novatex limited internship report

INTERNSHIP PROGRAM REPORT

(Polycon department)

Duration period is 28 December to 20 Jan 2017

PREPARED BY

SYED ASIM ALI SHAH

(03022700702)

Ameer Hamza

Tabish ali jamali

SUBMITTED TO

Hr department

DAWOOD UNIVERSITY OF

ENGINEERING AND TECHNOLOGY

INTERNSHIP REPORT (Novatex Limited)

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ACKNOWLEDGEMENT

All praises belong to almighty ALLAH who is the supreme Authority Knowing the

ultimate relations underlying all sorts of phenomenon going on in this universe.

without His guidance, I am nothing. All our faith belongs to him and by his grace I

have completed our three-week internship program in NOVATEX limited.

It was an interesting period of learning because the knowledge that I gained

theoretically from the books became practical here with additional technical aspects,

and the experts here made that much fruitful for me by their guidance. Another thing

is that the other staff became very helpful in the whole process of learning they

showed their high moral behavior to us.

I also want to pay high regards on behalf of my institution “Dawood University of

Engineering and Technology” for giving me this opportunity and I was very grateful

from the depths of my hearts to my supervisor Sr. Manager Productions and other

engineers and the other staff that was included in this program.


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INDEX

S.NO CONTENTS

1 INTRODUCTION

2 HEALTH SAFETY AND ENVIRONMENT

3 POWER HOUSE POWER HOUSE 1 POWER HOUSE 2

4 QUALITY CONTROL

5 MECHANICAL DEPARTMENT

6 UTILITY COMPRESSOR UNIT NITROGEN PLANT UNIT DEMIN WATER UNIT RAW WATER UNIT

7 PROCESS POLYCON DEPARTMENT SOLID STATE POLYMERIZATION (SSP)

8 POSITIVE SIDES

9 SUGGESTION

10

CONCLUSION


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INTRODUCTION GATRON Ltd. and NOVATEX Limited belong to a group of companies, G&T – GANI &

TAYUB. The group is in business since 1948. These five decades of operational

excellence, experience and expertise have all formed a combined strength to

empower the group as a leading name in fashion garments (BONANZA), Synthetic

Textiles, Polyester Filament Yarn, Polyester Chips and PET Resin in Pakistan. The

group employs more than 6,000 people in the country.

NOVATEX Limited (along with GATRON Limited) is the only PET Resin Bottle Grade manufacturer in Pakistan, with the brand name of "GATRONOVA."

NOVATEX produces PET Resin for Domestic & Export sales. GATRON produces PET Resin for in-house use in the manufacturing of PET

Preforms. The Group is in Polymer production since 1988 and in PET Resin production since

1998. The total PET resin production capacity is 235,000 mt/annum, out of which more

than 70% of the quantity is available for export. Certified to meet FDA & EEC standards. Suitable for all applications of PET, including sheet. Widely approved by major CSD and Mineral water brands in the World. Used by customers in more than 45 countries with major quantities going to

Western Europe. Fast Reheat resin is also available. With the advantage of regular in-house testing on both injection molding and blow

molding machines, GATRONOVA has the advantage of utilizing this complete loop to continuously optimize it's quality.

Capacity to produce over 1.5 billion preforms per year. The PET Resin (raw material) for these preforms is produced in-house by GATRON and NOVATEX and therefore gives standardized & consistent preforms.

Sizes range from 13 gms to 55 gms, with neck sizes 28 mm PCO / BPF & 30/25, for 330ml to 2250 ml Water / CSD bottles.

Produced on Husky HYPET & G-Line Machines mainly installed after 2004. Nearly half of the perform production is exported. Preforms are tested not only in the laboratory but also by actual blowing into

bottles on regular basis. So, quality of preforms is also monitored in actual use.


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HEALTH SAFTY ENVIRONMENT

OBJECTIVE

The main objective of this department is to insure safety of employees, department

and plant. It is the most mobilized department from all. Safety training is given to all

employees and internees on daily basis where they learn the basic of safety rule.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

PPE is used to prevent the employee from hazard. It is an used according to

determined hazard that can be taken place.

“Identify the hazard, do the safety”

Some examples of PPE are cloths, helmets, goggles, garments or equipment.

TERMINOLOGIES FOR SAFETY:

RISK: Risk is the chance of hazard

ACCEDENT: Accident is undesired and unplanned event

NEAR MISS: A known hazard that is about to be occurred.

LOCKOUT/TAGOUT: It is a tag put on the equipment for safety purpose.

MECHANISM OF FIRE

There are three things to need for fire.

Fuel

Oxygen

Temperature

Fire can be put off by three ways.

1. Starvation: cut off the fire supply

2. Smothering: cut off the air supply

3. Cooling: lowering the temperature

How to cut off the air supply?

Start rolling on floor

Put the blanket on fire


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TYPE OF FIRE

A class fire: fire on wood, paper, plastic etc.

B class fire: fire on liquid like oil and petrol etc.

C class fire: fire on flammable gas like CH4, CO, H2 etc.

D class fire: fire on metals Al, Mg, Ti etc.

E class fire: fire on electrical apparatus.

EXTINGUISHER

Extinguisher is the equipment which is used to put off the fire

PASS TECHNIQUE

Pass technique is use to operate the fire extinguisher.

P: pull the pin

A: aim the nozzle

S: squeeze the lever

S: sweep side by side

TYPES OF EXTINGUISHER

The following types of extinguisher NOVATEX is using.

1. DRY CHEMICAL POWDER (DCP):

It can be identified with BLUE color tags

It is used for A, B, and C class fire

2. FOAM:

It can be identified with CREAM color tags

It is used for B class fire

3. CARBON DIOXIDE (CO2):

It can be identified with BLACK color tags

It is used for B and E class fire

4. HYDRANT:

It can be identified with GREEN color tags

It is used for A class fire


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QUALITY LAB

OBJECTIVE:

The control laboratory of NOVATEX is modern facility and equipped with state

of the art instrument for testing and examining the in process and out process

material quality. The purpose of having laboratory is to ensure quality and

standard production to meet the consumer requirement. The samples are tested

and the results are collected to evaluate and compare with standards. This samples

are raw material, in process amorphous and crystalline chips and final product.

They go through various chemical, thermal and physical tests in the lab and the

results are forward to the decision body. There is no recommendation given by lab,

it’s the upper authority that decides whether to reject or clear it to proceed further.

NOVATEX ensures reliable and standard product to their clients and follows

strict no tolerance policy in terms of quality and barriers.

TEST:

The lab works non-stop 24/7 where series of around 40 different types of tests

are carried out in the lab. The types and choice of test depends upon the

required parameters, nature and characteristic of the material on which the

quality depends. The test can be done on daily and on monthly basis

depending on the needs. There are some important test, carried out multiples

times in the day. The list of such type of tests are:

Determination of Intrinsic viscosity of PET & PBT ( I.V test ).

Determination of ash content in EG & TPA.

Determination of acid number of EG & TPA.

Determination of H2O and aldehyde in EG & liquid samples from polyester

production

Determination of iron in Antimony Triacetate, EG, TPA & in PET.

Determination of color number in TPA, EG & polyester chips.

Determination of density and crystallinity of chips from PET.

Determination of EG, DEG & TEG in the distillation products obtained from

the respective recovery plant.

The chemist are being appointed to carry out all these tests by following the

proper procedures and methods. Each and every test are done on different

scales and parameters to collect essential information regarding all the

concerned materials to check there properties that matters the quality.


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MECHANICAL DEPARTMENT

OBJECTIVE: Mechanical section of any industry is considered to be the strong support on which the whole industry heavily relies. The mechanical department of NOVATEX deals with all type of plant and equipment maintenance. The Mechanical department is responsible to workout engineered standards by providing operating support to implement planned and schedule maintenance and also manage the modification and expansion projects of industry.

MAINTENANCE: The Mechanical department of NOVATEX follows complete guidelines to ensure optimization of the process by proper maintenance with following types.

Types of Maintenance in NOVATEX: 1) PREVENTIVE MAINTENANCE: A simple activity to ensure to get reliable and

efficient performance from the plant and to prevent any unplanned downtime due to breakdown.

2) PREDICTIVE MAINTENANCE: Predictive maintenance is a method to extend the life and reliability of your machines and processes by identifying problems using vibration analysis, thermal imaging, ultrasonic analysis, oil testing, emission testing.

3) BREAKDOWN/EMERGENCY MAINTENANCE: Breakdown Maintenance is referred to repair and performed on a machine, production plant or component, be it mechanical or electrical after it has failed or broken-down unexpectedly.

4) SHUTDOWN MAINTENANCE: It is the form of preventive maintenance where maintenance work is performed when the equipment is not in use or plant is completely shutoff at desired areas.

5) STRUCTURAL MAINTENANCE: This includes checking and inspecting of the construction holding the giant units of plant including all the buildings and taking necessary action to fix them.


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ENGAGING AND EXAMINING AREAS: The Process and Electrical department are interconnected with Mechanical department. We can say Mechanical Section is like a center point on which rest of the departments are in equilibrium. The Mechanical departments pays full duty to examine and check over the plant to accommodate the Process and Electrical department of NOVATEX. This includes all the units (Poly I, Poly II, SSP I, SSP II, SSP III). The equipment that concern the ME department are:

EQUIPMENTS TYPES QUANTITY

Agitator SNR-Type SDR-Type

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Heat Exchanger Shell & Tube Plate Type

Cooling Tower Forced-Draft Induced-Draft

Storage Tanks MEG Tank HFO Tank Diesel Tank

1 1 1

Silos PTA Silo Blending Bagging Silos Off Spec Silos

1 1 1

Pressure Vessel SS Material Carbon Steel

19 8

Pumps Centrifugal pump Gear Pump Screw Pump Vaccum Pump Pit Pump Others

69 17 9 4 2 15

PROJECT MANAGEMENT SECTION: Along with maintenance and regular inspecting of all the units (Poly I, Poly II, SSP I, SSP II, SSP III) the Mechanical engineers are also involved in the expansion and modification of plant as per feasibility and requirements. However, requirements and operating parameters are set by the Process department but the case study is done by Mechanical Engineers. From the initial study of project till its completion, the Mechanical department keeps the steers in their hands to manipulate the directions of project. We can say ME plays a strong role to keep the growth of NOVATEX forward.


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UTILITY

OBJECTIVE: Utility department is responsible to handle all the operation and maintenance

of all areas and equipment under utility. It also supply soft water to the plant

and maintains firefighting equipment and cooling tower.

MAIN COMPONENTS (UTILITY):

1) WATER TREATMENT: Supply soft water and denim water (palletizing plant

and cooling tower only) to the whole plant.

2) NITROGEN GENERATION PLANT: Produces technical nitrogen (from air) and

supply the nitrogen gas (both pure & technical) to the plant (especially to SSP

units).

3) AIR COMPRESSORS (Screw Type): Pressurizes the air by reducing it's volume.

4) CHILLER: Vapor-Compression chiller is installed to decrease the temperature

of water and by removing it's heat.

5) AIR HANDLING UNIT: Drops the temperature of air by using chilled water.

This air is then use to cool M.C.C and Control room.

6) FRESH & WASTE WATER SYSTEM: Produces portable and drinking water

from waste water.

7) CHEMICAL TREATMENT OF COOLING WATER: Scaling and corrosion of

cooling towers is a real concerned. Chemical dosing is done to avoid such

happenings to keep the operations of cooling tower without any trouble.

The regeneration steps of cation and anion exchanger involves:

Reverse flushing of cation exchanger

Filling of HCL

Slow rinsing of cation exchanger

Reverse flushing of anion exchanger

Filling of NAOH

Slow rinsing of anion exchanger

Fast rinsing of cation & anion exchanger

Consumption of HCL per regeneration = 346 kg

Consumption of NAOH per regeneration = 200 kg


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SUPPLY LINES Each supply lines are indicated by unique color

Raw water

Cooling water

Soft water

Compress air line

Fire fighting

Instrument air line

Technical nitrogen

Pure nitrogen

Drain line

Rain drain line

AIR COMPRESSOR UNIT Air filter is used to remove dust.

Air is compressed at 3 bar in first element compressor.

Inter cooler to remove heat and increasing compressibility.

Air is compressed at 10 bar in second element compressor.

Refrigerated air dryer remove the moisture.

Further moisture remove in adsorption air dryer unit.


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NITROGEN PLANT Nitrogen is separated from air by pressure swing Adsorption.

Carbon sieves are used in absorption and regeneration and desiccant dryer

unit.

Compressor is used to compress the gas and to build up the pressure to

utilize it for transporting purpose.

Deoxidation reactor purified the nitrogen by removing oxygen

DEMIN WATER PLANT Demin water is supplied to:

Palletizing plant

Centrifuge

HCl and NaOH is used to regenerate the exchangers.

Water is used to dilute the HCl, NaOH and formation of Demin water.


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RAW WATER PLANT Raw water is supplied to

Cooling water.

Demin water plant.

HTM circulating pump priming.

Filter cleaning area.

Bottom discharge pump.

TiO2 and additive feed line.

NOTE:

Dosing unit dosing Nalco (corrosion inhibitor) and NaOH dosing increase PH

range 7.5 to 8.


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POLYCON DEPARTMENT

OBJECTIVE;

NOVATEX has two polymerization plants. The main function of chemical engineers is

to run Polycone and SSP department. They utilized the raw material and all the

accessories like electricity from power house, technical nitrogen, oxygen, raw water

and demine water from utility for the production polyethylene terephthalate (PET).

NOVATEX makes three PET grades.

Textile grade are formed in poly 2 having intensive viscosity 0.60.

Film grade are formed in poly 1 having intensive viscosity 0.635-0.640.

Bottle grade are formed in poly 1 having intensive viscosity 0.635-0.640.

SNO PLANTS TECHNOLOGY PRODUCTION (TPD)

1 Poly 1 Zimmer Germen 300

2 Poly 2 China 900

PASTE PREPARATION VESSEL:-(11 TA-01)

RAW MATERIAL

Two main raw material which are used in bulky for the production of PET are as

following.

1) Pure terephthalic acetate (PTA) is main reactant and added 84% to 86%. It brought

from Indonesia (KASIE BAKERI), Thailand (MITSUI), Pakistan (LOTTE), india

(RELIANCE).

2) Mono ethylene glycol (MEG) is limiting reactant and added in 14%. It is brought

from Saudi Arab (SABIC). NOVATEX store MEG in three tanks of volume of 3000m3,

3000m3, 1800m3.

ADDITIVE

The additive which are used for the production of PET.

1) Antimony triacetate (Sb(CH3OO)3) or cobalt acetate (Co(CH3OO)) is added as

catalyst. It provides the activation energy and speed up the reaction.

2) Titanium oxide (TiO2) is added in 250 ppm to use as lusting agent is added to reduce

elasticity


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3) Hypo phosphoric acid (H2PO4) is added in 12 ppm to use as heat stabilizer. It

controls the side reaction when temperature goes high.

4) Diethylene glycol (DEG) is added 1% while Iso propylene glycol (IPA) is added 2%

ratio. It is used to lowers the melting point and to retard crystallization.

5) Red Tonner is cobalt acetate to provide bluish tone to chips.

6) Blue Tonner provides bluish tone to chips.

All these ingredients are prepared in separate vessels which are then store in their

separate vessel and then all the ingredient are transferred in the paste hopper. Paste

hopper fed the paste into the paste vessel where materials are mixed uniformly by

agitation. Nitrogen is introduced from bottom of Paste hopper which prevent to stick

the material with hopper.

ESTER 1 (12-RO1) AND ESTER 2 (13-RO1)

Ester 1 and Ester 2 are CSTR type reactor for esterification reaction, in which

continuous agitation is done to maintain uniform temperature i,e about 260 to 267 C

and build up certain intensive viscosity i,e about 0.5 to 0.95 respectively. Reaction

processed between TPA and MEG and from Bis 2- hydroxyethyl (BHET) and water

(H2O). It gives about 90% to 96% conversion respectively. It takes about 3.5 to 5-hour

residence time to complete reaction. Reactors are arranged in such way that material

is transferred from one reactor to other by gravity.

TPA + MEG (In excise) BHET + 2H2O (by product)

In this reactor, the two types of heating system material is used to give an appropriate

temperature to the paste.

1) SANDOTHERM: heat is given by liquid HTM hydrogenated poly phenyl present in

the coils

2) DOWTHERM: heat is given by vapors poly phenyl from in the jacket.

DISTILLAION COLUMN (13C01)

The reaction between TPA and MEG is reversible reaction and water is by product

therefore, for the higher conversion of product, EG should be in excise and water

should be removed so the vapors of EG and water from CSTR 1 and CSTR 2 are brought

to distillation column where EG is condensed and water and aldehydes are removed

from the top of column, vapors is then condensed in condenser some of the vapor are

stored in the reflux tank for water reflex in column.


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Column is consisted of 18 plates

Temperature at bottom of column is maintained about 180˚c

EG content in water at top of column is less then 0.5 wt

water content in EG in bottom of column is less then 1.5%,

PRE POLY- CONDENSATION 1 (14-R01)

PP 1 is a PFR type reactor, consist of hollo tank and having two zones which are

separated by wall between column. Material enters in second zone after passing from

top of wall of second zone. This wall provides the residence time material to react. The

temperature is maintained about 277C while vacuum of 100 to 120 mbar is created in

order to remove water from the reactor for high conversion. Vacuum is created by the

combination of scrapper condenser (14-E01) and liquid ring vacuum pump. Material

achieve intensive viscosity about 0.13.

BHET + BHET n PET (product) + (n-1) MEG

PRE POLY-CONDENSATION 2 (15-R01)

PP2 is PFR or mixed type reactor horizontal vessel and containing numbers of disk

rings, attached with single shaft, driven by single motor which help in agitation. Disk

contains many holes to allow the passage of material. Material enters from poly 1 to

poly 2 under pressure difference. The temperature is maintained about 282 C and

system is maintained under vacuum of 15 to 17 mbar pressure by the combination of

scrapper condenser (15-E01) and liquid ring vacuum pump. The intensive viscosity

build up 0.25 to 0.30. The material is then fed into the filter (16-F01) where the dust

and impurities separated out to ensure the purity of the material. The size of filter

16F01 is 100 micron and has 70 candles.

DISK RING REACTOR (17-R01)

DRR is PFR or mixed type reactor which have same design as pp2 but the only

difference is that its single shaft is driven by double motors for agitation purpose which

build up intensive viscosity to 0.60. HTM vapors is present in the jacket to melt the

polymer that stick with wall as the material is so viscous as well as to maintain the

temperature of the reactor at 283 degree centigrade. system is maintained under

vacuum of 2 to 0.05 mbar pressure by the combination of scrapper condenser (17-E01)

and vapor jet ejector.


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SCRAPPER CONDENSOR:

PP1, PP2 and DRR are connected with scrapper condenser where vapors of E.G and

water are entered in scrapper condenser. Scrapper condenser is a vessel having tom

like shape liquid EG is showered from top of the tom column which contain umbrella

type perforated baffles that allow the larger contact area to condense the EG vapor

but some amount of E.G vapors remain uncondensed which are condense in separate

condenser and collect in separate vessel. it is low velocity vapors therefore a

supersonic velocity vapors of E.G that coming from glycol evaporator take these slow

vapors to the jet through venture to maintain the pressure.

E.G VAPOR JET (17-J01)

EG vapor jet is a unit with 4 stage of E.G vapor jet and three condensers. Off gas from

EG vapor jet is sucked by the first jet where it is condensed by showering of spray E.G

with jacketed heating to prevent the formation of oligomers. It is then fed into second

and at last third jet where the remaining vapors are condensed. Tank 17T02 is used to

collect the condensed E.G from the three jets. Tank 17TO3 is used to collect all spent

E.G including E.G condensate by distillation column 13C01, scrapper condenser 14E01

and 15E01. The remaining uncondensed is then sucked by the vacuum where it is

further condensed and remaining E.G is then vent to the atmosphere but it is less in

amount.

FILTER (18-F01)

The material from DRR is enter into filter 18F01 where the further impurities is

removed. The size filter 18F01 is 40 micron and having 74 candles. The material from

DRR is highly viscous and due to its smaller micron size as compared to 16F01, 18F01

filter is blocked easily and then sent to the filter cleaning area.

CUTTER

The material from filter is then divided into 2 sections. One goes to three cutters and

other goes to another three cutters by passing through die head having 78 laces, 39 in

front and 39 at the back. Die head has 19 sensors that alarm at any dangerous and

unhealthy conditions, in this situation cutter goes at the waste. It uses three types of

water:

1) CONVEYING WATER: It is used in the cutter to prevent from high temperature.

2) OVER FLOW WATER: It is used to convey the laces or spaghetti.

3) SPRAY WATER: It is used to maintain the temperature during conveying.


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DRYER

After cutting, the chips are fed into the dryer where the water content is removed

from them by air sucked with the help of blower.

VIBROS CREENING Over size and under size chips is separated in this section and then remaining sent to

the amorphous silos by the help of conveying air.

EVAPORATOR

The evaporators (12V01, 14V01, 15V01 and 17V01) are used to heat up the

condensate of HTM vapors by using HTM liquid. HTM vapors are responsible for

jacketed heating.

PROCESS FLOW DIAGRAM (PFD)


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SOLID STATE

POLYMERIZATION (SSP)

OBJECTIVE

The main objectives of solid state polymerization SSP are

To upgrade the intensive viscosity

To remove the moisture

To minimize the aldehyde

To crystallize the chips

To increase the molecular weight of chips

SURGE SILOS

Amorphous chips are stored in three silos of having 300 m3 ,300 m3, 80 m3. The level

of these silo are monitored by laser sensor in order to maintain the level of chips

nitrogen is continuously blow from bottom of silo

AMORPHOUS CHIPS HOPPER

Chips are fed into amorphous chips hopper by pneumatics purge system then fed into

rotary feeder which is set at known rpm that feed certain amount of chips weight into

pre crystallizer

PRE CRYSTILLIZER

Hot nitrogen gas fed from bottom of pre-crystallizer at 200 C and fluidize the chips.

Fluidization prevent the lambs formation, remove the aldehydes and dust particles

and transfer certain amount of heat for crystallization and chips achieve glass

transition temperature i,e about 78 to 80 C

SNO PLANTS TECHNOLOGY PRODUCTION (TPD)

1 SSP 1 UOP Sinco Chines 225

2 SSP 2 UOP Sinco Chines 225

3 SSP 3 Bhular German 600


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1) TWINS CYCLONE: nitrogen gas is exhaust from upper portion of pre-crystallizer to

twin cyclone in order to remove the dust

2) NITROGEN FILLER: Nitrogen goes to nitrogen filler where it is sucked by a jumbo

blower.

3) NITROGEN PRE-HEATER: Jumbo blower discharges the nitrogen into pre-heater

from where nitrogen again utilize in pre-crystallizer, hence complete the cycle.

CRYSTILLIZER

Chips move down to crystallizer # 01 then to crystallizer # 02 where it achieve

temperature 160 to 180 while having pressure of 155mbar to 125mbar and 55 to 57%

crystallization occur respectively. Crystallizer contain two hollow screw in order to

transfer heat from HTM (heat transfer medium). These screws continuously agitate

the chips

SOLID STATE POLYMERIZATION (SSP)

SSP reactor is a PFR reactor and have residence time of 12 hours. It permits the

initiation and polymerization reaction. Melted chips are fed into SSP (solid state

polymerization). In SSP reactor counter currently moving hot nitrogen and HTM in

pipes is used for heating purpose where crystallization increase further and its

intensive viscosities increases from 0.78 to 0.82.

FLUIDIZED BED COOLER

Fluidized bed cooler consist of two zones. Material enters in first zone from SSP reactor

where cooled nitrogen enters from the bottom of first zone of cooler and transfer it

to second zone by fluidized it which lowers down the temperature of chips.

1) HOT NITROGEN FILTER: Two giant blower suck the nitrogen and pass discharge into

hot nitrogen filter where remaining dust particles are removed.

2) ECONOMIZER: Nitrogen enters in gas to gas economizer where its temperature

rises to 250 C by coming exhaust nitrogen of 330 C form NPU reactor.

3) NPU REACTOR: Nitrogen is mixed with oxygen and heated into electrical nitrogen

heater and then mixture of oxygen and hot nitrogen enters in NPU (nitrogen

purification unit) reactor where combustion reaction take place in the presence of

1% platinum catalyst which remove Aldehydes and hydrocarbon present in

nitrogen. The exhaust nitrogen temperature riches to 330C which utilize

temperature in economizer.


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4) NITROGEN COOLER: Nitrogen goes to nitrogen cooler which is cooled by water.

Cooler is shell and tube type tube contain water shell contain nitrogen. Cooling is

done to increase the relative humidity so that maximum drying can achieve and to

prevent the molecular sieves of the dryer.

5) NPU NITROGEN DRYER: The byproduct of combustion such as water vapors and

CO2 in nitrogen gas are removed in

nitrogen dryer. Nitrogen dryer

consist of two cylinder which is filled

with aluminum oxide sieves (zeolite)

and working on pressure swing

adsorption (PSA) method. First

column adsorbs the nitrogen while

other regenerate the column and

they shift after each 12 hour. After

passing this dryer cooled nitrogen

goes to nitrogen filter to fluidized

bed cooler and preheated nitrogen

to SSP after passing from electrical

preheater.

STATIC BED COOLER

Chips from fluidized bed cooler enter to

static cooler. Static cooler is shell and

tube type. Shell contains chips while

tube contains water. Water lowers the

temperature of chips to 35C.

VIBRO SCREENING

Material goes to VIBRO screen. Screen

separates the oversized and under sized

chips which separately collected in two

silo and then used for molding purpose.


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POSITIVE SIDES

1) NOVATEX is ISO and HACCP certified and having other certification.

2) NOVATEX follows all the standard and SOPs.

3) Cooperative and discipline staff.

4) First rate safety and security.

5) Planed and schedule maintenances.

6) Neat and clean environment.

7) Experienced and skillful engineers.

8) Regular training session of health and safety.

SUGGESTION

1) There should be a research and development department in industry.

2) Quality control department should cooperate and guide the internees properly

specially process engineers because process engineers are the back bone of

industries and they have decided process parameters in the fields so they should

be aware of basic concept.

3) Silo are corroded from bottom. Effective measures should be taken on this issue.

4) The SSP building Silos (concrete and filling i.e. paints) are damaged and large cracks

can be seen at the edge of building.

5) Permission is given to internees to bring reading material with them.

6) Permission should be allotted to Internees specially process engineer to visit DCS

room under concerted supervision.

7) There should be session of simulation and instrument software for internees.


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CONCLUSION

The 3 weeks in NOVATEX is proved a worthwhile experience for all three of us. The

time in the industry shows us a picture that realizes us to rethink and reconstruct our

learning style in different manner. The complex and large scale operations provided

us with a great value of information to broad and expand our educational sphere. We

assure with complete confidence that we had completed the given tasks and objectives

within the time and our purpose of doing internship is being fulfilled.

NOVATEX is a great place to apply the theoretical concepts on practical applications.

In this short time we observed how the departments interacts with each other and how

the employers of the company works to complete the daily targets or objectives of the

industry. The industry is a loop where each workforce is bonded together with a single

chain, and they create a net output on which the company revenue grows in terms of

their productions and sales.

In last, concluding the 3 weeks of internship, that we had not only learned about

technical and engineering aspect of industry but we had been taught how the industry

runs, how the system works, how to expose the professionalism and technical skills

with discipline and dedication, and how an engineer can contribute to the industry.

Signing off and stepping out from the industry (NOVATEX) by saying we spent a

beneficial time.