Mitali Zinc Report

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College of Technology & Engineering

A

Project Report

On

Practical Training At

HINDUSTAN ZINC LIMITED

ZINC SMELTER, DEBARI

UDAIPUR

Duration: 15 June to 14 July, 2010

Submitted to: Submitted By:

Mr. Kotangle SIDHESHWARI CHOUHAN

(Head, IT Dept.) B.E. IInd Yr. (C.S.E.)

HZL,Debari CTAE Udaipur


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ACKNOWLEDGEMENT

I wish to acknowledge the encouragement received from Mr. Naveen Choudhary (HOD,

Computer Science and Engineering Department, C.T.A.E. Udaipur) & Mr.Dharm Singh(Training Incharge) for initiating my interest in training.

I earnestly acknowledge my profound sense of gratitude to Mr. Kotangle (Head IT Deptt. HZL,

Debari)under whose supervision I have been able to complete the project.

Their mastery & work helped me in covering out this work smoothly. I am also grateful to all the

workers of various departments who have helped me to improve practical knowledge.

Finally, I wish to add that I am indebted to god & my parents for everything good that hashappened to me.


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PREFACE

Practical training is a way to implement theoretical knowledge to practical use. To become asuccessful engineer it is necessary to have a sound practical knowledge because it is the only way

by which one can acquire proficiency & skill to work successfully in different industries. It is

proven fact that bookish knowledge is not sufficient because things are not as ideal in practical

field as they should be.

Hindustan Zinc Ltd. is one of the best examples to understand the production process &

productivity in particular of Zinc.

It is a matter of great pleasure that our college authorities have recommended a practical training of

30 days to supplement our theoretical knowledge acquired in the college.

This report is an attempt made to study the overall production system & related action of ZincSmelter, Debari a unit a HZL. It is engaged in the production of high grade Zinc metal & other

byproducts viz. Cd, Sulphuric acid etc. since 1968 adopting hydro metallurgical technology.


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CONTENTS

1. Acknowledgement

2. Preface

3. Certificate4. About HZL,Debari

5. Project Profile

6. How to use the Project7. Functions Description

8. Program Coding

9. Sample Outputs


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ABOUT HZL ,DEBARI

Zinc smelter Debari, is a unit of HZL. It was started in 1968. It was the first Zinc smelter of HZL.

In this plant,zinc along with its products viz. Silver, Cadmium, Sulphuric acid etc. are produced

from Zawar Mines and other mines of the company. Initially this Smelter started with 18,000tonnes per annum capacity, but at present the capacity of plant is 49,000 tonnes per annum, the

recovery of Zinc in this plant is 99.52%.

In HZL Various Departments (Plants) as under:-

Roaster and Acid plant

Leaching plant Zinc Electrolysis plant

Zinc Dust plant

Instrumentation plant

Finance Department

Project Department

ROASTER AND ACID PLANT:-

The raw materials used for production of zinc is named blend which is prepared by the concentratewith comes from various mines. The main constitute present in the blend is ZnS. For the leaching

of ZnS it is necessary to first convert it into oxide i.e. roasting of ZnS is done here at roaster.

LEACHING AND PURIFICATION:-

Leaching is a selective dissolution of ore minerals /oxide minerals in acid or solution of other

reagents according to the condition adjusted in a manner to leave maximum gangue in theinsoluble residue.Calcine comes into the hopper from roaster with the help of bucket elevators.The

average rates of calcine consumption is 11MT/hr, whereas the rate of solution supply is 90

m3/hr;this corresponds to 140-150MT of Zinc ingots per day.

ZINC ELECTROLYSIS AND MELTING:-

Electrolysis of zinc sulphate solution take place in electrolysis cell with aluminum sheet as cathodeand silver lead alloy as anode:

The reaction can be represented as:

As cathode (reduction)

Zn2+ +2e- ZnAt anode (oxidation)

So42 +H2O H2So4 + 2e

Over all reaction

2ZnSO4 + 2H2O 2Zn + 2H2SO4 + O2

The zinc gets deposited on the Al cathode and is stripped after


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24 hours of deposition whereas oxygen is given OFF at the anode.As SO42- ions have strong

affinity for hydrogen ions this results in formation of sulphuric acid. The oxygen which is liberated

oxidizes the MnSO4 in solution to MnO2 which deposits as anode mud which is cleaned outperiodically.

Solution cooling and storage:Neutral electrolyte from purification shall be available at 60-70% as hot purification process has

been adopted for expansion. The neutral solution is fed directly to atmospheric coolers where

solution is cooled to 35oC, coolers have been provided for this circulating spent solution cooled inseparate 5nos. coolers out of which normally three are in services and two are standby. Here

temperature drop is from 42oC to 35o. Gypsum deposit take place in these coolers.

ELECTRICAL DEPARTMENT:-

Power situation in any industry is alarming. The gap between demand and supply keeps widening

day by day. The energy SBU thus determines how each business unit or processconsumes power. This helps to promote accountability, increase efficiency and

productivity. Electrical energy acts as a raw material for industry. It implies energysaving through various ways after all energy saved is energy generated.

PERFORMANCE:-

Zinc Smelter Debari, has achieved an impressive growth pattern and condition and endeavors are

being made to improve the production, as productivity. Emphasis is given for energy conservation,

improvement in recovery efficiency and reduction in process chemical consumption which isprime factor in controlling the cost of production.

In order to sustain above achievement, TQM and workman participation through suggestion

scheme are in Zinc smelter Debari, now is a 9002 certified unit for quality management systemfrom 05-11-1998.

PROJECT PROFILE


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TITLE: - Medical Bill Settlement

Aim of the Project:-To maintain medical bills and its related

records of customer.

Submittedto: - Hindustan Zinc Limited, Debari

Application: - 1.To handle the working of bill amount transactions.

2. It can keep track records of each employee of the

industry.

Memory used: - 64 KB.

Designed by: - SIDHESHWARI CHOUHAN (B.E. IInd Year C.S.E.)


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HOW TO USE THIS APPLICATION

Execute the C.P.P file and press enter to continue. Enter your choice as 1,2,3 from

keyboard .Menu is as follows :

1.DATA ENTRY

2.CHECK LIST

3.PAYMENT LIST

4.SEARCH

5.NOTICE BOARD

6.EXIT

The above options have following effects :

1.It will add new employee details.

2.It will display the check list .

3. It will display the payment list of every employee.

4.It will display all the details of the required employee.

5.It will display the notice board.

6.Exits the program.


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FUNCTIONS DESCRIPTION

CLASS EMP

1. int getcd():It is used to return the employee code entered by the user.

2. char *getname():

It is used to return the employee name entered by the user.

3. char *getdept ():

It is used to return the employee department entered by the user.

4. void insert (int n):

It asks the user to input the employees name, and department. The code is

provided by itself.

5. void display ():

It displays the code, name, and department of every employee sequentially.

CLASS BILL

1. int getref():

It is used to return the employees reference number entered by the user.

2. int inserts (int n):

It first checks whether the entered employee code exists or not. If it does, it

asks the user to enter the bill amount, N.R. amount, dependency code, andthe bill type code.

3.void display():

It displays the entire details of the employee. 4.void notice():

It displays the employee code, bill amount and N.R. amount sequentially.


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PROGRAM CODING

#include

#include

#include

#include

#include

#include

#include

void sort();

class emp

{

int empcd;

char name[20],dept[20];

public:

int getcd()

{

return(empcd);}

char* getname()

{

return name;

}

char* getdept()

{

return dept;

}

void insert1()

{

coutempcd;

cout


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fflush(stdin);

gets(dept);

}

void display()

{

cout


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flag=1;

fin2.close();

break;

}

}

if(flag==0)

{

cout


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{

case 1:tag="Self";

break;

case 2:tag="Wife";

break;

case 3:tag="Father";

break;

case 4:tag="Mother";

break;

case 5:tag="Son";

break;

case 6:tag="Daughter";

break;

case 7:tag="Other";

break;

}

cout


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}

void displaycheckhalf(int n)

{

if(n==0)

cout


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else

{

while(!fin.eof())

{

fin.read((char*)&d,sizeof(d));

if(!fin.eof())

{

d.display();

getch();

}

}

}

fin.close();

break;

case 3:

int flag=0;

fin.open("empl",ios::binary);

if(!fin)

{ cout


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fin.read( (char*)&e,sizeof(e));

bno=e.getref();

}

bno++;

int r=e.insert(bno);

fin.close();

if(r!=0)

{

ofstream fout("bill",ios::app | ios::binary);

fout.write((char*)&e,sizeof(e));

fout.close();

}

break;

case 5:

clrscr();

int sr=1;

fin.open("bill",ios::binary);

if(!fin)

cout


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getch();

fin.close();

break;

case 6: fin.open("bill",ios::binary);

if(!fin)

{

cout


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fin.close();

break;

case 8:

fin.open("bill",ios::binary);

if(!fin)

cout


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if(!fin.eof())

d[k++]=e;

}

fin.close();

for(i=0;i


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SAMPLE OUTPUTS

Main Menu:

1. Employee Data Entry:


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2. Search Employee:


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3. Data Entry:


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4. Check List:

5. Payment List:

6. Search:


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7.Notice Board:

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