QUENCH AIR CALCULATIONS

Prep'd by: AS Date: Oct.29, 2003

1. CALCULATING STAPLE FIBER THROUGHPUT PER POSITION a) Calculation in terms of denier Spun denier per Filament (d) = 6.74 dpf (denier per filament) Holes per Spinneret (n1) = 944 nos Spinning Speed (N) = 1669 m/min Fiber Throughput (W), kg/hr = 0.06*d*n1*N/9000 W, kg/hr 70.79 b) Calculation in terms of dtex Spun dtex per Filament (d) = Holes per Spinneret (n1) = Spinning Speed (N) =

7.488 dtexpf (dtex per filament) 944 nos 1669 m/min

Fiber Throughput (W), kg/hr = 0.06*d*n1*N/10000 W, kg/hr 70.79 Notes: 1) 1 denier is defined as 9000 meters of a single filament weighs 1 g. For example 210 denier means 9000 m of yarn weighs 210 g. 2) 1 dtex is defined as 10000 meters of a single filament weighs 1 g. For example 210 dtex means 10000 m of yarn weighs 210 g. 3) From 1 & 2 , we have the relation 1 dtex = 1.111 denier 2. CALCULATING FILAMENT YARN THROUGHPUT PER POSITION a) Calculation in terms of denier Spinning denier (d) = Spinning Speed (N) = No of ends per position (Z) = 126 den 3500 1

Filament yarn throughput (W), kg/hr = 0.06*d*N*Z/9000 W, kg/hr a) Calculation in terms of dtex Spinning denier (d) = Spinning Speed (N) = No of ends per position (Z) = 2.94

140 dtex 3500 1

Filament yarn throughput (W), kg/hr = 0.06*d*N*Z/10000 W, kg/hr 2.94

Examples of commercial POY products Spun No of Spun Denier filaments Yarn DPF Product 51/14 51 14 3.64 70/27 70 27 2.59 85/68 85 68 1.25 86/27 86 27 3.19 115/136 115 136 0.85 115/100 115 100 1.15 132/34 132 34 3.88 150/34 150 34 4.41 170/34 170 34 5.00 215/34 215 34 6.32 245/34 245 34 7.21 250/68 250 68 3.68 250/34 250 34 7.35 255/34 255 34 7.50

3. HEAT LOAD q ON QUENCH SYSTEM PER POSITION (STAPLE FIBER) Melt temp.of PET (Tmelt) = 285 C Freezing temp. of PET (Tfreeze) = Avg Sp heat @ melt temp. (Cp-melt) = Latent Heat of fusion of PET (l) = Filaments cooled to temp (Tfinal) = Avg Sp heat @ solid fiber (Cp-solid) = 260 C 0.48 kcal/kg C 11.5 kcal/kg (This value needs confirmation) 80 C (Cooling to be done upto glass transition temp, which is considered 80C) 0.41

q = (W*Cp-melt*(Tmelt - Tfreeze)) + (W*l) + (W*Cp-solid*(Tfreeze - Tfinal)) q, kcal/hr 6864

File Name: 164860955.xls.ms_office

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QUENCH AIR CALCULATIONS

Prep'd by: AS Date: Oct.29, 2003

4. HEAT LOAD q ON QUENCH SYSTEM PER POSITION (FILAMENT YARN) Melt temp.of PET (Tmelt) = 285 C Freezing temp. of PET (Tfreeze) = Avg Sp heat @ melt temp. (Cp-melt) = Latent Heat of fusion of PET (l) = Filaments cooled to temp (Tfinal) = Avg Sp heat @ solid fiber (Cp-solid) = 260 C 0.48 kcal/kg C 11.5 kcal/kg (This value needs confirmation) 60 C (Cooling to be done below glass transition temp, which is 70 to 80C) 0.40

q = (W*Cp-melt*(Tmelt - Tfreeze)) + (W*l) + (W*Cp-solid*(Tfreeze - Tfinal)) q, kcal/hr 304 5. MINIMUM THEORETICAL AMOUNT OF QUENCH AIR PER POSITION (STAPLE FIBER) Quench Air supply temperature = 20 C Quench Air exit temperature = 60 C 2 Quench Air Pressure = 0.045 kg/cm g (to be confirmed) Sp heat of Quench Air = 0.25 kcal/kg C Mass flow of QA required = 686.44 kg/hr 3 Density of QA = 1.25 kg/m 3 Actual Volume flow = 549.15 m /hr 3 Volume flow at NTP (Qtheo) = 533.98 Nm /hr 6. MINIMUM THEORETICAL AMOUNT OF QUENCH AIR PER POSITION (FILAMENT YARN) Quench Air supply temperature = 20 C Quench Air exit temperature = 40 C 2 Quench Air Pressure = 0.007 kg/cm g (to be confirmed) Sp heat of Quench Air = 0.25 kcal/kg C Mass flow of QA required = 60.72 kg/hr 3 Density of QA = 1.25 kg/m 3 Actual Volume flow = 48.58 m /hr 3 Volume flow at NTP (Qtheo) = 45.57 Nm /hr 7. ACTUAL AMOUNT OF QUENCH AIR REQUIRED PER POSITION (FILAMENT YARN) These calculations applicable for filament yarn only where crossflow QA system is followed. Table for row number factor for the Quench Air quantity

Polymer PET

Tmelt, C 285

Tquenchsupply, Tquenchexit, C C 20 40

f factor for no of filament rows per spinneret 4 1.113 7 1.188 9 1.735

Actual amount of QA required = Min. Theoretical Amount of Air* f factor from table* 14 Example: 3 For f = 4, Qact = Qtheo*1.113*14 710.1 Nm /hr 8. EXIT TEMPERATURE OF QA BASED ON ACTUAL QA FLOW (FILAMENT YARN) 3 Actual QA Vol flow at NTP (Qact) = 710.1 Nm /hr Density of QA at NTP = Actual Mass flow of QA = Sp heat of Quench Air = Quench Air supply temperature = Heat load for Quench Air = Exit Temperature = CONCLUSION: Product: POY No of rows Polymer per throughput, QA supply QA return spinneret kg/hr temp, C temp, C (1 position) 2.94 20 21.3 4 1.31 930.20 0.25 20 304 21.31 kg/m3 kg/hr kcal/kg C C kcal/hr

Denier 126

Spinning speed, m/min 3500

Row factor 1.113

QA flow, Nm3/hr 710.1

Prepared by: Ankur Srivastava email: ankur_2061@hotmail.com

File Name: 164860955.xls.ms_office

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