 42,000 TPA. Advanced technology, automation, computerized process control systems and captive power, make the operations of Pasupati extremely efficient and reliable. Pasupati is one of the best plants in the world, running on SNIA technology.
Pasupati product conforms certification under ISO 9001:2008, this certificate indicates its commitment in meeting global quality and standards
COMPANY PROFILE
Pasupati Acrylon Limited has been set up in technical collaboration with SNIA BPD of Italy. It is situated at Thakurdwara, district Moradabad, in Uttar Pradesh, the largest state of India. The plant is spread over an area of approximately 90 acres & 80 Meter wide natural and thick forest ,has been developed along the boundary of the factory premises comprising over 10,000 trees, which has been instrumental in restoring the ecological balance and keeping the atmosphere pollution free. It also adds to the aesthetic appearance of the factory and its surroundings.
HISTORY OF ACRYLIC FIBRE:-
History of Acrylic Acrylic was developed by DuPont in 1944 and was first commercially produced in 1950. Acrylonitrile, the substance from which acrylic fibers are produced, was first made in 1893 in Germany and was used as another chemical in research for the DuPont Company. First used for outdoor purposes, technology has allowed acrylic to come a long way, and it is now most commonly used in apparel and carpets. DuPont ceased production of acrylic in 1991, and only a handful of companies produce acrylic today. Definition of Acrylic Acrylic is defined as a manufactured fiber in which the fiber forming substance is any long-chain synthetic polymer composed of at least 85% by weight of acrylonitrile units. Acrylic fibers create a fine, soft and luxurious fabric with the bulk and hand of wool. Production of Acrylic Acrylic fibers are produced from a petrochemical called acrylontrile and are dry spun or wet spun. In dry spinning, the polymers are dissolved in a suitable solvent, extruded into warm air, and solidified by the evaporation of the solvent. "After spinning, the fibers are stretched hot, three to ten times their original length, and then crimped, and marketed as cut staple or tow. In wet spinning, the polymer is dissolved in solvent, extruded into a coagulating bath, dried, crimped, and collected as tow . . . or cut into staple."1 Acrylic fibers are usually modified to create special properties best suited for their end-uses and are unique because of their uneven surface.
WORLD CLASS TECHNOLOGY
There are ways of making acrylic fibre. PasupatiAcrylon has opted for one- the continuous Solution polymerization & wet spinning process which is acknowledged internationally to be the best.
The collaborator SNIA BPD of Italy, part of the famed FIAT group- is the proven world leader in the manufacture of acrylic fibre.
The acrylic fibre that comes from PasupatiAcrylon’s plant at Thakurdwara , in U.P., meets all SNIA BPD quality specifications as well as customer requirement and specification.
The acrylic fiber of Pasupati has unique Kidney shaped cross-section which imparts special characteristics like softness and suppleness to the garments produced from the fiber.
ENVIRONMENT
SAFETY AND ENVIRONMENT CONCERN
As a responsible corporate citizen, PasupatiAcrylon is very much alive to the need of caring for human and material safety, the concern for the environmental protection and conservation of natural resources. In view of the nature of chemicals used in the manufacture of Acrylon , the best possible safety systems against fire , air and water pollution have been installed.
Well designed auto fire prevention systems and alarms are in place which are frequently and periodically tested and checked for performance and accuracy. Smoke detectors have been installed in all electrical sub-station and other fire proven areas with a provision of alarm facilities in control room, for quick warning and prompt mitigation of fire emergency.
The technology adopted for the manufacture was selected to have the minimum polluting effect. In addition, the most advanced treatments are meted to the effluents whether it is water or air.
A modern effluent water treatment plant has been functioning in our factory. This plant is based on extended aeration and suspended growth activated sludge process to give an output performance which fully meets the requirement laid down by the statutory authorities. Pasupati has well equipped sophisticated plant for treatment of Gel dyeing effluent. This plant is well capable of removing the colour of the effluent as well as maintaining the characteristics of treated water well within the norms laid down by the statutory authorities. Treated effluent water used for irrigating green belt and horticultural has responded well for the healthy growth of plants.
HEALTH & SAFETY
FIRE SAFETY
Textiles, carpets and all other products made from fibers will burn if subjected to the right conditions. Depending on the physical size, orientation and chemical nature of the fibers, differences may occur in such important fire characteristics as ease of ignition, rate of flame spread, and heat release.
FACTORS AFFECTING FIBER FLAMMABILITY
How easily does a fire start, and how rapidly will it grow? One property of a material that is central to these questions is its surface to mass ratio. Items that have a large surface area for a small amount of material tend to ignite easier and burn faster. Thus, a twig is easier to ignite than a log. A heavy, tightly woven fabric is more resistant to ignition than a light, sheer fabric made of the same material. Igniting a fabric edge is usually easier than igniting a flat surface — fabrics with raised surface fibers, such as fleeces or terrys. Their raised fibers have a very large exposed surface and they can ignite easily with a very rapid flash of fire across the fabric surface. In some cases, these surface flashes may cause the entire fabric to burn, but in others the surface flash may not produce enough heat to ignite the base fabric.
Garments that are loose and flowing may present a greater risk of ignition because they are more apt to come in contact with a flame. If they are made of sheer, non-thermoplastic fabrics, they may present a real danger to the wearer.
The chemical nature of a fiber can also affect its burning characteristics in ways not related to thermoplasticity. In general, the more carbon and hydrogen that is present in the chemical structure, the more heat the material will give off when it burns. Thus many synthetics have a potential to give off more heat when they burn than an equivalent amount of a cellulosic material. In addition, to become involved in a flaming fire, the polymeric material which makes up the fiber must break down into small volatile fragments. Fibers from polymers with very high thermal stability, such as aramids and PBI, exhibit greatly reduced flammability. Other fibers, such as the modacrylics and FR (flame resistant) polyesters, contain chemical structures which can act as flame retardants. These inherent flame retardants can be very effective in preventing fabrics from becoming involved in fires from small ignition sources. However, they are frequently overwhelmed in larger fires, such as a burning building.
SMOKE AND TOXIC GASSES FROM FIBER PRODUCT FIRES
Unlike garment fires, where the primary hazard is heat release, building fires can generate both heat and toxic gasses. Often the primary human hazard is smoke and toxic gases. When cellulosic materials, either textiles or wood products, are burned the only gases formed are CO, (carbon monoxide), CO2(carbon dioxide) and H2O (water). Although carbon dioxide can cause suffocation, the dangerous material is carbon monoxide, which poisons the bloodstream in much the same way as cyanide. The relative amounts of CO and CO2 produced in a fire depend primarily on the amount of oxygen present. Well ventilated fires produce mostly CO2. However, in well-developed building fires, there is almost always a shortage of oxygen and larger amounts of the much more toxic CO are produced.
Some synthetic fibers, such as polyester and polyolefins, also produce only these three gases when burned. Other fibers, such as polyamides (nylon) or acrylics, contain nitrogen and are thus theoretically capable of producing other toxic gases during burning. While small-scale tests of nitrogen-containing textiles frequently show the evolution of toxic materials, such as HCN (hydrogen cyanide), these gases are probably not a major factor in real fire situations. Work at the Center for Fire Research of the U.S. National Institute of Standards and Technology has shown that the primary toxicant in most structural fires is CO, regardless of the presence of a wide variety of synthetic fiber products. Thus most common synthetic fibers usually behave no better, nor worse, than other organic materials in large fires.