Académique Documents
Professionnel Documents
Culture Documents
1.1. INTRODUCTION
HINDALCO INDUSTRIES LIMITED OVERVIEW
A GLIMPSE OF HISTORY
HINDALCO the ADITYA BIRLA GROUP of company is amongst India largest
business house with commanding presence in widely diversified business set up in
several countries.
HINDALCO INDUSTRIES LIMITED, a flagship company of the ADITYA BIRLA
GROUP, is structured into two strategic business aluminum & copper, powerhouse, close
to globe scale, it ranks among Indias top companies in term of market capitalization. In
financial year 2010-11, HINDALCO recorded a turnover of Rs 22313.00 Crore.
It was set up in collaboration with KAISER ALUMINIUM & CHEMICAL
CORPORATION USA, in a record time of 18 months. The plant started its commercial
production in the year 1962 with a capacity of 20000 tons per annum. The company has
grown manifold and is managed by Board of Directors, with Mr. KUMAR
MANGALAM BIRLA as the Chairman of Board of Directors. Day to day affairs of the
company is managed by Professional Executives headed by Sri D.K. Kohli as the Chief
Operations Officer- Aluminum & Power.
The dream of the great visionarys GD Birla to locate an Aluminum plant near Rihand
Power Plant comes true. The late Prime Minister, Pt. Jawaharlal Nehru formally
inaugurated the plant in January 1963. Going around the extensive works, PANDIT Jee
saw his dream of brighter future of India take shape before his eyes. From the modest
beginning in 1962, HINDALCO has now become an industrial giant with a capacity to
produce 345000 tons of aluminum per annum.
1.2.
HINDALCO TODAY
Aluminum has turned out to be the wonder metal of the industrialization world. No other
single metal can do so many jobs, so well, and so economically.
Aluminum growth rate is the highest amongst the major basic metals today. HIDALCO
ranks as the largest aluminum produced in India, whose more than 58% sales are in
1
value-added products and has more than 40% I total market share. The companys fully
integrated aluminum operations consist of the mining of Bauxite, conversion of Bauxite
into alumina, production of primary aluminum from Alumina by electrolysis and
production like Foil and Wheel at Silvasa. HINDALCOS integrated operations and
operational efficiency have enabled the company to be one of the worlds lowest cost
producers of Aluminum. The company cost efficiency has helped it to record on
outstanding performance in the face of adverse market condition.
HINDALCO also owns a large captive THERMAL POWER PLANT at Renusagar that
meets the power requirement of the company very effectively.
HINDALCO has embarked upon a Rs 18 billion brown field expansion project which
will smelter capacity by 100000MTPA, refining capacity by 210000MTPA, and captive
Power Generated to 769MW in the year 2000, HINDALCO acquired Alcons 54.6
majority stake in another Indian aluminum major Indal. This was followed by public
offer for an additional 20% stake the acquisition makes possible and excellent synergistic
fit Indal. Strength in Aluminum and downstream, products dovetail admirably with
HINDALCO strong presence in metal.
An ISO 9002and 14001 certified company, HINDALCO achieved significant export in
the year 2001-02 & so on, and is registered on the LONDON METAL
EXCHANGE. HINDALCO also has star trading house status. HINDALCO products
range includes Primary aluminum, Ingot, Alloy Ingot, Billets, Cast Slabs, Alloy Wire
Rod, Sheet Products, Extruded Profile, Conform Products, Foil and Alloy.
CHAPTER 2
ALUMINA TRANSFER SYSTEM
2.1.
The primary alumina is being feed to each FTP from the existing conveyors through a
diverter valve leading the alumina into air slides (2 airsides / one standby) for filling of
the primary alumina silo (Cap 350 tons).
An emergency airlift is also provided for filling the primary silo.
2.2.
The primary alumina silo (350 tons) is equipped with two manually operated discharge
valve, one(bypass) leading directly to the distribution box, the other feeding air slide to a
feed box with loss-of-weight control system.
Two blowers are being used to supply fluidizing air to the primary alumina silo and for
the feed & distribution system. From the feed box, the primary alumina is being feed into
the reactors through distribution air slide where it gets reacts with the pot gases.
2.3.
Adsorption of fluorides take place after the primary alumina has been injected into the
raw gas in the reactor. For more enrichment alumina is recirculated from the screw
conveyer to the same injection point where the primary alumina has injected.
By varying the speed of the screw conveyer we can control the rate of recirculation. All
screw conveyers (6 nos) rotate with the same speed and is being controlled by frequency
converter.
2.4.
Conveyers
Conveyers
Air slide
Air lift
3
Tankers
Elevators
2.5.
FLUORIDE ADSORPTION:
The fresh alumina injected into the reactor serves as an adsorption for the fluorides and it
also helps in creation on the filter bags in the order to collect particles even smaller than
the fabric mesh itself.
2.6.
2.7.
Blower is used
Compressor is used
- above 10 psi
2.7.1 FANS:
Throughput of centrifugal or axial fans can be changed by varying the inlet or outlet
dampers.
(1) Axial fan is used, where air or gas moves parallel to the direction of rotation of axis
and to move large quantity of air at low pressure.
(2) Centrifugal fan is used, where air or gas moves perpendicular to the axis and for
greater heads.
2.7.3. BLOWERS:
Blowers are generally single stage, high-speed machines or multistage units that operate
at pressure close to or in the range of compressors.
2.8.
Diameter
- I.D 127mm
Length
- 6066 mm
No of bags/ lines
- 3240
Top design
Longitudinal seam
Bottom height
Fabric used
Composition
- 100% polyester
Weight
Thickness
- 1.9 mm
Air permeability
- 82 85 m3/m2/hr
Density of fabric
- 0.29 g/cm3
Gas temperature
Tensile strength
- 1275 N/m
Bursting strength
- 18 Kg/cm2
Life guarantee
- min 24 month
Performance
Equipment used for emission measurement: APM 620 supplied by M/S envirotech. New
Delhi
2.9.
10 150 m
CHAPTER 3
COMPRESSORS
3.1.
INTRODUCTION:
Compressors are machines designed for compressing air or gas from an initial intake
pressure to a higher discharge pressure.
3.2.
APPLICATIONS:
Pneumatic cylinder
3.3.
CLASSIFICATION OF COMPRESSORS:
Type:
1.
Reciprocating
2.
Rotary Vane
3.
Screw
4.
Turbine
5.
Centrifugal
Single acting, Double acting, Single stage, Multi Stage, Two Stage, Single Cylinder,
Multi Cylinder, Water Cooled, Air Cooled, Electrical, Diesel, Gas, and Steam.
3.4.
3.5.
Crank Case: Heavy Duty grain cast iron frame. It also serves as lubricating oil
reservoir.
Crank Shaft: Made of forged steel is provided with bolted counter weights.
Connecting Rod: Made of nodular gray iron or forged alloy steel and are
Cross Head: Made of nodular gray iron and is designed to ensure true running of
piston rod.
Cylinder: Made of graded close grain cast iron. These are provided with water
jackets to ensure efficient cooling of the surface that comes in contact with hot
compressed air.
Piston: Made of nodular gray iron or high grade aluminum alloy and having the
same weight i.e. L.P. Piston hollow and H.P. Piston Solid.
Oil Pump: Gear pump is driven from the free end of crank shaft for lubrication of
all parts.
Inter Cooler: It is device for removing the Heat of Compression of the air
After Cooler: These are meant for removing the heat of compression of the air
after is compression is completed. These are also used for removing moisture from
compressed air.
Air Receiver: It is used to store the air and help to eliminate pulsation in the
discharge line.
Valves: Each cylinder is provided two suction and two delivery valves for the
upper and lower compression. The valve is opened and closed by the means of the
pressure difference occurring in the cylinder.
3.6.
RECIPROCATING COMPRESSOR:
Piston ring gaps in plates 0.2 to 0.3% dia. Of cylinder or 0.20 to 0.024 per 100
mm dia.
Lateral clearance of big end between connecting rod and crank shaft = 0.008 to
0.025
3.7.
CENTRIFUGAL COMPRESSORS:
Model: C 55 MX3
Motor BHEL make: 950 kw, 3.3 kV, 3 Ph., 50 Hz, and squirrel cage induction
motor.
3.8.
PRINCIPLE:
The Centac compressor is a dynamic centrifugal type compressor. The air being
compressed enters the compressor through the machine mounted inlet control device and
flows to the first stage where the impeller imparts velocity to air.
The air proceeds through the stationary diffuser that converts velocity to pressure. The
built-in inter cooler removes the heat of compression, which improves efficiency. The air
then passes through a stainless steel moisture separator in a low velocity zone to remove
condensate. Entrained moisture in the air is reduced when the air is forced through
stainless steel moisture separators. This sequence repeats in each succeeding stage until
the compressor archives the desired operating pressure.
3.9.
DESCRIPTION:
A main driver that directly drives a bull gear that is common to all stages.
10
A moisture separator and a moisture removal system are fitted after each cooler to
remove condensate.
Rotor Assemblies
Bearing
Seals
Diffusers
Intercoolers
Moisture Separators
Vibration Probes
Casing
Compressor Driver
Lubrication System
Diffusers: A diffuser, located between each impeller and cooler, converts velocity energy
in pressure energy.
Intercoolers and After coolers: The Coolers are donut types with the water over tubes
and oil in shell.
Moisture Separators: The moisture separator is a SS mesh screen type construction
located at points in the air compressor where air velocities are relatively low permitting
efficient moisture separation.
Vibration Probes: A non-contacting vibration probe is mounted on each stage next to
the plain bearing to measure vibration of each rotor assemblies. Each probe is connected
to a vibration transmitter.
Casing: The gear case consists of a casing and casing cover jointed vertically by bolted
assembly which is opened for servicing the bull gear and its bearings.
11
Rotor Assemblies: Each rotor consists of an SS impeller and a removable thrust collar
mounted on a helical geared pinion shaft each secured to the shaft by a polygon spline,
eliminating the need of keyways.
Bearings: Each rotor assembly is equipped with a thrust bearing near impeller and a
plain journal bearing, Babbitt lined, near bull gears for radial loads.
Seals: A single cartridge seal is mounted in the plain bearing housing behind each
impeller. Each cartridge consists of three, one piece, fully floating non-contact carbon
rings. One ring is used as an air seal and the remaining two as oil seals. Buffer air is
supplied to the oil a seal assuring that lube oil is not drawn past the seals, thus ensuring
oil free air.
Leaky Valve
Inter cooler and after cooler must be perfect and to be cleaned periodically.
Tapping in air lines, receiver outlet should be from top to avoid water moisture
carry over.
12
Global valves should be used in air system as pressure drop is very high. In 1
gate valve pressure drop is 1.14ft of used pipe whereas in 1 global valve is 30ft of
used pipe.
Hydraulic testing of receiver should be done on every year at 1.5 times the safety
of valve setting.
Cleaning operation should be done with 30-40 psi air pressure only to save air
13
Intake air temperature decreases 3deg C and due to this increase in volume
delivered by 1%.
14
CHAPTER 4
CRANE
Crane is material handling equipment.
4.1.
TYPES OF CRANE:
1.
Jib crane
2.
Mobile crane
3.
4.2.
1.
2.
3.
2.
MAKE
CAPACITY
DRIVE
LINE 1
P&H
6.0 M.T.
SINGLE DRIVE
LINE 2,3
P&H
7.5 M.T.
SINGLE DRIVE
LINE 4
A.C.C.
7.5 M.T.
SINGLE DRIVE
LINE 5
W.M.I.
7.5 M.T.
DOUBLE DRIVE
LINE 6 TO 11
MUKAND
7.5 M.T.
DOUBLE DRIVE
B/F#1 TO 3
W.M.I.
6.0 M.T.
DOUBLE DRIVE
B/F#4
CIMMCO
6.0 M.T.
DOUBLE DRIVE
MAINT. AREA
W.M.I.
7.5 M.T.
SINGLE DRIVE
15
4.3.
BRIDGE UNITS:
1.
2.
3.
4.
5.
6.
5/8 inch)
2.
Gear box
3.
Driving wheel
2.
3.
4.
Rope drum (dia. 15 inch, length 4 ft. 11.5 inch, groove 18 nos. L.H. & R.H. & 0.5-
4.4.
Anode setting, metal tapping, crust breaking, metal pouring, skimming, pot relining and other
material handling jobs.
4.5.
1.
They eliminate the need for wide passages and do not block any space at ground level.
2.
They cover the entire working area without limiting the layout.
16
3.
Operating cost are very low, since it needs only one operator, require very little
These cranes are especially suited for handling unit loads and for such material like
4.6.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Trolley derailment
2.
3.
Crossing of crane
4.
Misalignment of pantograph
5.
Crossing of crane
2.
3.
Finger broken
4.
5.
6.
Misalignment of pantograph
2.
3.
4.
5.
Misalignment of wheels
6.
7.
2.
2.
3.
N.R.V. leakage
4.
5.
6.
Looseness of connector
7.
8.
9.
10.
11.
12.
13.
14.
4.7.
4.7.1. BRAKES:
Trolley: nil
Bridge speed
122 MTR/MIN.
Trolley speed
58.0 MTR/MIN.
Hoist speed
12.8 MTR/MIN.
Line 4
5.5 MTR.
Line 5 to 8
5.8 MTR.
Line 9 to 11
6.1 MTR
B/F# 4
4.9 MTR
19
Line 4
Line 5 to 8
Line 9 to 11
B/F #4
--DO-
Maintenance area
Hook material
4.8.
POT LINES
CRANE NUMBERS
LINE 4
2, 4
LINE 5
1, 3
6, 8
LINE 6
5, 7
12, 14
11, 13
LINE 7
16, 18
15, 17
LINE 8
20, 22
19, 21
LINE 9
26, 28
25, 27
LINE 10
30, 32
29, 31
LINE 11
34, 36
33, 35
B/F #4
9(NORTH)
10(NORTH)
MAINTENANCE AREA
23(NORTH)
24(NORTH)
4.9.
BRIDGE SPAN:
Line 4
13.056 MTR.
Line 5 to 8
13.970 MTR.
Line 9 to 11
13.900 MTR.
Maintenance area
B/F #4
13.970 MTR.
85.0 feet
2.0 MTR.
20
Rope drum & rope wire (if 10 wire broken in 01 ft. of 6/19 wire rope) then wire rope
should be changed
21
CHAPTER 5
DRY SCRUBBING SYSTEM:
The dry scrubbing system treats exhaust gas from pots. This treatment of gases is based
on adsorption of gaseous fluoride by means of injection alumina, which is followed by
bag filter where enriched alumina is collected and being sent to pots for alumina feeding.
This plant can also be named as Fume Treatment Plant.
F.T.P. serves the two functions, first it reduces the emission of the HF gas and the dust
particulate into the atmosphere, and secondly it recovers aluminum fluoride, which is an
important input to the pots. This reduces the consumption of ALF3, which we purchase
from outside party.
5.1.
During the electrolysis process for producing aluminum, the alumina (AL2O3) liberates
Oxygen and the metal aluminum is produced. The electrolysis process takes place in an
electrolytic bath consisting of aluminum fluoride and some other chemicals. During this
process hazardous gases are emitted (mainly consisting of Hydrogen fluoride and other
fluorides). To prevent these gases to escape into the atmosphere, it is mandatory to install
F.T.P. Since fumes are treated by adsorption of fluorides gases into dry alumina, hence
the system is called Dry Scrubbing System. The F.T.P. treats exhaust gas from aluminum
reduction cells by dry scrubbing process, followed by bag filter to collect fluorinated
(enriched) alumina. F.T.P. reduces the emission of the HF gas and the dust particulate
into the atmosphere.
22
The process description of the F.T.P. is divided into four main sections: 1.
2.
3.
4.
Alumina consumed in the pots is transported from the belts conveyors to the primary silo,
through the F.T.P. During this process the primary alumina is mixed with the pot gas in
the reactor and forms the enriched alumina. This enriched (secondary) alumina in turn
transported to the reduction pots where aluminum metal is produced. Other particulates
are collected on the filter bags.
5.2.
The main ductwork is designed in such a way that it gives nearly same velocity
throughout the system. Each individual pot has the branch duct having a manually
adjustable damper. These dampers are set in a fixed position after balancing, so that an
even suction is obtained from each pot.
23
For the suction of the gas there are three main exhaust fans (Centrifugal type) in each
line. Each fan has inlet and outlet damper. There are 6-filter unit in each FTP and each
filter unit comprises a reactor and a filter compartment.
Each filter unit can be isolated for main jobs by the inlet duct damper and outlet duct
damper.
5.3.
The cleaning od the bags is an accomplished by the pulse jet technique, where a medium
pressure pulse of air is introduced into the open top of each filter bag through nozzle
header through nozzle arranged on a nozzle header. The pulse air enters the nozzle header
through solenoid diaphragm valve installed on pulse tanks. There are 30 rows in each bag
house and each row comprises of 18 bags. The injection of pulse air results in a rapid
expansion of the bags. Alumina and dust having accumulated on the outside of the bags is
dislodged and collected in the hopper.
One row in all the filter unit is cleaned simultaneously. The next row in line is cleaned
after a set time interval has elapsed.
The permeability of a new bag is very high, resulting in a low-pressure drop. Fumes and
alumina in the gas flow will increases the pressure drop through the bags.
24
5.4.
The bag cleaning process is controlled by the PLC installed in control room. All filters
are cleaning on-line. This on-line pulsing indicates that one row of bags in each filter unit
is cleaned simultaneously. The gas flow, dust load and gas temperature are normally
given parameters. The pulse cleaning intervals, valve opening time and pulse air pressure
for the bags can be varied within limits for optimal operation of FTP.
The pressure drop affects the power consumption of the fans whereas bag-cleaning
parameters may affect the life of the bags.
5.5.
PULSE SYSTEM:
5.6.
BAG HOUSE:
CHAPTER 6
CRUST BREAKER
6.1.
EQUIPMENT DESCRIPTION:
The Pot Rooms Crust breaker is comprised of the following principle sub-assemblies:
Upper Frame
Upper Works
Lower Works
Hydraulic/Pneumatic System
6.2.
UPPER FRAME:
Connection of the Crust breaker to the crane cross-travel trolley is by means of a crane
adapter frame (Permanently fixed to the trolley framework), and the mating upper frame
of the Crust breaker.
The upper frame incorporates four (4) spring-loaded, pneumatically actuated locking pins
that locate in slotted holes on the crane adopter frame. It is attached to, but insulated
from, the outer frame of the upper structure of the Crust Breaker.
6.3.
UPPER WORKS:
The upper works consist of an inner and outer frame. The inner frame is mounted on
guide bushes that run on four (4) verticals guide bars that are in turn attached to the outer
frame
It is possible to raise and lower the inner frame within an operating range of 400mm to
cater for (1) the variation in pot depth from 14 to 22; an (2) the requirement to lift the
crust breaker over the various arrangement of the sloped bus.
Vertical travel of the inner frame, relative to the outer frame, is achieved by the rising and
lowering of the crane hook is raised, the inner frame is pulled up against two (2)
26
hydraulic cylinders, which act on the outer frame (and the attached upper frame) against
the crane adapter frame.
These cylinder operate at a constant hydraulic pressure, which is preset via a pressurereducing valve to provide the required preload. A pressure-relieving valve allows the
cylinders to be compressed by the action of the crane raising the inner frame, thereby
maintain the same preset pressure.
If the end of stroke of the hydraulic cylinders is approached (which should not be
necessary)
An Audible indicator will sound to warm the operator.
An additional function of these cylinders is to minimize the risk of the crane hook if an
operator inadvertently allows the crust breaker to bear against a fixed obstacle.
The inner frame also incorporates the hydraulic reservoir, air-over-oil pump, oil filters
and compressed air lubricator.
6.4.
LOWER WORKS:
The lower works of the Crust breaker incorporates the operator controls and the
pneumatic Crust breaker hammer. The moving parts of the lower frame are captured
within replaceable slide-ways and bushes.
The operator controls the motions of the Crust breaker via a joystick. The joystick
controls the following motion:
Tilting of the hammer to change the horizontal location of the tip of the chisel
Extension and retraction of the hammer and activation of the percussion mode of
27
6.5.
The support bearing assembly is attached to, and insulated from, lower section of the
inner frame. It forms the connection between the upper and lower works and incorporates
the following components:
An outer tube well-meant that is attached to the inner frame and incorporates a
A hydraulic motor that acts on the ring gear to provide rotation for the lower
A telescope air transfer unites that provide transfer of compressed air to the
A rotary union that provide hydraulic and pneumatic connection between the
6.6.
The crust breaker is serviced by a Hydraulic Power Unit mounted to the inner frame of
the upper works. The Hydraulic Power Unit supplies hydraulic fluid under pressure to a
control valve manifold and joystick where individual valves control the hydraulic
functions of the Crust breaker. The Hydraulic pump is an integrated air over oil piston
pump and supply extra hydraulic capacity during peak demand.
6.7.
The Pot Rooms Crust breaker breaks the frozen bath (cryolite) crust from the top and
sides of the spent anode by the action of a pneumatic percussion jack hammer.
The jack hammer has three (3) degrees of motion to position the jackhammer pick for
crust breaking. The entire lower works can be rotated without restriction, the jackhammer
move vertically on a sliding carriage, and jackhammer and the carriage, can extend on a
guided scissor mechanism.
Before crust breaking can commences, the following condition must be met:
1.
The three safety pins need to be removed, that is the pin that locks the turret
rotation, the pin that lock the scissor linkage from moving, and the pin that holds the jack
hammer carriage in the raised position.
28
NOTE:
The last two pins may require retraction of the carriage and raising of the jack hammer
under power to alloy easy removal.
2.
The platform operator using the Crust breaking joystick, on the operators panel, controls
the Crust breaking function. To extend the jack hammer (scissor mechanism) the joystick
is pushed forward, the joystick is serviced by the proportional hydraulic valve, therefore
the further forward the joystick is pushed the faster the jack hammer will be extended. To
retract the jack hammer (scissor mechanism) the joystick is pushed backward, pushing
the joystick to the left will rotated the lower works clockwise. Pushing the joystick to the
right will rotate the lower works counter clockwise. Depression the joystick button on the
top of the joystick causes the hammer too lower and the percussion action to commence.
Releasing the joystick button, the hammer causes the hammer to raise and the percussion
action to stop.
29
CONCLUSION
It was a great privilege to undergo vocational training at Hindalco Industry Limited,
Renukoot. Working in such an encouraging atmosphere with people dealing with latest
technology working in tight schedule, dedicated to help was a privilege. While carrying
out the industrial training, I received tremendous support from all the staffs of the various
departments. Working in different shops provided a real time experience of engineering
and technology being used currently in manufacturing industry. The training helped me
in great deal as I came to know and explore more information and gained invaluable
knowledge about the subject. The training also helped me to gain knowledge about the
industrial environment. This invaluable experience will help me further to adapt quickly
in the environment of the company in future when I will have to join any company.
30
REFERENCE
BOOKS REFERRED:
Financial Management I.M. Pandey, 9th edition; New Delhi: Vikas
Fundamentals of Financial Management R.P. Rustagi, 3rd edition; New Delhi:
Galgotia Publishing Company; 2002.
Financial Management Prassanna Chandra
WEBSITES REFERRED:
www.hindalco.com
www.workingcapital.org
www.investopedia.com
www.adityabirla.com
31