Process

The production process is briefly illustrated in the schematic flow diagram. The main raw material is pulp made from wood which is a renewable resource , Caustic Soda , Suphur & Charcoal. There is strict process control at every stage and latest computerized control systems have been installed at the critical points. This ensures uniform and consistent quality.

A co-product of the production process is Anhydrous Sodium Sulphate which is of the highest purity. For every ton of fibre produced we are presently recovering 0.75 ton of Sodium Suphate.

We are also producing Sulphuric acid & Carbon bi-sulphide for captive consumption.

The plant is equipped with a modern laboratory and latest testing equipments. The laboratory scientifically anlayses samples of raw materials, materials in process and finished product. Special emphasis is given in testing to key parameters like tenacity, elongation, whiteness and oil pick up.

Soda Station : This section deals with preparation of caustic soda solution from 50 % to 42 %, 30 %, 18 % & 12 %, clarification and supply of caustic solution to various places of its consumption.

Slurry Mixer : This section deals with conversion of cellulosic wood pulp to alkali cellulose. This is done in batch process. Fix quantity of pulp & 18% steep lye is fed to the slurry mixer. Slurry from the slurry mixer is pumped to homogenizer and then to slurry press.

Slurry Press : In this section excess lye is removed from pulp slurry and squeezed alkali cellulose is sent to maturing drums through pre-shredders & shredder.

Maturing Drum : Ageing of alkali cellulose (Alk-Cell) is done in maturing drum (M.D.), a long jacketed cylindrical vessel. Temp. of alk-cell is controlled by circulating water at controlled temp. in the M.D. jacket. Alk-Cell is then pneumatically transferred to silo through cooling device.

Simplex (Xanthators) : In this section of process matured alk-cell reacts with Carbon di-sulphide to get sodium cellulose xanthate. Dilute caustic soda is added to this xanthate and then the slurry is dropped to dissolver for dissolving the xanthate & thus making of viscose.

1-2-3 STAGE (Ripening Room ) : viscose from dissolvers is received in receiving tanks through homogenizers. The process of ripening of viscose i.e. attainment of right salt index is achieved in 8 – 10 hrs. While the process of ripening is taking place, the viscose is filtered in three stages and deaerated. After 3rd stage of filtration the viscose is received in Spg. tanks for pumping to Spinning department.

Spinning : In this section, cellulose is regenerated in the form of filaments of different denier by extrusion of viscose through fine hole of a cluster type spinnerette into a coagulating acid bath followed by stretching and cutting to desired staple length. Sodium sulphate is produced here as a by-product and is sent for recovery.

CS2 recovery : Cut staple fibre from the cutter along with water flows to CS2 recovery trough through a trunk and forms a mat. Steam is injected in this trough through perforated steam pipes. CS2 present in fibre mat gets liberated and goes to CS2 condensing section along with steam. In the CS2 condensing system CS2 gets condensed and flows to storage tank. Almost 44% of CS2 is recovered back.

Aftertreatment : This section deals with washing & finishing of fibre. This section is divided in different zones like De-sulphurization, Desulph wash, Bleaching, Bleach wash, Final wash and Soft Finish. After application of soft finish in Soft finish zone, fibre is squeezed hydraulically and opened by wet mat openers.

Dryer : Fibre coming from wet mat openers of the aftertreatment section, contains ? 100 % moisture and is dried to ? 13 % moisture in Dryer Section. Fibre is dried by counter current hot air supply. To achieve 13 % moisture dryer has been divided in different zone. The circulating air temp. in different zone is maintained by controlling steam flow in the steam coils. Dried fibre from dry end is send to baling press.

Baling Press : The dried fibre from dry end of dryer is conveyed pneumatically to separator drum of baling press. In the baling press bales are being made as per set weight & dispatched to Ware house after passing through online moisture & weight measuring system.

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