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)

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,
its 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 7
SDR-Type 5
Heat Exchanger Shell & Tube
Plate Type
Cooling Tower Forced-Draft
Induced-Draft
Storage Tanks MEG Tank 1
HFO Tank 1
Diesel Tank 1
Silos PTA Silo 1
Blending Bagging Silos 1
Off Spec Silos 1
Pressure Vessel SS Material 19
Carbon Steel 8
Pumps Centrifugal pump 69
Gear Pump 17
Screw Pump 9
Vaccum Pump 4
Pit Pump 2
Others 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.
Consumption of HCL per regeneration = 346 kg
Consumption of NAOH per regeneration = 200 kg

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

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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 180c
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

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

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

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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.

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