amreli steel-internship report-yaseen raza

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2012

Yaseen Raza

NED University of

Engineering and Technology

INTERNSHIP REPORT

YASEEN RAZA NED University of Engineering And Technology | 2

INTERNSHIP

REPORT

SUBMITTED TO

MR. Abdul Latif Bhano

MANAGER PRODUCTION

SUBMITTED BY

YASEEN RAZA (MY-50)

NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY

BATCH: 2009~2010

DURATION: 05TH DECEMBER 2012 TO22NDDECEMBER 2012


ACKNOWLEDGMENT

Starting with the name of Allah who is the most merciful and

beneficent

My report work has accomplished under excellent guidance and

supervision of production and management team of Amreli

Steels Limited, SMS Dhabeji. I offer my heartiest gratefulness

to ASL team for its step to step guidance and close supervision

during the conduct of all the period of internship at ASL.

No acknowledgement could ever adequately express my

obligations to my affectionate parentsfor their all inspirations

and guidance which always motivated us to carry ourselves

through the noblest ideas of life and solving all troubles and

boosted my moral to fly high to accomplish our goals.

I convey special thanks to my dear class adviser MR

IFTIKHAR AHMED CHANNA, NED Universityfor his

excellent, efficient, accurate and reliable help to completion of

this internship as well as completed our report.


I also convey special thanks to

SMS plant Planning & production team

MR Noman Sajjad (Executive Manager)

MR Inayat Ullah Baig (Maintenance Manager)

MR Abdul Latif Bhano (Production Manager)

MR Hammad Ali (Manager Planning& Development)

MR Sohail Mumtaz(Deputy Manager, Mechanical)

MR Abdul Majeed Jagirani (Deputy Manager, Electrical

MR Muhammad Farooq (Assistant Engineer,Mechanical)

MR Zaigham Masood (Shift Incharge IF)

MR Kamran Memon (Shift Incharge LRF)

MR Adnan (Asst Engg Ref)

MR Alam (AsstEnggIF)

MR Naeem Khatti (Shift Incharge CCM)

MR Said Haneef (Incharge QC)

MR Qadeer (Incharge QC)

MR Zubair (InchargeUtility)

MR Sarfaraz (Trainee Engg)

MR Ammar (Trainee Engg) Mr Zeeshan Moeen (Ass. Engg Vezzani)

Mr Noman Amjad (Trainee. Vezzani)


INDEX

Sr. No Plant Description PG.NO

1 ASL Process flow chart 6

2 Introduction 7

3 Raw Material

Types

Vezzani

8

4 Steel Melt shop (SMS) 9

5 Induction Furnace

Furnace specification

Furnace Operation

Furnace Lining

Furnace Crucible

Furnace Control

Furnace Slag

10-14

6 Ladle Furnace

Ladle lining

15-16

7 Continuous casting

Process

Mold Body

Operation modes

Metallurgical Length

Calculations

Cooling zones

Liquidus Temp

Carbon equivalent

16-20


8 ASL Grades and Composition 21

9 Slag Processing Area 22

10 Quality Control

Spectro lab

Wet Lab

24-25

11 Logistic and Stores 25

12 FES (Fume Exhaust System) 25

13 Reverse Osmosis Plant (RO) 26


Scrap

Scrap Yard

Vibratory Feeder

Scrap Area

Charging

Vessani Shear

LRF

Transfer trolley

Melting

Spectro Lab

Deslagging

Continuous casting

Billets

Induction Furnace

Shearing of

Oversize scrap

Quality Control

Heat taping

Wet Lab

Slag processing

area

Temperature

check

Billets stock

area


INTRODUCTION

Company`s Profile

The Company was incorporated in Pakistan as a private limited company under Companies

Ordinance 1984, to take over from partnership firm doing business in the name of Amreliwala

Hardware Industries. Prior to 1984, the Sponsors were operating manual re-rolling mills to

manufacture mild steel bars. These rolling mills were dependent for raw material on sponsor-

owned ship breaking business.

The Sponsors are in steel business for many decades; because of this exposure and experience

the family was able to foresee the advent of strong demand in quantity and quality of steel bars.

To cater to this, all manual rolling mills were scraped in 1984 and fully automatic plant of

Danieli brand was imported and installed with production capacity of 35,000 tons, the capacity

of which over the years was increased to 75,000 tons.

Amreli Steels has been in steel business for decades and have earned a respectable name in the

business world through commitment to its customer by providing the best quality product and

adherence to the corporate and ethical principals in conducting business operations. Amreli

Steels is one of the few steel bar manufacturers that used billets of Pakistan Steel Mills as raw

material for its hot rolling process. Good quality billets and advanced automatic manufacturing

facility with professional and motivated team has given Amreli a competitive edge over its

fellow manufacturers.

This report will cover the areas of

Induction furnaces (IF)

Ladle Refining Furnace (LRF)

Continuous Casting Plant

Refractory Shop

Utilities

QC

Which I learned during the internship.

Amreli steels limited produce

High strength Xtreme bars conforming to BS 4449:2005

Hot rolled deformed bars conforming to ASTM A615

Above grade reinforcedsteel bars from high quality billets. These billets are produce through

continuous casting process. Induction furnace is used to melt the scrap, which is the prime raw

material for producing desire melt.


RAW MATERIAL Scrap is the prime raw material used for producing quality melt. This scrap is imported from

UAE and India. It is then transferred to scrap yard through containers from port. As per

requirements, different types of scrap are used. They are classifies as

HMS

Heavy Melting Scrap is a designation for recycled steels. Its size is above 600mm. It is

divided in two categories

HMS-1: Consists of non-galvanized parts, engine blocks, some Aluminum and Copper

parts

HMS-2: Consists of galvanized parts etc.

HMS: Soft scrap like sheets, pipes etc.

SHREDDED Consist of small parts, crushed scrap. Size is below 600mm

BUNDLED LMS: Light Metal Scrap

UBC: Used Beverages Canes etc

GI: Galvanized sheets or parts are Bundled scrap

20% HMS, 30% shredded, 25% bundled and remaining 25% mix scrap is used. As per

requirement, scrap is transferred from yard to scrap bay through dumpers. Scrap size more than

600m is first shifted to Vezzani shear for shearing than to melt shop.

VEZZANI SHEAR

Vessani shear is used to perform shearing of oversized scrap. Crane is operated manually. Scrap

is charged over a taper plate of vezzani at the end of which there is a ram. Scrap is compressed

first by horizontal ram then by vertical ram and shearing blade shear the scrap to size of

600mmthen the gate is opened. it is then passed over a vibrating conveyer, it consist of a

magnetic drum. It is 1/3rd

magnetic so it attract ferrous scrap and nonferrous scrap like

aluminum, copper etc fell down on debris conveyer belt.

From scrap car it is transferred to furnace floor i.e. vibratory feeder. Vibratory feeder is used to

feed scrap to the furnace crucible at a rate of about 400kg/min. its surface is slightly tapper so as

to allow easy feeding


SMS- STEEL MELTING SHOP

Steel melt shop consist of:

Two induction furnaces (IF) each with 2 crucibles

Ladle Refining Furnace (LRF)

Continuous Casting Plant

Ladle Preheating area

Refractory Shop

Slag processing Area

INDUCTION FURNACE

Induction furnace is an electrical furnace which utilizes electricity as fuel. Electromagnetic

heating is used to melt the scrap in the crucible. Copper coils are used which acts as primary and

generate low voltage high current in secondary (scrap). Alternating current(A.C) passes through

it and magnetic flux is generated within conductor.The magnetic flux generated eddy current that

enables the heating andmelting process in the crucible.


FURNACE SPECIFICATION

Power requirement: 10MW

Melting transformer: 12 MW

Sintering transformer: 1.2 MW

Capacity: 25-30 MT

Current: 2000A

Voltage :3670V

Frequency : 192Hz

Temperature :960-1620oc

There are two crucibles for each furnace. One crucible is on melting operation and another is on

sintering operation. Crucible is changed after 12-15 heats

FURNACE LINING

Lining of If is acidic because of acidic slag formed. Quartzite lining also called acid ramming

mass is used as lining material and boric acid as binder.

It consist of

a) SiO2 -98.5%

b) Al2O3 – 0.02%

c) Fe2O3 – 0.02%

d) Boric acid ((H3BO3) 1-1.2%

Preheating is done to 90oc for removing moisture. 70% grain and 30% powder is mixedin mixing

mill, 1.2% boric acid is added then transferred to bin then to floor. Cooling of furnace is carried

out through blower for about 6 hrs and then lining is breakout in 3 hrs. Pneumatic drills are used

for this purpose, after breaking the lining, furnace is tilt and waste is thrown down in pot.

Mixture is heated to about 90°c.

Former is used to prepare efficient lining. Two types of former are used.

ASL Former: It is consumable former made of low carbon steel sheet. Lining is

placed layer by layer and rammed through pneumatic hammer. In ASL former 11 layers

of lining are placed because former is melt able and after melting a fine lining surface is

obtained.

Chinese Former: It is non-consumable former. In Chinese former 24 layers of lining

are placed because former is removed after lining and close accuracy of lining is

required. When it is removed, patching is done.


Sintering Sintering is performed after lining so that the binder get hold strongly the acid riming mass and

to induce strength in lining. The greater the time greater will be the strength.

Sintering time (hrs.) Power (KWH) Crucible state

2 125-175 Empty crucible

1 300-450 Filled with scrap

1 500-600

1 650-800

1 850-900

1 900 or above

FURNACE CRUCIBLE Induction furnace crucibles are made of highly conductive hollow, rectangular copper tubes. 12

pairs of copper coils i.e. 24 coils are mounted rigidly. Also there are 3 SS coils at the top and 4

SS coils at the bottom to facilitate cooling. SS is used because it has high oxidation-resistance,

corrosion resistance and wears resistance.

Induction Furnace Coil


This coil is coated with AH60 refractory material in order to protect from moisture etc.

First coil is painted with a special paint. Each copper tube is then wounded with glass tape.

Scandium blocks are place with the gap between the copper tubes. Then finally it is painted with

resin and aluminum coating.It is then dried in air.

FURNACE CONTROL Total power supplied to ASL is 63MVA

Total power consumption of both furnaces is 25MVA

Generator room, Crucible room and operating room control all operations on IF.

Generator room consists of:

DC chock: converts AC to DC. Input is 600V x 4 = 2400V, four Converters are used.

Output is 3600V. Inverter convert DC to AC, in this way we can control (inc/dec)

Frequency

DM unit:

Capacitor unit: Capacitor bank is usedto maintainpower factor. Eight capacitor are used,

each consistof 2,4 capacitors respectively. if p.f increases above 1, first 8th

capacitor trip

then 7th

and so on to maintain p.f 0.98-0.85

ITC-control inverter

Turnover voltage cct – detect problem and trip furnace in case of problem

Earthling cct, ET-SL, PLC etc. are other controlling units

Hydraulic power pack: Provide pressure of 6 bar, (single acting cylinders) used for tilting

furnace

RTT sensor – Shows temperature

ELC machine: Filters magnetic particles from hydraulic oil.

Operating room controls power flow, current voltage, etc.

FURNACE OPERATION Initially shredded scrap is charged because it can melt easily, quickly and efficiently and forms a

conductive molten pool of metal. About 15 tons is added initially, after melting of this first

sample is taken from furnace and analyzed for composition. On the basis of this result, further

scrap is added to control compositions of elements. On this basis HMS or bundled etc are added.

If composition is not accurate different alloying additions are made.

SiMn - added to control % of Mnand Si

FeMn- added to control % of Mn

FeSi- added to control % of Si

Main elements in the melt are carbon, silicon, phosphorous, manganese and iron.

Silicon increases fluidity and facilitate for ease of flow in casting.


Carbon induces strength and hardness as well as reduces ductility (If added in excess quantity).

Manganese induces ductility and wear resistance in the melt.

Deslagging

FURNACE SLAG

Slag of IF is acidic slag, because our lining is acidic. Basic slag will consume acidic lining very

rapidly. This acidic slag consist of

SiO2,Al2O3, FeO, MnO, P2O5

Fe+O2 ----- FeO

C+O2 ----- CO

Si+O2 ----- SiO2

Mn+O2 ----- MnO

2P+5/2O ----- P2O5

Excess of sulphur and phosphorous causes hot shortness and cold shortness respectively.


LADLE FURNACE The ladle is a vessel used to transfer and pour molten metal from furnace to desire plant for

casting, refining etc.

Sometimes the ladle acts as a furnace normally used to heat up, and to hold different kinds of

metal melts. Heating is done either by graphite electrodes, Depending on metal, ladle size and

expected heating rate, electrical power of up to several megawatts may be applied.

LADLE FURNACE (top view)

Ladle Refining Furnaces are a proven technology used for producing alloy steel, desulfurizing

liquid steel and for improving the productivity from a steel plant. Ladle Refining is a post-

melting treatment that is after melting in the Induction Melting Furnace Whenever LRF is

installed online, liquid metal is transferred from the main melting source to the LRF at a nominal

tapping temperature and either Argon/Nitrogen is purged from the bottom apart from arcing

(using electrodes) on the top to bring about homogeneity of liquid metal composition and

temperature. Fused lime/CaSi is added to the liquid metal to reduce sulphurup to 0.015% and

bring it within acceptable limits

Ladle Refining of liquid metal is a proven technology to produce high quality steel. Ladle

Refining Furnaces (LRFs) are used to desulphurize steel, remove other impurities and hold the

molten steel for casting operations. Without LRFs, higher tap temperatures are normally required

from steel making furnaces due to heat losses during transfer and casting of liquid metal. LRF

facilitates higher productive time to the melting furnace besides producing better quality of steel

at lower cost.


When alloying is done in the LRF, the main melting furnace is freed from this activity providing

more productive time to the melting equipment and this external treatment has a few distinct

benefits like reduced alloy consumption, better lining life, excellent homogeneity of chemical

composition & temperature and relatively lower energy cost.

LADLE LINING

The total height of ladle is 2900mm and top, bottom dia are 2400mm, 2090mm respectively.

First lining of ladle is broken after 80 heats aprox. Bottom is prepared by Chrome Magnesite

bricks [chromite (40–50 percent or higher)]. QC well block and porous plug well block are also

placed and adjusted. Asbestos sheet (1000x1000x08mm) is placed. Safety lining of side walls is

done by Chrome Magnesite bricks.

There are for zones in ladle lining. Each zone consists of certain layers of refractory bricks

lining.

ZONE 1: Metal Zone 1-4th

layer using High Alumina bricks(175x154/146x100) and

(175x170/130x100) mm with Doloram as back filling mass

ZONE 2: Metal Zone 5-13th

layer using High Alumina bricks(150x154/146x100) and

(150x165/135x100)mm with Doloram as back filling mass

ZONE 3: Slag Zone 14-18th

layer using Carbon Magnesite (150x154/146x100) and

(150x154/146x100) mm with Doloram as back filling mass

ZONE 4: Free Board 19-22nd

layer using High Alumina bricks (250x150x100) mm

Zone

AH-90 paste (90% Al2O3, 4% CaO, SiO2+FeO) and SRA-95H (High % Al2O3) are used to fill gaps

and inner side of well blocks.


CONTINUOUS CASTING

Continuous casting is a process in which metal is cast in shape of billet, bloom or slab

continuously. Metal ore or scrap is melted in a furnace and then transferred to ladle. Here

refining, alloying additions if required are carried out. Ladle is then transferred to continuous

casting plant. Tundish dummy bar, mold tube, entry and withdrawal rolls, straightener, crop and

pinch, precutting roller table, discharge roller table, cooling belt, pusher, water spray nozzles,etc

are some of the parts of continuous casting mill.

Products obtained from continuous casting are mainly billet, bloom or slab. Heavy, four-piece

plate molds with rigid backing plates are used to cast large, rectangularslabs, (50-250 mm thick

and 0.5–2.2 m wide), which are rolled into plate or sheet. Similarmolds are used for casting

relatively square blooms, which range up to 400 x 600 mm in crosssection. Single-piece tube

molds are used to cast small, square billets, (100 - 200 mm thick)which are rolled into long

products, such as bars, angles, rails, nails, and axles.

Continuous casting


PROCESS Ladle after metal being taped in it and after refining is placed on a stand above tundish. Bottom

of ladle consist of a slider gate assembly, which is operated hydraulically.

The tundish allows a reservoir of metal to feed the casting machine while ladles are switched,

thus acting as a buffer of hot metal, as well as smoothing out flow, regulating metal feed to the

molds and cleaning the metal. Capacity of tundish is 4 tons.

Before starting the casting process, dummy bar is prepared. A bolt is attached along with an

asbestos sheet and metal sheet with the dummy bar. It is used to hold and drawn out cast product

uniformly and accurately from mold. As the mold insert at the bottom, we add steel and iron

chips and some asbestos power for ease of solidification. There is 4 mm gap between mold tube

and jacket of mold for water circulation.

The process is started by plugging the bottom of the mold with a dummy bar. After enough metal

has solidified like a conventional casting onto its head, the dummy bar is then slowly withdrawn

down through the continuous casting machine and steady state conditions evolve. The maximum

casting speed of 1-5 m/min is governed by the allowable length. Once in the mold, the molten

steel freezes against the water-cooled walls of a bottomless copper mold to form a solid shell.

The mold is oscillated vertically in order to discourage sticking of the shell to the mold walls.

Drive rolls lower in the machine continuously withdraw the shell fromthe mold at a rate or

casting speed that matches the flow of incoming metal, so the process ideally runs in steady

state. The liquid flow rate is controlled by restricting the opening in the nozzle according to the

signal fed back from a level sensor in the mold.

Mold Body:-

B

ase


plate Sincere or detector Mold jacket Mold tube Flanges Flange Cobalt-60 Water Outlet Oil plate Water inlet Bottom plate

OPERATION MODES There are four operation modes

Test mode: in which equipment`s working like oscillation etc is checked out

Casting mode: oscillation and withdrawal

DBI: Dummy Bar Insertion

Run out

The most critical part of the process is the initial solidification at the meniscus, found at

thejunction where the top of the shell meets the mold, and the liquid surface. This is where the

surface of the final product is created, and defects such as surface cracks can form, level

fluctuations can occur. To avoid this, oil or mold powderis added to the steel meniscus, which

flows into the gap between the mold and shell. In addition to lubricating the contact, a mold slag

layer protects the steel from air, provides thermal insulation, and absorbs inclusions.

Water or air mist sprays cool thesurface of the strand between the support rolls. The withdrawal

speed, mold level and water cooling are synchronized. The spray flow rates are adjusted to

control the strand surface temperature with minimal reheating until the molten core is solid.

After the center is completely solid (at the “metallurgical length” of the caster) the strand is cut

with gas torches billets of any desired length.

Gas torches move along the billet and cut at desire length. Fuel gas is LPG along with oxygen at

pressure of 2 bars. Launder pipe is used to open the nozzle, and then tundish is filled metal to

desire level. Tundish has two nozzles for two strands. Dia of nozzle pouring hole is 14mm. it is

made of 95% zirconium to avoid erosion


Metallurgical length The length at which core of billet solidifies is called metallurgical length. Metallurgical length

depends upon the rate of cooling and speed of withdrawal or casting speed, temperature and

dimensions of billet. Temperature required for CC is 1510-1550oc mold level is controlled by

Auto Mold Level Control (AMLC). 6/11 radius ratio is used for this continuous casting. 6 is

bending radius and 11 is unbending radius.

Calculation

Metallurgical length can be calculated by

L= (A2/4k

2) x V

L = Metallurgical length

A = Crossectional Area

K = Constant

V = Casting Speed

Also it can be calculated by

S = K√ (L/Vc)

For 150 x 150 billet and speed of 1.2 m/min when constant = 30

Metallurgical length = [(150x150)2/ 4 x (30)

2] x 1.2

Metallurgical length = 8.1 meters

Cooling zones There are three cooling zones

Spray ring

Zone 1: consist of 32 nozzles

Zone 2

Volume flow rate are different for different nozzles. Nozzle angle is same i.e. 65o

57-65

50-65

35-65

25-65


Liquidus temperature

Temperature at which steel starts to solidify is called Liquidus temperature. Liquidus

temperature is about 1512oc. For carbon content (For %C < 0.5) it can be calculated by

Tliq (°C) = 1537 - 73.1%C - 4%Mn - 14%Si - 45%S - 30%P - 1.5%Cr - 2.5%Al - 3.5%Ni - 4%V

- 5%Mo

Carbon Equivalent

Carbon equivalent is a value used to predict the process of treatment to be performed on the

specimen, to predict the weldability etc.

Effect on weldability:

Upto 0.35 excellent

0.35-0.40 Very Good

0.40-0.45 Good

0.45-0.50 Fair

Above 0.50 Poor

Carbon equivalent can be calculated by

CE = %C + (Mn + Si)/6 +(Cr + Mo + V)/5 + (Cu + Ni)/15


ASL Grades & Composition

ASL Grade Billet

Chemistry(%)

CE Colour

Coding

Bar size to be

Rolled

Mold

Lubrication

BS 4449-3 C 0.20-0.24

Mn 0.55-0.65

Si 0.15-0.30

S <0.05

P <0.05

Max 0.35

For 3/8

Rolling

Yellow

Cut in 6m

905mm Oil/powder

BS 4449-1 C 0.18-0.26

Mn 0.60-0.80

Si 0.15-0.30

S <0.05

P <0.05

0.36-0.380

For Xtreme

Bars upto

25mm

Green

Cut in 6m

12mm, 16mm Mold powder

BS 4449-2 C 0.26-0.30

Mn0.60-0.80

Si 0.15-0.30

S <0.05

P <0.05

0.39-0.44

G-60 Bars

upto 25mm

Blue

Cut in 3m

19/22/25/28/32mm Mold powder

Special

Grade

C 0.22-0.25

Mn1.05-1.15

Si 0.15-0.30

S <0.05

no tolerance

P <0.05

0.41-0.51 To be

confined

40mm Mold powder

Special

Grade with

High

Carbon

C 0.30-0.34

Mn 0.60-0.80

Si 0.15-0.30

S <0.05

P <0.05

0.48-0.51 To be

confined

40mm Mold powder


Slag Processing Area The molten oxide by-product obtained during smelting and refining is called slag. Oxides like

SiO2, Al2O3, P2O5 and B2O3 are acidic oxides. They form acidic slag. Oxides like MgO, FeO, and

MnO are basic oxides. They form basic slag

The slag, poured in slag pot is transferred to slag processing area. Here the slag is crushed first

into small size by labours. Then it is transferred to slag crushing area. It is transferred to hopper

then to conveyer belt. It goes to Jaw crusher, from where it goes to 2nd

conveyer belt. A magnetic

screen separates ferrous particles from them. Again it is passed to a roller crusher and crushed

parts are moved on 3rd

conveyer belt. Another magnetic drum separates iron contents and it fell

down. Slag particles transferred to 4th

conveyer belt and at last fell to stock area.

Quality Control

At ASL there are two laboratories for checking the composition of metal and billet, and also the

quality of water, silica sanded. Distilled water also produces here.

Spectrolab

Wet lab

Spectroscopy Lab

Spectroscopy is a terms used to refer to the measurement of radiation intensity as a function of

wavelength. Device used to measure the intensity of the radiation emitted is called spectrometer.

The energy of a photon is related to its frequency by

Where is Planck's constant. Spectroscopy is a method to find out the composition of specimen by generating a spark on the

surface of sample. This spark makes the electrons move in an exited stage as a result they change

their energy. As they move to high energy state they absorb energy and when they come back to

ground state they emit energy in the form of radiations. This principle is used in spectroscopy.

Each element in a sample has its own radiation emission. A magnifying glass is attached which

magnifies these radiations and guide to their respective silts. In this way elements are detected.

Before starting this process, samples grind and polished, Grit size 36 and 60 paper is used.

Sample must be homogenized i.e. no trapped inclusions or slag, and it must be iron base for

proper conductivity.

http://en.wikipedia.org/wiki/Planck_constant


Wet lab

Wet lab uses classical method of Volumetric, gravimetric, and instrumental analysis for

analyzing the metal samples, silica samples and water samples. It also produces Demineralize

water by electrical distiller at a rate of 5lit/hr.

Etching is done about 1/2hr for finding defects in billets like pin holes, pipes etc.

Moisture Content is find out by using electrical ovens i.e. %loss in weight after drying.

Loss of ignition (volatile matter, gases) of silica is finding out by using Box furnace. First silica

is heated to about 1000oc, then cooled about 2-3 min in air then cooled in desigator.

Logistics and stores

At ASL, all the spare parts, extra equipment’s etc. is placed in store. In case of any emergency,

they may be utilized. Different sections are made for each plant. There are Refractory storage,

LRF, IF, FES, CCM etc. sections with their respective spare parts, nuts, bolts, pipes etc.

Whatever the parts are required are first undersigned on a paper by incharge and then give to

store incharge, he then handover the desire part to the worker. All details of store, i.e. item

entered in the inventory, items given, remaining stock, all are managed through ERP- Enterprise

Resource Planning.

Fume Exhaust System (FES)

Fume exhaust system is to exhaust the gases, dust evolving from induction furnaces.Scrubbing

the exhaust air prevents the release of aggressive and harmful vapors into the environmentan

impeller creates suction and transferred to air bags. These bags allow them to pass through but

dust, in which main content is zinc, does not pass through it, it is then transferred to hopper, from

where it is collected in bags.


Reverse Osmosis Plant (RO)

Reverse osmosis (RO) is a filtration method that removes many types of large molecules and

ions from solutions by applying pressure to the solution when it is on one side of a membrane.

The result is that the solute is retained on the pressurized side of the membrane and the pure

solvent is allowed to pass to the other side

Osmosis is a natural process. When two liquids of different concentration are separated by a

semipermeable membrane, the fluid has a tendency to move from low to high solute

concentrations for chemical potential equilibrium.Formally, reverse osmosis is the process of

forcing a solvent from a region of high solute concentration through a semipermeable membrane

to a region of low solute concentration by applying a pressure.

There are 5 underground bores, among which 3 are in operation.

Water is extract from here and transferred to pressurized vessel, which holds it. Some

suspended particles settle down and separated. There are 4 pressurized vessels

Then it is transferred to multimedia filter tank.

It filters water, suspended particles.

Filter size is 30 microns.

VFD – Variable Frequency Distribution: Controls, change frequency.

This water is then transferred to Cartage filter in which it separates 5 microns

particles.

Then membrane is used for final filtration of about0.03 microns. It consists of

biosites, anti scalant which kill bacterial effects. Electromagnetic Dosing pump is

attached along with this.

Suggestions

Safety precautions are not followed. Therefore many accidents have been occurred.

Safety inspector must be appointed in order to check these precautions by workers,

engineers etc

There are many health hazards because of evolution of gases, dust. Feeding of charge can

be done through vibratory feeder completely, because open feeding through cranes causes

problems like splashes dust evolution etc

Training period for trainee engineers can be reduced to 4 months instead of 6 months,

along with their initial salary, which is somehow low.

Scrap feeding can be done fron scrap yard to transfer trolley directly. It saves time,

because first it is transferred to scrap bay, then by EOT cranes to transfer Trolley.

http://en.wikipedia.org/wiki/Filtration

http://en.wikipedia.org/wiki/Molecules

http://en.wikipedia.org/wiki/Ions

http://en.wikipedia.org/wiki/Membrane_%28selective_barrier%29

http://en.wikipedia.org/wiki/Solution

http://en.wikipedia.org/wiki/Solvent

amreli steel-internship report-yaseen raza

Documents

technology internship

ned universityfor

technology batch

ladle furnace ladle

asl team

supervision of production

excellent guidance

asl grades