INPLANTTRAININGREPORT

TRLKROSAKIREFRACTORIESLIMITEDBELPAHAR,JHARSUGUDAORISSA-768218

Thisreportissubmittedasapartof fulf illmentof B.TechsemesterexaminationSUBMITTEDTOMR.K.PANDA(P.R&H.R.D)

GUIDEDBYSUBMITTEDBYDR.JYOTIPRAKASHNAYAKSATENDRASINGH(Manager-Technology)CERAMICENGINEERINGN.I.TROURKELA

DECLARATION

I hereby declare that the plant report is faithful records of bonafied & original workcarriedoutbymeundertheguidance&supervisionofDR.JYOTIPRAKASHNAYAK(Manager-Technology) and with the help of the entire employees of TRL KROSAKIREFRACTORIESLTD.Ihavecompletedthisreport.

SATENDRASINGH

N.I.TROURKELAB.TECH(DUALDEGREE)CERAMICENGINEERINGROLLNO:710CR11743rdYear6thSemesterCompleted.

CERTIFICATEThis is to certify that SATENDRA SINGH bearing roll no: 710CR1174 branchCERAMICENGINEERING,NITROURKELA (6th semester completed)haspreparedaplant report at TRL KROSAKI REFRACTORIES LTD. Under the supervision of DR.JYOTI PRAKASHNAYAK (Manager-Technology).I further certify that this report hasbeencompletedbySATENDRASINGHforpartialfulfillmentofmyanalysis.

DR.JYOTIPRAKASHNAYAK(manager-technology)

TOWHOMSOEVERITMAYCONCER

This is to certify thatSATENDRASINGH, studyingB.TECH in ceramic engineering inNITROURKELAhasundergonevocational training andprepared aplantreportinTRLKROSAKIREFRACTORYLIMITED.Hehascompletedhisplantreportsuccessfully.

Dr.MIHIRRANJANNAYAK(ChiefofP.R&H.R.

ACKNOWLEDGEMENT

IamverythankfultoDr.S.ADAK(Vicepresidentoftechnology)whogavemeachancetoworkinR&D.IamsincerelythankfultoDR.JYOTIPRAKASHNAYAK(Manager-Technology)forgivingmetimefromtheirbusyscheduleforguidingmyvocationaltraining.IamthankfultoMR.K.PANDA(PR&HRD)forhissupportthroughoutmytrainingforhisvaluableguidance&co-operationinmywork.Iamthankfultoalltheemployeeswhohavehelpedmealotincollectingthenecessaryinformation.Thereloving&caringwordpraisehasreallyencouragedme.

YOURSFAITHFULLYSATENDRASINGHROLLNO:710CR11744CERAMICENGINEERING(6thsemestercompleted)NITROURKELA

CONTENTS

ACKNOWLEDGEMENTACKNOWLEDGEMENT INTRODUCT IONTOTKRLINTRODUCT IONTOTKRL Environment Innovation InformationTechnology GlobalCollaborations GlobalNetwork TKRLAnExportHouse TKRLACitadelofLearning SIL ICAREFRACTORIESPRODUCTSSIL ICAREFRACTORIESPRODUCTS Introduction: RawMaterials: SourcesofRawMaterials: AdditivesandBinders:

ProcessProcess Flowchart CrushingandGrinding: ScreeningandGrading:

Pressing: Drying: Firing: Sorting: PackingandDispatch: ProductsandApplication:

HIGHALUMINAREFRACTORYHIGHALUMINAREFRACTORY Introduction: ProcessFlowsheet RawMaterials :RawMaterials : Mixing: Pressing: Drying: Firing: Sorting: Packaging&Despatch: Applications:

DOLOMITEREFRACTORYDOLOMITEREFRACTORY Introduction: ProcessFlowchart RawMaterials: CrushingAndGrinding: Mixing: Pressing: Firing: Tempering: TarImpregnation,WaxCoatingandDrilling: Sorting: Packaging: Despatch:

BASICREFRACTORYBASICREFRACTORY Introduction: RawMaterials: ProductRange: ProcessFlowSheet: Crushing&Grinding:

Mixing: Pressing: Drying: Firing: Sorting: Inspection: Packing&Despatch:

FLOWCONTROLPRODUCTSFLOWCONTROLPRODUCTS Introduction: RawMaterials: ProcessFlow-Chart: RawMaterialProcessingAndStorage: Mixing: Pressing: Drying: Firing: Tempering: Drilling: TarImpregnation: Tempering: ShotBlasting: SteelCassetingandBaking: SurfaceFinishing: Despatch: Application:

MONOLITHICREFRACTORIESMONOLITHICREFRACTORIES Introduction: RawMaterials: PrecastSection: Processflowchart: ApplicationofvariousCastables:

INTRODUCTIONTOTRLKROSAKIREFRACTORIESLTD.

ThedevelopmentofrefractoriesindustryinIndiaisinextricablylinkedwiththegrowthanddevelopmentofTRL.Toachievethetwinobjectivesofself-relianceanddevelopingbackwardareas,TRLwassetupin1958atBelpaharinOrissa,aneasterstateofIndiabyTATASteelandDidierWerkeofGermany.TKRLhastodaygrownintotheleadingrefractoriesmanufacturerinIndia,meetingthedemandsofsophisticatedrefractories,steel,glass,non-ferrousandpetrochemicalindustriesbothinIndiaandabroad.Withanannualcapacityof241600MT,thecompanyhasalsoequityparticipationfromSAIL,thelargestpublicsectorsteelproducerinIndia.TKRLsmainplantisstrategicallylocatedatBelpaharinthedistrictofJharsuguda,inOrissawhichisnearmajorsteelplantsandsomerawmaterialsources.TKRLalsohasaDBMplantandoperationsinSalem,TamilNadu,inJamshedpurandcaptiveminesinChhuinpalliandTalbastainOrissa.TKRLsdolomiteplantistheonlycommercialdolomiteplantinIndia.AnewplanthasbeensetupinChinatomanufacturemagnesite-basedbricks.AlsoanewoperationhascomeupinSamkhiyalinearBhujinKutchdistrictofGujarattomanufacturehighaluminacastableandbauxite-basedbricks.Thecompanyhasawiderangeofproductssuchasbasicrefractories,dolomiterefractories,flowcontrolrefractories,high-aluminarefractories,monolithicrefractoriesandsilicarefractories.TKRListheonlycommercialproducerofburntresinouspitch-bondeddolomitebricksandmonolithicinIndia.Continuousupgradationofproductsisbeingdonethoughin-houseR&Dandtie-upwithglobalcompanies.ThecompanyisnowcertifiedtoIntegratedManagementSystems(IMS)encompassingISO9001:2010forQualityManagementSystems,ISO14001:2010forEnvironmentalManagementSystems(EMS)andOHSS18001:2010.TKRLisequippedwithhightechnologyequipmentlikerotarykiln,HTK(1850C),high-capacitymicroprocessorcontrolpresses(SACMIpresses),highcapacitymixer

machines,tunneldriers,shuttlekilns,silicatunnelkiln,freightelevator,fullyautomatedCMCmachine,highintensitymagnet,heattreatmentfurnaceetc.TKRLhastakenanumberofinitiativesrecentlytobeyoungandgloballycompetitivesuchasmassivecapitalinvestment,planninginstrategicallyfocusedbusinessareassuchasdolomite,silicaandhighaluminaplants.Anewautomatedmonolithicplanthasbeencommissionedwiththebackwardintegrationofabinderplant.TheR&DlabunderthecompanysTechnologyDivisionenablesTKRLtokeeppacewiththerapidadvancesmadeintheprocesstechnologyofconsumerindustry.Toenhanceitscompetitiveedgethroughinnovationandimprovements,thecompanyispursuingafocusedR&Dstrategy.Researcheffortsarealsostructuredtowardsensuringcost-optimizationandenvironmentprotection.RecentlyanumberofnewandimprovedproductslikehighperformingMag-Canddolomitebricks,DBMCbricksforcopperindustry,highaluminabricksfornon-recoverycoke-oven,improvedslideplateandlances(OLPandARS),precastprefiredshapeswithgelbondedcastableforH.B.minofblastfurnace,gelbondedcastableforblastfurnacetrough,castablesspongeironindustry,precastsnorkelforRHunitandprecastladleshellhavebeendeveloped.Anumberofhigh-qualitynewproductshavebeendevelopedthroughTISTRIASynergy,agroupformedwithTATASteel,toprovidesolutionstoTATASteelsspecificproblems.R&DlaboratoryofTKRLhasreceivedtheprestigiousNABLCertificateofaccreditationinaccordancewiththestandardISO/IEO17025:2005.

ENVIRONMENTAnumberofpollution-controlmeasureslikeinstallationofstate-of-the-artcassettetypeJetFilter,Pulse-jetFilter,ESPhavebeentakentomaketheplantdust-freeandworkingontheshop-floormoreconvenientandcongenial.2.5lakhtreeshavebeenplantedinandaround

theworkstomakeTKRLagreenplant.TKRLisarecipientoftheGoldenPeacockandGreenTechEnvironmentAwards.

INNOVATIONFortheexcellenceintechnologyandmarketing,TRLKrosakiRefractoriesLimitedhasbeenawardedbyfollowingnationalandinternationalawards.

CAPEXIL-TopExportAwardforexcellentexportperformanceintheCeramics&AlliedProductsincludingRefractoriescategoryfortheyear2010-11

GoldenPeacockEnvironmentManagementCommendationAwardfortheyear2011onEnvironmentManagement.

TERICorporateSocialResponsibilityAward2009asarecognitionofTRLKrosaki'sOperationKhushiprogramme.

InformationTechnologyTKRListhefirstrefractoriescompanytoimplementERPthroughBAAN.ItisnowimplementingSAP.ProjectKMisyetanotherinitiativetoimplementknowledgemanagementintheorganization.

GlobalCollaborations

TKRLhasagreementswithanumberofglobalcompaniesfornewtechnologyandworl-classproducts.DolomitWerke,GermanyDolomiteRefractories

StopingAG,SwitzerlandLSsystemslidegateMonoconRefractories,UKBasictundishsprayingmaterialLichtenberg,GermanyCoke-ovengunningandsprayingmassesAPGreen,USACastablerefractoriesInterstopFlowControltechnology

GlobalNetworkBesidesanextensivemarketingnetworkacrossthelengthandbreadthofthecountry,TKRLhasaSouth-EastAsiaOfficeatKualaLumpur.Thecompanyalsohasatie-upwithTATAInternationalLimitedfortheglobalmarket.AGreenfieldprojectinChinahasstartedcommercialproductionfromJanuary2007.TKRLAnExportHouse

ConsistentgoodperformanceontheexportfronthasearnedTKRLthestatusofanExportHousebesidestwelveCapexilawardsfromtheGovernmentofIndiaandrecognitionfromtheGovernmentofOrissa.TKRLACitadelofLearning Astate-of-the-artLearningCentrenamedastheJJIraniCentreforLearningandauniqueRefractoriesEngineeringWorkshophavebeenputupinBelpaharatacostofRs.1.5crorestoimpartandenhanceknowledgeandskillonRefractoriesApplicationandEngineeringtoitsemployees,customersandrefractoriesusersatlarge.

SILICAREFRACTORIESPRODUCTSIntroduction:Silicaisarefractorymaterial.Themeltingpointofwhichis1710C.Itisusedmainlyinglasstankfurnace,constructionofcokeoven,steelmakingfurnaceparticularlyattheroofofacidopenhearth,checker,slagpocketetc.

RawMaterials:Quartzite is themainrawmaterial forthemanufacturingofsilicabrick. It iscomposedofquartz grains cemented together by finely divided silica (secondary silica) along with

impuritiessuchasironoxide.Itshardnessis7inMohrsscale.The chemical requirements for silica for use in refractory brick demand aminimum SiO2contentof97%&preferablygreaterthan98%,Al2O3 lessthan1%&preferablygreaterthan0.5%andtotalalkalislessthan0.2%.Quartzitecontaining~98%SiO2 isusedformanufacturingofsilicabricksused incheckersand blast furnace stoves. They are also being used incokeovensandroofofglasstankfurnace.Forrefractoryuse,thecombinedAl2O3andTiO2shouldbe

therawmaterial.Note:Note: ChhuinpalliQuartzitecontainslowaluminaandhencefluxfactoris50 0-1,1-3 3.5

Applicationofgrindingcircuitequipmentisforsizereductionoffollowingmaterials:A.BallClay/PlasticClay/SambalpurClay:Ground inClayDisintegrator togenerateall threedesiredfractions.Oversizedoutput isrecycled back into Clay Disintegrator through a screw conveyor after being separated inVibratingScreensB.Hi-AluminaRejectionbricks:Primary size reduction takes place in Jaw Crusher and secondary grinding in ImpellerBreakertoobtaindesiredfractionsC.CalcinedClay/Bauxite:Generally feed size is within range of 0 50mm. Primary size reduction takes place inImpactMillwhichgeneratesfourfractions:

0-1mm:separatedinvibratingscreenandfedintosilo 1mm3mm:separatedinvibratingscreenandfedintosilo 3mm 20mm: fed intoBarmac Crusher for secondary grinding and generationof

desiredfractions

20mm+oversize:recycledbackintoImpactMillSilos:Allothernaturalandsyntheticrawmaterialareprocuredingradedfractionsandfeddirectlyintosilos.Thereare52silosinthisdepartment;40attachedtogrindingcircuitand12separateforstoringpre-gradedrawmaterialsdirectly.Batching:The balance car is the carwhich takes away the rawmaterial from the silos as per thecompositiongivenonthebatchcardandthendropsthewholematerialintheskipbucketelevator.Twomotorizedbalancecarsof2MTcapacityeachareusedforbatching.Skipbucketelevator:Skipbucketelevatorliftsthematerialtothemixermachineanddropsthematerialintoit.

MIXING

MIXERMACHINES

Twotypesofmixermachinesareused:

Name Type No.ofunits Capacity(Ton)

EirichMixer Inclined 2 1.8

MIXINGSEQUENCES

Mixedfor3mins.

Mixedfor7mins.

PRESSINGInHighAluminaDept.machinesusedforpressingsare:-

Name Type No.ofPresses Capacity(Tons)SACMI Hydraulic 2 1600

HORN Semiautomatic,hydraulic

1 630

FrictionScrewPress

Manual 2 120

FrictionScrewPress

Manual 1 150

Coarse +BallClay Slurry +Dextrin+Phosphoric Acid

Middlings +Fines

Total = 10 mins.

Sacmi Presses are fully automatic, horn presses are semi-automatic and Friction ScrewPressesaremanuallyoperated.GenerallytheFSPsareusedforpressingrelativelycriticalshapeshoweverhavealowerproductivity.TypicalSpecificPressurerequiredfordifferenttypesofbricksisasfollows:

Checkers(0.6T/cm2),

FireClay(0.7-0.8T/cm2),

HighAlumina(0.8-0.9T/cm2),

HighAlumina[

moisturecontentofthebricksshouldnotbemorethan0.5%.

Firing:Therearetwotunnelkilnsinthisdepartment.Themaximumtemperaturethatcanberaisedisupto15500C.Afterdryingthebricksaresetinkilncarsandsentforfiring.Thekilncarismadeupoffireclayrefractories.Inthesideportionofkilncarsthegrogisusedinformofchannelstopreventheatflowfromthesides.

Thespecificationsofthefireclaytunnelkilnsare:

Length 115m.

No.ofzones 57

Lengthofeachzone 2m.

Preheatingzone 121

Firingzone 2229

Coolingzone 3057

Lengthofeachkilncar 2m.

Width 1.55m.

Height 1.4m.

Fuel Furnaceoilandproducergas

Firingrange 1420- 1550C

42%- 45%Al2O3bricks 1450C

52%- 60%Al2O3bricks 1470C

>60%Al2O3bricks 1550C

Soakingtime 4- 6hrs.

No.ofburners 12

Provisionofburners 44

Oilpressure 1- 1.2kg/cm

Compressedairpressure 1- 1.8kg/cm

Pushingcarrate 1zone/hr.

WhileFTK2iscompletelymanuallyoperated,FTK1isequippedwithcomputerizedprocesscontroltohelpintemperatureandraftmonitoring.

Sorting:Thetermsortingmeanssortingoutthebestbrickswhichattainedtherequiredspecifications.Thedefectsappearedinthesebricksarelamination,cracks,warpage,angledefect,underburning,blackcore,ironspot,alkalispot,oversize,segregationetc.Thebrickshavingwarpageoroversizearesendingforsurfacegrindingandpolishing.Brickshavingironspotoralkalispotontheworkingsurfacearerejected,butifthosearefoundnotontheworkingsurface,theironischoppedoutandthenitispolishedbyasemiliquidmixtureofbrickcomposition.Underburntbricksareagainsetforfiring.Therejectedonesareagaintakenasrawmaterialforthecrushing&grinding.

Packaging&Despatch:Thewholelotofbricksispackedattheweightof1tons.Thepackagingisalsodonewithpropercareandthebricksarestampedwithblackinkgivinganidentificationregardingproductnameandsize.Thedespatchisdoneonlywhentheinternalandexternalinspectioniscompleteandtheproperlabelingisdone.

Shrinkpacking:

Shrink packing machine, which ensures airtight packs of polythene. The machine iscapableofpacking200ton/day.Aftervacuumshrinkpacking,thebricksaregivenafinalpackagewithcardboardboxes.

Applications:

% Rawmaterials

Phasespresent

Applicationtemp.(0C) ApplicationArea

30 Fireclaybased:

Fireclaygrog

MulliteandGlass,

sometimes1200-1450

Backuplining,Blastfurnacestacklining,BFstovecheckers,non-recoverycokeovens,cementrotarykiln,glasstankfurnace,lime

freesilica calcinationkiln,torpedoladlelining,

50

HATYPE:

Andalusite,Sillimanitesand,BFA,WTA,WFA,ReactiveAlumina

Mullite

(major),Glass(minor)alsofreesilica

1350-1700

BFstovecheckers,glasstankfurnace,anodebakingfurnace

DenseType:BFA,Fireclaygrog,HighAlkaliClay

Blastfurnacehearthandtuyere,cokeovenwharfregion,limekiln

65MulliteBased:FusedMullite,Bamul60,Ch.Bauxite

Mullite

(major),Corundum(minor)and

Glass(minor)

1500-1750Blastfurnacehearthandtaphole,glass

tankfurnace,wearzonesofladles,roofofelectricarcfurnace

75BauxiteBased:CalcinedBauxite

Corundum

(major),Mulliteand

glass(minor)

1600(max)Roofofelectricarcfurnace,ladlelining,Aluminiummelting&holdingfurnace

90 SyntheticAlumina

Corundum 1600-1800 BFhearth,Carbonblackreactor,Petrochemicalindustry,secondarysteel

Based:WFA,

WTA,BFA

(major),Mulliteand

glass(minor

makingvessel

UseofFireclayRefractories:1. Highgrogandmediumgrogbricksforsteelladles.2. Lowporosityandhighgrogqualityforblastfurnaceandladle.3. Highheatdutyqualityforladle.4. Pouringrefractorye.g.Sleeves,stopperheads,etc.5. Blastfurnacestacklining.6. Blastfurnacehearthandboshlining.7. 42%aluminaqualityforladles,densequalityforblastfurnace.8. Bottompouringrefractory.9. Cementrotarykiln.10.Anodebakingfurnace.11.Limecalcinationkiln.UseofHighAluminarefractories:1. Blastfurnace&cementrotarykiln.2. Limecalcination&glasstankfurnace.

3. Checkerforblastfurnacestove.4. Blastfurnacebottomlining.5. Glassmeltingfurnace&regeneratorchimneyblock.6. Ironcarryingladle&sidewalloftorpedoladle.7. RoofofEAF.8. Almelting&holdingfurnace.9. Non-recoverycokeovenlining.10.Petrochemicalindustries.

DOLOMITEREFRACTORY

INTRODUCTION

Dolomite is a naturally occurring mineral consisting of calcium and magnesiumcarbonates [CaCO.MgCO] in equimolar ratio.Thegangueminerals associatedwithdolomite imparts alumina, silica,ironoxideetc.tothematerial.Itisdesirabletohaveasmuchlowaspossibleamountofimpurities(silica,alumina,iron,manganese)sothatitcanbeused as arefractorymaterial.Fromeconomicalaswellasperformancepointofview,total impurity level of less than1.5% is accepted in the rawdolomite. Rawdolomiteissintered to a temperatureofover1800Ctoachievegrainporosityoflowerthan4.0%.Suchalowporosityisrequiredinthesintereddolomitetohavehydrationresistance.Themaincomponentsarecalciumandmagnesiumoxidespresentinthesintereddolomitearethermodynamically stable and hence suitable for application at high temperature (morethan1700C)aswellasreducingatmosphere.

TypesofProducts:

TRLproducesfollowingproductsinDolomitedepartment:

DOLOMITEPRODUCTS

BURNT BRICKS UNBURNT BRICKS

PUREDOLOMITE

MAGNESIAENRICHEDDOLOMITE

CARBORASEBONDED

RESIN BONDEDPITCHBONDED

BACKFILLRAMMINGMASS

FETTLINGMASS

RAWMATERIALSRawdolomiteofhighpurityisavailableinabundance,keepingtheaboveview,TRL

hassetupastate-of-the-artdolomiterefractoriesplantwiththetechnicalcollaborationofworldrenownedM/S.DolomiteWerkeofGermany.TRLhasdolomitesourceinSalbariinBhutanwhichisaverypureinnature,comparedtootherdolomitesavailableintheworld.Thechemicalanalysisofrawdolomiteisgivenbelow

ComponentAmountinpercentageCaO29.12MgO21.54LoI 48.4 SiO20.42Al2O30.30Fe2O30.26

TotalFlux1.12

Low amount of impurities is required for lowering the sintering temperature and forachievingrequiredpropertiesofdolomitebricks.Soaccordingtotherequirementstherawmaterialshavingdifferentimpuritiesarechosen.

FLOWCHARTFORPROCESSINGOFDOLOMITEBRICKS

RAWMATERIALPROCUREMENT

SINTERING OFRAWDOLOMITE

CRUSHING ANDGRINDING

BATCHING ANDWEIGHING

SinteringOfDolomite:Therawdolomitederivedfromitsoriginal locationneedssomesinteringtreatment.Rawdolomitefeedsizeisabout5-25mm.Topreparerefractoriesfromdolomite,atfirstdenseand volume stable grains of sintered dolomite are produced by dead-burning them at atemperatureof1850-1900?Cinarotarykiln.TheincreaseinB.D.isfrom2.86g/cctoabout3.22g/cc.Chemicalanalysisofsintereddolomite ComponentsAmount(wt%)

CaO56.39

PRESSING

FIRING

TEMPERINGSORTING

INSPECTION

PACKING ANDDESPATCH

MgO41.71 SiO20.81 Al2O30.58 Fe2O30.60

RotaryTunnelKiln:The raw dolomite in size range of 5-25 mm is fed to the rotary kiln (Throughput-100Mt/day)throughsurgehopperandweighfeeder.Thecontinuousrotarykilnisalong,slowlyrotatingrefractory linedsteeltubesupportedonseveralsetsofdrivingand idlingrollers.Thefeedendiselevatedalittlesothatthekilnisinclinedataparticularangle.

Parametersof RotaryKiln:

LengthofKiln 79m.

Diameter 2.55m.

Inclination 3%withrespecttohorizontal

Rotationalspeed 0.66-1rpm.

Retentiontime 4.5hrs.

Fuelused Petroleumcoke&FurnaceOil

Capacity 100tonsperday

Primaryairtemperature >300?C

Yield 48%

Flowrate 693lt/hr

Oiltemperature 90?C

Exhaustgastemperature >180?C&18%

Detailsof RotaryTunnelKiln:

ZONESINRTK

LENGTHOFZONE TEMPERATURE MECHANISM

REFRACTORYUSED

DryingZone 3.5m 550-7000C DryingofRawDolomiteLC60

(60%Al2O3)

Preheatingzone 9m 700-950

0C MaterialisPreheatedLC60

(60%Al2O3)

CalcinationZone 23m 950-1500

0CCarbonates

decomposestooxides

TATA80BC

(Bauxitebased)

TransitionZone 7m 1550-1750

0C

Phasetransformationtakesplace.Solidtosemiliquidstate

TATA80BC

(Bauxitebased)

SinteringZone 34.4m 1750-1900

0C Sinteringofmaterial

TATAMC40S3

(Mag-Chromebrick)

CoolingZone 1.14m 1900-15500C CoolingofmaterialLC90

(90%Al2O3)

CoolerParameters:

Length 30m.

Diameter 1.8m.

Retentiontime 1.5hrs.

Inclination 4%withrespecttohorizontal

Rotationalspeed 2rpm.

GRINDING

Impactmill andBallmill areused inthissection.Bythisprocessthesinteredrawmaterials are grinded to get various rangeofparticle size.Then they are stored inbigbucketlikestructurecalledassilos.

BATCHING

Varioustypesofsizefractionsareusedinbatching.Fractionsusedindolomiteproducts

a. 5-3mmb. 3-1.6mmc. 1.6-0.3mmd. 0.3mme. dust

MIXING

DE-18 and Inclined mixer machines areused in this section .Inmixingprocedurefirstly, coarse particles are collected from silos, then binder is used and then fines areadded.Fordifferentproductsdifferentbindersareused.

MixingSequence:

ForBurntbricks:

Coarse

1min.mixing

Binder(wax+Stearicacid)

3min.mixing

Fine+Dust

5min.mixing

(Totalmixingtime9min)

ForUn-burntbricks:

Coarse

1min.mixing

Binder(Liquidresin)

4min.mixing

Fine+Dust+Graphite(Flakytype)

10min.mixing

Resinpowder

3min.mixing

(Totalmixingtime18min)

PRESSING

Threepressesareinoperationinthissection.

Sacmi(PHR1600)-3nos.

FIRING/TEMPERING

Firing:BurntdolomitebricksarefiredinDTK(DolomiteTunnelKiln)at1640Cto1650C.

Dolomitetunnelkiln:

IndolomitesectionofTRLtherearetwotunnelkilnusedforthefiringofgreenbodyofburntbrick.

>>DTK1 >>DTK2

Lengthoftunnelkilnis72m.Thiskilnisdividedin52chamberslengthsofchambersaresameandequaltothelengthofthecar.Thiskilnisdividedinfourzonesasfollows

1. PreheatingZone 2-172. FiringZone18-233. NeutralZone244. CoolingZone 25-52

Furnaceoilisusedwithcompressedair(primaryair)andcombustionairinthefiringzonetoattainthetemperatureof1650C.Thisfurnaceoilwithcompressedairischargedthrough the burner by which proper atomization of fuel is maintained so that properutilizationoffuelisdonetoattainhighertemperature.Eachchamberhastwoburnersfromtwo sides and they are so arranged that their flamedonotstrikeeachotherandproperhomogenizationofheattakesplacethroughoutthechamber.TherearefivetypesoffansusedinDTK:-

1. Combustion fan- This fan is used for proper combustion in firing zone it drawscombustionairfrom32-35thchamberandchargeittothefiringzone.

2. Airinjectionfan-Itdrawshotairfrom43-44thchamberandchargeittothe2-6thchamberofpreheatingzonetomaintainthetemperatureofthosechambers.

3. Wasteheatfan-Itremovesextrahotairfromchambers41-42nd.4. Contrabackfan-Ittakesairfromatmosphereandinjectittothe52ndchamberof

the kiln. It creates the shielding effect to maintain neutral pressure at the 24thchamberinthekiln.

5. Coolingfan-Itcoolsthebrickscomingoutoffthekiln.

TEMPERING

Unburntdolomitebricksaretemperedintemperingkiln.Forpitchbondeddolomitebrick ,workingtemperatureisabout300Candforresinbondeddolomitebrickworkingtempis220C-250C.

Inthistemperingchamberproducergas(asfuel)isfiredinthecombustionchamberandthentheheatistransferredtothebricki.e.thebrickisheatedindirectly.

34 chambers are there which is divided into 1st zone, 2nd zone, 3rd zone,Pre-coolingzoneandcoolingzone.

TarImpregnation,WaxCoatingandDrilling:

Several grades of burnt dolomite bricks are tar-impregnated to prevent hydration priorapplication.Adrill-boringmachine isusedfordrillingaccurateholesinbrickstobeusedinTuyeres.Afterdrillingtheyarecoatedwithalayerofoil.

Sorting:

Thesortingtermsmeanssortedoutthebestonesandrejectingthecrackones,ordamagedcorners,notfiredproperly,segregation,warpagedonesetc.Theworkerthenkeepsthemasideandtherejectedonesareagaintakenasrawmaterialforthegrindingandcrushing.

Duetotimeconstraintandcriticalityinpacking,itisensuredthatallbricksaresortedwith24hrsofprocessing.

PACKING

Packingofdolomitebrickisaverycrucialstep.Bricksarepackedsocarefullythatmoistureisremovedasfaraspossible.Twotypesofpackingprocedureismaintained

1.Shrinkpacking.2.Aluvacpacking.

Before packing the bricks are cooled down to working temperature by Dolomitecrashcoolingunit.Afterthatthebricksareinspectedforanykindofdefectsandtheyareproceeded for packing. In shrink packing thebrickswith thewoodencase are coveredwith a polythene cover and then the cover is shrinked with heat treatment by ITWSingnodemachine.Bythisprocessthemoistureisremovedanditpreventsfurthercontactof bricks with moisture. In Aluvac packing aluminium foil is wound over thebricks. Itkeepsthebrickssafelyforlongerduration,soitisusedforexportpurposes.

Despatch:

The packaged productsarestored inthestoreyardontherackconsistingof12columns(A-L) eachwith6rows.Thedespatchprocessofthisdepartment iscalledFIFOPROCESS.

The FIFO stands for FIRST IN& FIRSTOUT. Theprocess issuchbecausetheproducts,whicharemanufacturedearlier,aretobedespatchedearlierinordertomaintainitslife.

Dolomite-basedmonolithics

Someotherproductslikedolomite-basedmonolithicarealsoproducedinDolomitedepartment.

a. Doloramb. Dolofetc. DolomixKJDolofetisdolosintercoatedwithanthraceneoilandmillscaleisaddedasasintering

agent.ThisisusedinthefettlingmassbankandbottomofEAF.Doloramisthedolosintercoatedwithblendedpitch.Thisisusedinthebackfilling

massinAODandsteelladdle.DolomixKJismixtureofdolosinter,almoramagnesiteandeasteroil.Thisisused

intheknucklejointofAOD.DefectsfoundinDolomitebrick:

a. Crackb. Cornerbreakagec. Warpagedefect

d. Segregationdefecte. Sizedefectf. Waxmelthole

BASICREFRACTORYINTRODUCTION

Refractoriesareclassifiedintwoways.Oneisphysicalclassification,accordingtodifferentproductforms.Thesecondisachemicalclassification,basedondifferentchemicalcomposition.Thechemicalclassificationsincludeacid,neutralandbasictypes.Refractories,whicharemainlyRO2(suchasSiO2,ZrO2)areconsideredasacidtypes.ThosecomposedmainlyofRO(MgO,CaO)areincludedinbasiccategory,whileR2O3types(Al2O3&Cr2O3)areincludedinneutralrefractories.

Thebasicdept.isequippedwithmodernfacilitiesformanufactureofarangeofmagnesia-carbon,directbondedmagnesiteanddirectbondedmagchromeproducts,besidethestandardrangeofbasicbricks.Thefollowingaretheimportanttypesofproductsinthisdepartment.BASICBRICKSBurnttype Unburnttype1.Magnesia(90%-98%MgO) 1.Mag-carbon-(5%-25%carbon)2.Mag-chrome 2.Alumina-Mag-carbon3.Chrome-mag4.Directbondedmag-chrome5.Mag-Zircon6.Mag-Alspinel7.ForsteriteRAWMATERIALVarioustypesofrawmaterialsareusedinmanufacturingofBasicbricks.Theserawmaterialsaremainlyfourtypes,1. Magnesite2. Chromite3. Graphite4. FusedMagChromepowderMAGNESITE

Thisisthemainrawmaterialinbasicrefractory.Itproducedasthreevarieties. DeadburntMagnesite SinterMagnesite FusedMagnesiteAmongthesesomeareindigenousandsomeareimported.Indigenous: Almorahmagnesite SalemmagnesiteImported:

FusedMagnesia(FM)

Chinesemagnesite(9398%)

Deadburntmagnesia(DBM)

Seawatermagnesite(SWM)

CHROMITEThisisthesecondmostimportantrawmaterialformanufacturingofbasicrefractories.Therawmaterialsusedare

ChromiteGr-I(5054%Cr2O3)

ChromiteGr-III(45%Cr2O3) Chromedust

Chromiteflour

Fusedmag-chromepowderGRAPHITE:-ThisisanotherimportantrawmaterialformanufacturingofMag-Carbonrefractories.ThegraphiteusedinBasicDept.contains94%fixedcarbon.Itisaddedinthepowderformandthematerialisobtainedindigenouslyfromgraphitemines..Itprovides:

1. Highoxidationresistanceagainstslags2. Stopsslaginfiltrationduetononwettingnature.3. Highthermalconductivity4. Goodmechanicalproperties

ADDITIVESANDBINDERSUSEDAdditivesused

Aluminiummetalpowderasantioxidant Siliconmetalpowderasantioxidant

Pitchpowder

Carborespowder

Resinpowder

HexaminforAMCbricks

RutilepowderBinderused

LiquidresinforMag-Cbricks

Molassesforburntbricks Dextrinforburntbricks

MANUFACTURINGPROCESSRawmaterial

Crushing&Grinding

Batching

Mixing

Pressing

Drying/Tempering

Firing

Crashcooling

Sorting&Inspection

Packing&Dispatch

CRUSHING&GRINDING

The purpose of size reduction by crushing and grinding is to produce crushedproduct with desired size range. To ensure higher packing density; three fraction ofgradedmaterialsareused,

Coarse :46mm&14mm

Medium :01mm

Fine :Dust(

Theinstrumentsusedforcrushing&grindingareType Feedsize Outputsize

Jawcrusher 12-14inches 2-3inchesImpellerBreaker 6-7inches 1-4mm,0-1mmMexiconmill 6-7inches 1-4mm,0-1mm

Ballmill 10-20mm

MagChrome/ChromeMag Molasses+DextrinMagnesite Molasses+Dextrin Direct Bonded Mag Chrome(DBMC)

Molasses+Dextrin

MagCarbon(MgOC) ResinLiquidDifferenttypesofadditivesareusedinmixingprocedureofBasicrefractories.TheseareADDITIVES ROLEOFADDITIVESRutile Acts as sintering agent in Mag

Chromebricks.Aluminummetalpowder UsedasantioxidantinMgO-Cbricks.Siliconmetalpowder UsedasantioxidantinMgO-CbricksCarborespowder ImpartworkabilitytotheMag-CmixPitchpowder ImpartworkabilitytotheMag-CmixGraphite SourceoffixedcarbonHexamin Usedashardenerinnovalacresin.Millscale Used as sintering agent in Burnt

magnesitebricksLowsilicaChrome SourceofChrome.

MIXINGSEQUENCEForChemicalbondedorDirectbondedVarietiesCoarse(1-4mm)+Powderadditive+Binder

2min.mixingLiquidadditives7min.mixingFines(0-1mm)+dust8min.mixingTotal17min.mixingForMag-CarbonRefractoryBricksCoarse(1-4mm)+Graphite+AluminumPowder1min.mixingLiquidResin

10min.mixingFines(0-1mm)+Dust

15min.mixingTotal26min.mixingTYPESOFMIXERMACHINES

Eirichmixermachineor[Rv-19]

DE-18mixermachine

B-500mixermachineBINDER&ADDITIVESINDITAIL

BURNT UNBURNT

Binder :Molasses(liquid) Binder :Liquidresin Dextrine(powder) PowderresinAdditive:Rutile(TiO2), Additives:Graphite, Mill-Scal,Bentonite, PitchPowder

Boricacid HexamineCarborespowder

PRESSING

Typeofpressingmachine

Automatic ManualLAEIS(1600ton) FSP(FrictionscrewpressorHaripress)SACMI(1600ton) Machine(400ton,1000ton)

Name No.ofPressesLAEIS 1SACMI 1FSP 3(400MT-2nos,1000MT-1nos)

MODESOFPRESSING

Flatpressing

EdgepressingDRYINGThehotairfordryingisintroducedthroughductscomingfromtunnelkiln.Fuelgasfromthekilnisnotusedforthispurpose,asitcontainsmoistureandothervolatilematters,whichleadtounhealthyworkingconditions,e.g.dustpollution,pungentsmell,etc.DETAILSOFDRYER

Dryertype tunneldryer

Temperatureofdrying 80-1250C(max1300C)

Timeofdrying 2472hrs(varyingwithtypeofmaterialused)

FIRING/TEMPERINGZonesofTunnelkiln:

Preheatingzone Firingzone

CoolingzonePreheatingzone:Oncethecarenterthekiln,itfirstpassesthroughpre-heatingzone.Itisthesecondlongestzoneofthekiln.Inthiszone,thebricksgetpre-heatedbythewastefluegasofthefiringzonebymaintainingaconstantsuction.Thisincreasesthethermalefficiencyofthekiln.Firingzone:Itisinbetweenthepre-heatingandcoolingzones.Afterpassingthroughthepre-heatingzone,thecarsenterthefiringzone.Itisthesmallestzoneofthekiln.Burnersarepresentinthiszonetofirethecharge.Maximumtemp.isreachedinthiszone.Coolingzone:Thelastandlongestofthezonesisthecoolingzone.Thebricksaregraduallycooledtoaround100Cbeforecomingoutofthekiln.Burnerfansareusedtosuckincoldairintothecoolingzone.Thiscoolsthebricks.Subsequently,theheatedupairisusedindryerandcombustion.

PRODUCTS TEMPERATURE(0C)

MagChrome/ChromeMag 1560-15800C

Magnesite 1550-17300C

DirectBondedMagChrome(DBMC)

17500C

HTKItisdividedinto34sections.Thesearefurtherclassifiedintothreemainoperatingzones.Thesezonesare Preheatingzone(115)

Firingzone(1620)

Coolingzone(2134)Totallengthofthekilnis68meter.Thefiringtemperatureinthekilnis1800C.DETAILSOFHTK

Lengthofthekiln 68meter

Usefulwidth 1.60meter

Usefulsettingheight 0.7meter

Lengthofthecar 1.9meter

No.ofcars 34

Firingtemp.(max) 1500-18000C

Settingweightpercar 3ton

Goodstofired Basicmaterial

Fuelused Furnaceoil,petcoke,highspeedoil

BASICTUNNELKILN(BTK)Length

120m

Firingtemp.(max) 16500cCapacity

70MT

Fuel Furnaceoil,petcokeTEMPERINGTherearetwotemperingkilnsinthebasicsection.Amongthesetwooneismaintemperingkilnandanotherisstandby.MagCarbon(MgOC)bricksaretemperedintemperingkiln.Theoperatingtemperatureofthekilnis200C-250C.Thetimescheduleis1824hours(percycle).CRASHCOOLINGAfterfiringthebrickscomingoutfromthetunnelkilnhasatemperaturearound1000cto1500c.Socrashcoolingisusedtocooldownthebricksto500c,sothatworkercanhandlethebrickseasily.Lengthofthecooleris10m.SORTINGANDINSPECTION

Afterfiringortemperingofthebricksinthekiln,thecooledbricksaretransferredtothestoreyardsbyforklifts.Thebrickshavingcracksarerejectedduringloading.Afterunloadingofbricksinthestoreyard,theyareinspected(physicalinspection).Laboratorytestingisalsopreferred.Thepropertiescheckedinthelaboratoryare:

BulkDensity(B.D) ColdCrushingStrength(C.C.S) RefractorinessUnderLoad(R.U.L) ApparentPorosity(A.P)

Physicaldefectscheckedhereare: Lamination Warpage

Crack Cornerbreakage

Sizedefects Segregation Angledefects

Ironhole Diagonaldefects

PACKING

Basicbricksarepackedverycarefully.Becausetheseareverypronetoabsorbmoisture.Thereforedifferentstepsarefollowedtoremovethemoistureandfurthercontactofmoisture.Afterclearingthetest,thebricksarereadytobepacked.Normallytwotypesofpackingaredone,namely:

ParallelPacking. VacuumShrinkPacking.

Thenafterpackingthepackedbricksarereadyfordispatch.

APPLICATIONAREAMAGNESITEBRICK

NormalqualityburntmagnesitebricksareusedinLDconvertersandbasicopen-hearthfurnace.

Canbeusedinglasstankcheckerandchemicalindustries. LowporositymagnesitebricksareusedinliningEAF,BOF,LDconverters

andcopperrefiningfurnaces. DensemagnesitebrickswithlowsilicaareusedforapplicationinLD

converters,VADladles. Tarimpregnatedmagnesitebrickswithminimumresidualcarbonat2.5%and

maximum10%silica(restMgO)mayhaveapparentporosityof4%(max)andCCSof600Kg/cm2(min).AlsotheRULincreasesto1700C.SuchbricksareusedinLDconvertersandEAF.

MAGNESITE-CHROMEBRICK

NormalMagChromeburntqualityisusedintheendwallsandtheabovesteellevelsofopen-hearthfurnace.Sometimeschemicallybonded(withorwithoutsteelcladding)brickscanbeusedinsteelmeltingoperationsattemp.greaterthan15000C.

SpecialchemicallybondedsteelcladMagChromebricksareusedintheroofoftheopen-hearthfurnace,andburntqualityforopen-hearthfurnaceroofaswellasrotarykilnforcementanddolomite.

LDconverterlining.

Brickswithabout6%Cr2O3and72%MgOareusedinpaperandchemicalindustriesastheyareresistancetoalkalinesolution.

VODladles,cementkilnetc. Brickswith3%SiO2and80%MgOandmaximum10%Cr2O3areporousto

anextentof21%andhaveanRULof1600C,aregenerallyusedforrotarykilns.

CHROMEMAGNESITEBRICKS Normalchromemagnesiteburntqualitybricksareusedforconstructionof

open-hearthfurnacefront,backwalls,gaspartsanduptakes. Chemicallybondedbricks(withorwithoutsteelcladding)areusedinsteelmelting

operationsattemp.notlessthan1500CMAGNESIACARBONBRICKS

Steelladleapplication. BOF,VAD,LF,EBTapplications. LDconverterstapholes.

HotspotandsidewallsofEAF.BRANDPRODUCTSOFTRLKROSAKIBRANDNAME APPLICATIONMagnesiabricks MGR EAF,LD&LadlebackupMGD92S2 Limekiln,EAFM-96 Glasstank&Chemicalindustries.MGW-98 GlasstankRegeneratorcheckersMagnesiaChromebricks MCR OpenhearthroofMC40S3 Rotarykiln

CMN BackupliningofAOD,ladleDirect Bonded Magnesia Chromebricks

CRXS VOD, Glass, Zinc, Copperfurnaces

CRVV -do-CRXV Copper smelting & converting

furnaceCRVS -do-RH Snorkel & Lower vessel of RH

degasserMagnesiaCarbonbricks HMR-C-1 LDConverterBottom&TapPadHMR-C-2 LDConverterLowerconeHMR-C-3 LDConverterTrunionHMR-C-4 LDConverterTopconeHMRLS SteelladleslagzoneHMREH EAF Slag Zone, Hot spot and

holeALUMINAMAGNESIACARBONBRICKS

AMC1 SteelladlebottomandmetalzoneAMC3 -do-AMC5 -do-

FLOWCONTROLPRODUCTSIntroduction:FlowControlProductsbasicallycontrolstheflowofthemoltensteelorinertgas.

TRLmanufacturesthreerangesofFlowcontrolsystemsintheFCPdepartmentviz.:

Slidegaterefractories, Gaspurgingrefractoriesand Continuouscastingrefractories.

Slidegatesaresystemsusedtoregulatetheflowofmoltensteelfromladletothetundish.

Gaspurgingrefractoriesconsistsofporousplugsusedtoregulatetheflowofgasesflowingintotheladle.

Continuouscastingrefractoriesconsistofzirconorzirconianozzles.

FlowControlProductsatTRLaremainlydesignedforfollowingSlideGatesystems:

A.FLOCON

-6300series

-4200series

-3150series

B.INTERSTOP

-1QC,2QC,3QC,4QC

-1BK,2BK,3BK,4BK

-LS-50,LS-70,LS-90

C.SAFLOWSYSTEM

D.SANACSYSTEM

Differentqualitiesofproductsareofferedhavingdifferentrawmaterialcompositions;maybeclassifiedasfollowing:

A.Magnesiabasedfiredandtar-impregnatedproducts(90-98%MgO)

B.AluminaCarbonbasedfiredandtar-impregnatedproducts(8590%Al2O3)

C.AluminaCarbon-Zirconiabasedfired/tar-impregnatedproducts(85%Al2O3)

D.AluminaZirconiaCarbonbasedtemperedproducts

E.ChromeOxidebasedAluminafiredproducts

F.ZirconiabasedNozzles

RawMaterials:

Majorrawmaterialsusedare

WhiteTabularAlumina FusedAlumina(WFA&BFA) ZirconSand(ZrO260%),ZirconFlour SillimaniteSand Chromeoxide(usedinmortars) CalcinedAlumina SeaWaterMagnesia FusedMag-Dolo DBM(usedinporousplug) AluminiumOxide(increasesabrasionresistance) Q-Mag CarbonBlack Grogdust Zirmul(Zirconia-mullite) Metallicsiliconpowder ReactiveAlumina Chromeoxide

Binders:

Resinpowder Secar71,Secar80 Hexamine(usedashardening)

Boroncarbide(B4C) AluminiumPowder(additive) Dextrin

Additives:

Ballclay Plasticclay CMC(CarboxyMethylCellulose) STPP(SodiumTriPolyPhosph

ProcessFlow-Chart

RAWMATERIAL

BATCHING &MIXING

PRESSING

AIRDRYING

DRYING (110C)

FIRING

SLIDINGGATEPLATES &NOZZLES

POROUS PLUG

TESTINGTESTING

RawMaterialProcessingAndStorage:

There is no crushing and grinding unit in FCP department, as the raw materials are allprocuredingradedfractions.

For storage of rawmaterial twosets (4nos.each)ofmanuallyoperatedsiloshavebeenprovided where different grades of High-Alumina raw materials are stored as per

CASSETING

TAR IMPREGNATION

TEMPERING (220C)BAKING

QUALITYCONTROLCHECKPLATEWELDING

SHOT BLASTING

FINISHING

BAKINGQUALITYCONTROLCHECK

SURFACE GRINDINGPACKING & DESPATCH

POLISHING

PACKING & DESPATCH

QUALITYCONTROLCHECK

requirement.

The batching is done manually in this department. There is no automated car but thematerialistakenfromsilosasrequiredformixingintrolleys.

Mixing:Thereare4mixersinthisdepartment:

DE18(mixingdoneformagnesiabasedproducts) RV19(mixingdoneforcarbonaluminaproducts) TwosmallMullermixerforZirconiamixes

Mixingsequence:

TabularaluminaFraction(8/14,14/28,28/48)+Carbonblack+Hexamine

Drymixingfor5minutes+Resinliquid

Wetmixingfor5minutes+Tabularalumina[fraction(-325,300)fine]

Metallicsiliconpowder-50

Mixitfor20minutes

Maximum40minuterequiredformixing]

Pressing:This department has 5 presses suitable for different raw material grades and finishedproductshapes:

1HORN:Hydraulicpressureisused.Itscapacityis1000MT.Itisusedforporousplugsandnozzles.

1LAEIS:Hydraulicpressureisused.Itscapacityis400MT.Itusedforslideplates.

1FSP:Mechanicalpressureisused.Itscapacityis400T.Itisusedforpressingnozzlesandseatblocks

3MOSCOpresses:Eachcapacityis200T.Itisusedforpressingzirconnozzleswhicharerelative

Drying:Atfirsttheproductsareair-dried.Then,materialsaredriedindryingchambers.Thereare6dryersofcapacity90plates.Temperaturemaintainedisnearlyabout1100C.Thefuelusedisoil;gas&FTKwasteheatgas.

Recently the Drying Chambers have also been connected with Ducts to the exhaust ofShuttleKilnsforoptimumheatutilization.

Generally Un-burnt products are Chamber-dried for a period of 24 hrs whereas Burntproductsaredriedfor36hrs.

Firing:There are two types of firing done in FSP viz. in Shuttle Kiln/Chamber Kiln and HighTemperatureTunnelKiln(HTK)presentinthebasicdepartment.TherearetwoShuttleKilnspresent inthisdepartment,which isalsoknownasCARBELLKILN.Ineachkilnonlyonecarcanenter.TheZirconnozzlesandtheslideplatesarefiredherewhereastheporousplugs(whichhaveamagnesiabasedcomposition)arefiredinHTK.

Thefuelusedinshuttlekilnislightdieseloil/CompleteBurnerFurnaceSolution(CBFS)andgas.Thiskilnworksatatemperatureofabout1480-1550C.Therearearrangementsfor12burnerstoworksimultaneouslybutonlysixareusedwhenCBFSisbeingused.Ifgasisusedasafuelthen12burnersareused.Thenewkilnhasacycletimeofabout50hourswhiletheoldonehasacycletimeof65hours.Thekilnislinedwithceramicboard/insulatingbrick/HAbricks(outsidetoinside).

Alumina-carbonmaterials are fired in boxesmade of Burnt Alumina bricksandthespacebetween the bricks are filled with free carbon powder to prevent oxidation of carbonpresentintheslideplate.

Firingtemperatureofdifferent products:

RandomPorousplug:16800CinHTK. SN85:1450-14800C(7hrssoaking)inShuttleKiln.

SP85CA,SP85CAS,SP85CASS:1450C(9-10hrssoaking)inShuttleKiln. Alumina-zirconia-carbonslideplate(chemicallybonded):150Cfor12hrs,then200C

for24hrs. MPP(2)PorousPlugMagnesiabased:1680CinHTK. Slidegatenozzle90%Al2O3-C(SN90C,SN90CA,SN90CM):15500CinHTK. Nozzle(ZRN60):14800Cinshuttlekiln. ZRN66:15000Cinshuttlekiln. ZRN75:1530Cinshuttlekiln.

Tempering:

Un-Burntproductsaretemperedatatemperatureof200OCinfourBatch-typetemperingkilnsforaperiodof24hrs.Thisprocesshelpsinhardeningduetotheformationoforganicbondsinthepresenceofpitch/resin.

Drilling:

Drillingiscarriedoutincaseofslideplatesofrequiredborediameter.Unlikenozzles,itisnottechnically feasible to form the bores during pressing stage as this affects the tensilestrengthandcorrosionresistanceoftheplatearoundtheedgesofthebore.

Twomechanical drillingmachines have been installed for this purpose. The DrillbitsaremadeofdifferentgradesofAlloyswhichneedtobereplacedafterevery150180bores.

TarImpregnation:

Tarimpregnationisdonetoincreasetheamountoffreecarbonandreducetheporosityto3-4%,incarboncontainingmaterials.

Thehardpitchisinitiallystoredinanoverheadstoragetank.Fromtherethepitchisfedinacounter-currentHEIZAboiler.Meltingofthepitchtakesplacebythermooilf lowwhichisheatedpreviouslyatahightemperature(sinceithasaveryhighflashpoint).

The molten pitch is stored in service tank. Flow of the viscous liquid is inducedwith avacuumpump.

The fired products are placed in cubicle cages and then passed through a pre-heatingtunnel.Thetunnelcanaccommodateamaximumof13cagesatatime.AfterthecagesareprimarilyheatedinthetunneltheyarefinallyreadytoentertheAutoclave.

Thefollowingstepsarefollowedtooperatetheautoclave:

Thetopcoverofthestoragetankisopenedfollowingthecage. ThenthehardpitchischargedintothecagebycranefollowingtheVacuumiscreated

insidetheservicetankusingpump1upto450mm.ofHg. Tarvalvesareopenedandtarflowsfromstoragetanktoservicetank. The auto clave ismaintained at a temperature of 180-200C. Then twocagesare

positionedinsidetheautoclaveandthenitisclosed. Nowvacuumiscreatedinsidetheautoclavebypumps. The vacuum pump is stopped and then the compressor runs at 6 bars for tar

impregnation.The2electro-pneumaticvalvesareclosedandthisprocesspersistsfor

2hours.Thetar-impregnatedproductsaredrawnoutoftheAutoclaveandcooledinatmosphereuntilthetarsets.

Tempering:

Tempering is done for theproperdevelopmentofthebonding.Twotemperingkilnsarepresenthere:

ElectricOven:Temperingisdoneatatemperatureof200-210Cfor12hrs. FuelOven:Temperingisdoneat350Cfor8hrsbyGasorLightDieselOil.Thevolatile

matterwhichenterstheproductduringtarimpregnationisremovedinthisprocess.

ShotBlasting:

It isdonetoremovetheexcesscarbondepositedonthesurfaceoftheslideplatesduringtar-impregnation.Theplatesareplacedonawheelabratorbysprayingfinesteelparticles.

SteelCassetingandBaking:

Steel Casseting is done to preventanystructuraldamageduringhandlingandsupplying.Steel Casseting isdoneonlyforporousplugandslideplates. Itcanbemadeofstainlesssteelormildsteelaspercustomerrequirement.

Theprocuredsteelcassettesarebondedtotheformedsurfaceusingceramicmortars(SMA

90K).

Theyarethenheatedinanelectricfurnace,atatempof200-210Cfor10hrssetting,themortar sets. This process is called Baking. Two Batch-type electric furnacesareusedforPlatesandNozzleswhere-asonefurnaceisusedexclusivelyforPorousPlugs.

SurfaceFinishing:

In order to maintain the warpage of slide-plate surfaces within tolerable limits to theslide-plates are ground inmechanical grinderwith rotating disks. Thesmoothsurfaceofplateiscoatedwithgrease,whichhelpsinslidingapplication.Thereare4grindingmachinestocarryoutthisoperation:twoforroughgrindingandtwoforsmoothfinishing.Thishelpsinensuringthedesiredthicknessofplatesisnotaffected.

Thevisiblesurfacesofcassettes innozzlesandplatesarethenpaintedtogiveasuitablefinishandpreventrust-formation.

Anyundesirablesurfacedefectsareremovedduringvisualinspectionbymanuallyrubbingwithgrindingstone.

Despatch:After stenciling (labeling) is done the products are packed in suitable boxes andsenttostoreyard.ArecordoftheregularconsumablesismadeforreleaseasperMade-to-Stock

inventorycontrol.

Application:

Slide gate refractories in magnesia, magnesia-spinel-carbon, alumina-carbon andalumina-zirconia-carbon quality along with all suitable accessories including specialtypehighaluminamortars,readytousemortars,rammingmass.Thiscanbesuppliedindifferentdesignsandshapesforalltypesofslidegatesystems.

Gas purging refractories in high alumina, basic, alumina chrome and directionalporous plugs in high alumina quality up to 96% alumina for longerpurgingtime inladles.Porousplug inbasicandhighaluminaqualitywithM.S/S.Scasingalongwithseatingblockandsleeves.

Continuouscastingrefractorieslikezirconorzirconianozzles(65-95%zirconia)forslab,bloomandbilletcasting,basictundishsprayingmassanddryvibratablemassandprecastfortundishchargedpad.

FLOWCONTROLPRODUCTS APPLICATIONS

SlidePlateContinuousCasting

Ingot&ContinuousCasting

NozzleForStopperHeadSystem

ForSlideGateSystem

WellBlockForWellBlock&SeatingBlock

PorousPlug SteelLadle

LRF,VOD

MONOLITHICSINTRODUCTION

Monolithic refractory is thenamegenerallygiven to all unshaped refractoryproducts,thewordmonolithiccomingfromthewordmonolithmeaningsinglelayer.The general definition of monolithic refractories is batches or mixtures consisting ofaggregates , binder&additives, preparedfordirectuseeitherinthestateofdeliveryorafteraddingoneorseveralsuitedliquids.Theymaycontainmetallic,organicorceramicfibers.Thesearematerials,whichareinstalledatsiteandhardensaftersettingtoformajointlessstructure.

Monolithic refractorieshave increased inmarket shareof thetotalrefractoriesindustryoverthelasttwodecadesandwillcontinuetodoso.ADVANTAGE:

Rapidinstallation Process time for manufacturing monolithic is less as they dont need

mouldingandfiring Absenceoffiringformanufacturingmonolithicsavesenergy Monolithicrefractoryliningsarejointlessconstruction It can be repaired locally without disturbing the whole structure , thus

savingtime,energyandlabour. Reductionofdowntimeforagivenapplication Costofrawmaterialsfortheirmanufacture Lessmanpowerrequiredintheirinstallationandrequirementoflessskilled

people.

FORMULATION:Generallymonolithicformulationsconsistof:1. Aggregates(Coarse,Medium,Fines)2. Finefillermaterials(whichfilltheinterparticlevoids),and,3. Binderphase(thatbindstheparticulatetogetherinthegreenstate).4. AdditivesBINDER(HAC)

AGGREGATE

ADDITIVES FINEFILLERS

Monolithicrefractorieshaveamyriadofindustrialapplicationsthroughoutthe

steel, cement, non-ferrousmetallurgical,wastedisposalandpetrochemicalindustries.They are available inmany formsanddifferent formulations.Themainpropertiesofthesematerialsaretheirrespectivechemicalinertness,mechanicalintegrity,abrasionresistanceandthermalshockresistanceathightemperatures.

CLASSIFICATION OF MONOLITHIC REFRACTORIES DEPENDING ONSEVERALASPECTS:-

CastableTheseconsistofprecisiongradedcoarseandfinerefractorygrains.Theyare

gelled by means of a binder system in the green state. Following the heat-up of thematerialthebindereithertransformsorvolatilizesfacilitatingtheformationofaceramicbond. The most common binder used in castables is HAC (High Alumina Cement).Castablesaremixedwithwaterandtheninstalledbyeitherpouring,trowelling,pumping.Placementofthematerialthenrequiresvibration

1.Conventionalcastablescancontainaround15-20%cementbinder.2.Lowcementcastablescontainbetweenabout4-7%(wt.)cement.3.Ultralowcementcastablescontainlessthan3%cementcomponent.4.NocementCastablecontaineitherzeroorlessthan1%.ClassificationofCastablesonthebasisofflowbehaviour

Freeflow/Self-flowCastableFreeflow/Self-flowCastableisaspecialtypeofrefractorycastableswhichisinstalledwithoutvibration.Theyrequireamuchlowerwateradditionthantraditionalcastables.Thisisduetothefactthattheyhaveefficientparticlepackinganddispersingagents,whichmodifythesurfacechemistryofthefineparticlestoimprovetheflowofthematerial.

Castable

Vibratable Trowelable Self Flow

GunningmassThisisarefractorymaterialconsistingofcoarseandfinerefractorymaterialandasuitablebondingagentandinstalledwithagunningmachine.therearevarioustypesofgunningmaterialssuchas:-

1- Drygunning2- Wetgunning

Sprayingmass

Itconsistoffinerefractorymaterialandsuitablebondingagentandinstalled

with a sprayingmachine aftermixingwithwater .sprayingmaterials areextensivelyusedforliningtundishandrepairofcokeovens.

Rammingmass Refractorymaterial consists of coarse and fine refractorymaterial andsuitablebondwhichareinstalledbyramming.Therearetwotypesoframmingmassessuchas:-

1- Wetrammingmass2- Dryrammingmass

Wetrammingmassisinstalledbyrammingaftermixingwithwaterwhereasdryrammingmassisinstalledbyrammingindrycondition. Refractorymortars

Mortarsconsistoffinelygroundrefractorymaterials,whicharethenmixedwith water to form a paste. They are used for laying and bonding shaped refractoryproductssuchasbricks.Theyarenormallyappliedbytrowelling.Themortarsaresupplieddryorreadyforuse.Onegenerallydifferentiatesbetweentwotypes:

a.HeatSettingMortars:Ithardensandsetwhensubjectedtoheat,thatishardenduetotheirchemicalorceramicbondathighertemperaturesand

b.AirSettingMortars:Ithardensandsetwhensubjectedtoair,thatishardenduetotheirchemicalorhydraulicbondatroomtemperature.

Plastics Itisarefractorymaterialmixedwithliquidbinderandwater,whichhas

suitableplasticitytoberammedintotheplace.

INSTALLATIONPROCEDUREOFCASTABLEREFRACTORIES:

MixingThemixermust be cleanbeforeuse.GenerallyCastableRefractories aredrymixedinamixer for 1 mins for homogenisation. Then clean cold water (2350C ) are added andthoroughly wet mixed for 4-5 mins . The Percentage of water varies fromCastable toCastableanditshouldbeappliedaccordinglytotherecommendation.Aftermixing,itispourtomould.Installation1. Before installation , the forma should be checked according to the design and alsocheckwhethertheanchorsareinrigidandtightcondition.2. To preventpremature lossofmoisture from themix, formaused for castingmustbethoroughlyoiledorgreased.3.Aftercasting,neddlevibratorofproperdiameterareusedforcompaction.4.Preventlossofmoistureduringfirst24hrsafterpouringtheCastablebycoveringwithanapprovedcuringmembrane(bywetclothes).5.Thenremovetheshutteringandcheckthesoundnessofthecasting.6.Thenairdryingfor24hrs.7.Thenheating the lining asper standardheating schedule. ItisrecommendedthatthedryingandheatingofCastableliningshouldbedonewithinashortperiodaftercasting.

RAWMATERIALS

1. FireClayGrog2. InsulatingGrog3. Vermiculite4. Perlite5. CalcinedBauxite6. BrownFusedAlumina(BFA)

7. WhiteFusedAlumina(WFA)

8. WhiteTabularAlumina(WTA)

9. Reactivealumina

10.Syntheticmullite

11.Siliconcarbide(SiC)

ADDITIVES

a. BallClayb. PlasticClayc. Microsilicad. Bentonitee. Dextrinf. SodiumTriPolyPhosphate(STPP)g. SodiumHexaMetaPhosphate(SHMP)h. OrganicFiber

BINDERS

1.HighAluminaCement(6580%)

2.Lowaluminacement(4550%)

MANUFACTURINGPROCESS

Coarse Materials Fine Materials

Skip Hoist bucketAnd Shuttle conveyer conveying

systemCPneumaticco

nveyingSilo nos. 1-12Silo nos. 15-32

Automatic Batching car

Skip bucket

IFNOTIFOK

MixerMachines:-Newmonolithic:INCLINEDEIRICHMixer(Capacity2ton)OldMonolithic:Mixermachine Capacity Materialsmixed

Bagging hopper

BaggingandStitching

Store yard

ToBeReprocess

Testing

Dispatch

M500 1MT Basicrammingmass(M-95,M84,Basram)

Conicalblender 500kg Silicafreematerials,Castableforprecast

DE18 1MT Basicmaterials,M85,CH15

TRL-LITE 1MT Sprayingmass(TRLLITE-87/80,87/70),,Basicmortar

FM-4 1MT InsulationCastable,conventionalcastables,mortar,Aluminamortar

FM-2 1MT InsulationCastable,conventionalCastable,silicamortar,Aluminamortar

PRODUCTS&APPLICATIONSOFVARIOUSCASTABLES

FireclayandhighaluminaCastable1. Spongeironkiln2. Ladle,Tundishrepairing3. Cementkiln

4. CFBCBoilers

InsulatingCastable1. Back-uplining2. Heaters,stacksductinpetroleumapplications.3. Petroleumreformer.4. DRIkilnheaters.5.BFStove

LowcementCastables1. CementkilnandDRIkiln,incinerators.2. Tundish,aluminakiln,lances.3. Rotarykilnnose-rings.4. Strikerpads.5. Launders,snorkelofRHunit.

Cokeovengunningmixes1. Heatingfinecracksincokeovenwalls.

2. Head,roofandascensionpipes. Cokeovensprayingmixes

1. Airbornesealingcompoundforsealingcracksincokeovenwalls.2. Hotrepairofcokeovenwalls.

UltralowcementCastables1. Aluminacalciningkiln.2. Cementkilntipcasting,reheatingfurnacehearth.3. Waterquenchingareasofincinerator

FireclayandhighaluminaceramicsettingmortarsUsedforlyingofaluminabricks.

Fireclayandhighaluminachemicalsettingmortars1. Usedforlayingof45-50%aluminabricks.

Fireclayandhighaluminaplasticmasses

1.Incineratorsformediumandhightemperatureapplicationwithhighstrengthatintermediatetemperatures2.Steelandaluminiumfurnace3.Silvermeltingfurnaceandacidregenerationplant.4.CFBCBoiler

DenseCastables1. Cementkilncoolers,spongeironrotarykilns.2. Non-ferrousladlelining,generalpurposerepairing.3. Inductionfurnacecover,burnerblocks,ductileandmalleableironladles.4. Secondaryreformer,hydrogenreformer,R.G.boilers.

PRECASTSECTION:Precast-refractory-shapetechnologyhasbecomeaspecializedfieldwithintherefractoryindustryinrecentyears.Asdemandsincreaseforgreaterrefractory-liningperformanceandlowermaintenancecosts,refractoryusersarefindingthatoneeffectivewaytoachievethosegoalsistoincorporateabroaderuseofprecastrefractoryshapesintotheirliningsystems.Thissectionproducespre-fabricatedshapesfromrefractorycastablemix.MANUFACTURE

Manufacturing & Test of Castablesmix . used for PCPF department

Select the Castable mix and Pour into themixer

IFNOTOK

Drymixing (1 mins.)

Wet mixing (4-5 mins.)

Inspection of moulds

Casting and Compaction (vibration)ByVibrocasting

Curing

Demoulding

Air Drying / OvenDrying

Firing

REJECT/REUSESorting & Finished Products

APPLICATONS1. Wellblock,Seatingblockofsteelladles.2. EAFDeltaroof.3. RHSnorkel.4. BurnerBlock5. TundishImpactPad6. AluminiumLaddleapplication,AnodeBakeOvenfurnaceTop7. LaunderforAluminiumCastHouse

R&D

Sl.No NameoftheEquipment Source TestingStandard1 X-RayDiffractionunit Rigaku PhaseAnalysis2 EDX-RayFlourescence

SpectrometerPHILIPS ISO12677

3 Dilatometerupto1200C Netzsch,Germany IS1528Part19

4 ModulusofRupture Netzsch,Germany ISO5013,ISO5014,IS1528Part5,ASTMC583-00

5 HighTemperatureCreeptestingApparatus(3nos)

Netzsch,GermanyandLIRR,RPC

ISO3187/IS1528Part18

6 ThermalconductivityApparatusbyHotwire

Netzsch,Germany ISO8894-2/IS1528Part16

7 ThermalconductivityApparatusby

Indigenous DraftstandardofIS1528

Calorimetricmethod

8 LeitzMicroscopewithImageanalysissystem*

Leitz,Germany Microstructure

9 Porosimeter Micrometrics,USA PoresizeDistribution10 FlamePhotometer Systronics

(Indigeneous)IS12107

11 Spectrophotometer Systronics(Indigeneous)

IS12107

12 KarlFischerApparatus Systronics(Indigeneous)

IS2362

13 DeanandStarkApparatus

Indegeneous IS1211

14 RingandballApparatus Indegeneous IS120515 Viscometerwith

temperaturecontrolbath(R.Tto100C)

Brookfield(U.K) DIN16916-2

16 FlowdistanceofPowderResin

Indegeneous DIN16916-2

17 Determinationoffreephenolofresin

Indegeneous DIN16916-2

18 DeterminationofNon-VMofpwder&

liquidresin

Indegeneous DIN16916-2

19 Meltingpointofpowderresin

Indegeneous DIN53181

20 RULFurnaceApparatus TonIndustries,Germany

IS1528Part2

21 PCEFurnaces Indigenous IS1528Part1

22 ColdCrushingStrengthtesting

ToniTechnik,Germany

ISO10058&IS1528Part4

(40T&100T)23 AbradabilityIndex

ApparatusIndigenous BS1902

24 AbradabilityIndexApparatus

Indigenous ASTMC704

25 AbradabilityIndexApparatus

Indigenous DIN52108

26 CarbonmonoxideDisintegrationtest

Indigenous ASTMC288

27 Permeabilitytest Indigenous ISO8841&BS1902

28 Porositytest Indigenous ISO5017&IS1528Part8,IS1528Part12

29 RotarySlagCorrosionAppartaus

Indigenous ASTMC7874

30 InductionFurnace Inductotherm 31 OkayspallingFurnace Bysak IS1528Part3,DIN51068&

JIS32 pHmeter Systronics

(Indigeneous)

33 Conductivitymeter Systronics(Indigeneous)

34 Dryer Moisturecontent35 HighTemperature

Furnace(1750C)Nabertherm,Germany

Firing

36 Okay1600CFurnace Bysak Firing37 Okay1700CFurnace Bysak Firing38 CarboliteFurnace Carbolite,Shiefield,

UKFiring

39 NaskarFurnace Naskar Firing

40 Furnace(1600C) In-housemade Firing41 MuffleFurnace(1200C) Naskar Firing42 MuffleFurnace(1000C) Indegeneous Firing43 SuperKanthalFurnace Kanthal,Sweden Firing

44 Hotabrasiontest In-housemade AbrasionResistance45 Jawcrusher Indigenous CrushingStudies46 RollCrusher Indigenous CrushingStudies47 Vibratingscreen Indigenous ScreeningStudies48 Ballmill Indigenous GrindingStudies49 Potmill Indigenous GrindingStudies50 VibrocastingTable Indigenous Casting51 50LiterMixermachine Eirich,Germany Mixing52 20LiterMixermachine Aikosha,Japan Mixing53 VerticalBoringMachine Indigenous RULsamplepreparation54 VibroenergicGrinding

millIndigenous GrindingStudies

55 Hydraluicpress Indigenous XRFsamplepreparation56 VibroenergicGrinding

millIndigenous GrindingStudies

57 Brickcuttingmachine Indigenous Cutting58 Doublerollcrusher Indigenous CrushingStudies59 FusionbeadFurnace Claisse,Canada ISO12677

60DiscPlisher(2nos) Indigenous Microscopesample

preparation61 MicrowaveFurnace CPI,USA Sinteringstudy

CONCLUSION:

I had a thorough experience about the know-hows regarding the multi-step,complicated processes employed in the different plant units for the manufacturing ofvariousrefractoriesviz.,

1.SilicaDepartment2.BasicDepartment3.HighAluminaDepartment4.FlowControlProducts5.DolomiteDepartment

6.MonolithicDepartment