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NIT DURGAPURA Project report for INDUSTRIAL TRAINING

taken in TATA STEEL

PROJECT TITLE - DOOR CLEANING SYSTEM USED IN SCP MACHINES PROJECT GUIDE - MR.SHRIKANT SHARMA

BY : ABHISHEK PAUL VT20152577 4 WEEKS

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ABOUT THE COMPANY• TATA STEEL previously known as TISCO is an Indian-multinational company head-

quatered in Mumbai.

• It is the 11th largest steel producing company in world as on 2013.

• It is the second largest private sector steel company in India with annual production

of 9.3 Million Tonnes capacity.

• TATA STEEL has manufacturing operations in 26 countries including Australia,

China, India ,Singapore.

• Its largest plant is located in JAMSHEDPUR,India with an annual production capacity

of about 2 Million Tonnes.

• TATA STEEL and IRON company was established by DORABJI TATA on 25th august

1907 ,as part of his father JAMSHETJI’S TATA GROUP.

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TRAINING INSTITUTE (SNTI)• SNTI ( SHAVAK NANAVATI TECHNICAL INSTITUTE ), the

technical training department of TATA STEEL is a pioneer

establishment with IS0 9001-2000 accredition.

• It extends all its facilities for development of small and

medium scale enterprises ( SMEs).

• It even engages in training and development of students in

many areas like – 1. Computers ,2. Automobiles , 3. Mechanical

4. Refractories , 5. Fluid Power

• It also supports many Improvement projects

(QC,QIP,BM) ,value engineering , TPM Automation.

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COKE OVENS AND BATTERY• COKE OVENS are units in which COAL CAKE are heated to very high

temperatures, there by burning the coal.

• These CAKES are pushed in ovens from SCP Machines.

• The COAL GAS generated on heating the CAKE in OVEN is collected by

a VERTICAL HOOPER and sent to BY – PRODUCT plant for its use.

• The coke generated after heating has a high heating ( calorific value)

and is used for burning purposes in BLAST FURNACE.

• Each battery consists of at least 80 – 100 coke ovens.

• Batteries 10 and 11 in TATA STEEL – JAMSHEDPUR consists of 88 and

100 coke ovens respectively and 3 SCP Machines are in use.

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RAW MATERIAL

HANDLING UNIT

PRIMARY CRUSHER

SECONDARY CRUSHER

COAL BUNKER( TOWER )

SCP MACHINES • The role of SCP ( Stamping charging pushing ) MACHINES is pivotal in COKE PRODUCTION unit .• Its operation is being monitored by RSM ( RAM SIDE MACHINE ) Maint. Section.• The Machine consists of 3 main mechanisms namely - STAMPING , CHARGING , PUSHING• The operation can be illustrated by FLOW CHART -

SCP MACHINESCOKE OVENS QUENCHING TOWER

BLAST FURNACE

• STAMPING• CHARGING• PUSHING

1ST STAGE

COAL GETS CRUSHED

2ND STAGE

INTO FINER PARTICLES

3RD STAGE

COAL STORAGE

4TH STAGE

COAL CAKE ENTERS AND GETS HEATED

5TH STAGE

COAL IS COOLED BY A STREAM OF WATER

6TH STAGE

COAL IS USED FOR HEATING

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STAMP CHARGING TECHNOLOGYADVANTAGES :• Stamp-Charging Technology is a modern and proven coking technology and can fulfil all requirements of a coking plant today and in the future.• Stamp-Charging Technology meets any environmental requirements and regulations throughout the world.• Stamp-Charging Technology allows to produce high-strength blast furnace coke; CSR values of over 65 can easily be achieved by stampcharging.• The stamp-charged coke has an excellent performance in the blast furnace allowing to achieve high coal injection rates while total reducing agent consumption is extremely low.• Stamp charging allows to produce high-quality coke from a wide range of charge coals including low rank coals, petrol coke and coke breeze.• An excellent coke quality naturally requires a careful selection of the blend components. In this regard, stamp charging provides for a high degree of flexibility and at the same time creates a considerable savings potential on the side of raw material costs which has a positive impact on the coke production costs and consequently, the pig iron cost.

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SCP MACHINES

COMBINED MACHINE FOR STAMPINGCHARGING AND PUSHING

EXAMPLE -

SCP MACHINE IN TATA STEEL JAMSHEDPUR

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STAMPING MECHANISM• Stamping operation takes place in a STAMPING BOX.• It consists of COAL BLEND previously ground at a specific size, then successive layers are rammed mechanically.• It can be applied either vertically or horizontally.• Compaction and vibration is applied during 2 minutes for each layer through 24 plates covering all the surface of coke.• The Box is filled with COAL BLEND ,with defined grain size distribution and moisture content in 3 LAYERS.

VERTICAL STAMPING UNITLeft - charging,pressingRight – growing of cake in each step

HORIZONTAL STAMPING UNIT

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STAMPING MECHANISM

HAMMERS

LOCKING HANGER PLATES

STAMPING BOX

CAM LEVER SYSTEM

STAMPING BOX HAVING DIMENSIONS OF COKE

• Single hammer weight is approx. 300 kg• Drive system equipped with frequency converters• Each stamping car has its own hydraulic and lubrication system• Full automatic mode and interlocking devices with charging car and coal feeding system assure proper function of the stamping system• Electric switch gear and the automation system.

TECHNICAL DATA -

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STAMPING MECHANISMFLOW CHART :

COAL from COAL

TOWER

SCP MACHINES

COAL enters STAMPING

BOX

HAMMERS operate

alternately

COAL CAKE forms

• VIBRATOR feed gates allows entry of coal into STAMPING BOX.• HAMMERS are driven by CAM-LEVER mechanism.• Dimension of COAL CAKE= Dimension of COKE OVEN• The coal must have minimum MOISTURE CONTENT for it to form a STABLE CAKE.

• Standard MOISTURE CONTENT of coal in Batteries 10 & 11 were 3-5%• COKE CSR - 4.6

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CHARGING MECHANISM

CHARGING OF VIBROCOMPACTED COAL CAKE

• The coal cake forms over the CHARGER PLATE ,which then moves towards the oven for charging purpose.• The charging process is similaiar for VERTICAL and HORIZONTAL OVENS.• For VERTICAL OVENS ,the cake charging takes place through PUSHER SIDE DOORS.• This leads to high emissions ,which are reduced through use of SEALING FRAMES.• For HORIZONTAL OVENS,charging is also carried out from the front door with a specific machine.• The cake formed over the CHARGER PLATE is exactly of the same dimensions as that of a coke oven.

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CHARGING MECHANISM

COAL CAKE BOX WITH CHARGER PLATE

CHARGER PLATE CONNECTING DEVICE

FINISHED COAL CAKE AFTER STAMPING - READY FOR CHARGING

STANDARD COAL CAKE SIZE 6m (L) X 16m(B)

SEALING FRAME ( for reducing high gas emissions)

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PUSHING MECHANISMFLOW CHART :

PUSHER PLATE is driven by a large RACK & PINION through the OVEN , for pushing the MELTED COKE out of oven.

SCP Machines (PUSHER PLATE)

COAL out of OVEN

COAL GUIDE CAR (CGC) QUENCHING

Pushes Gets collected in Crushes coal more finer

In QUENCHING TOWERDriven by RACK-PINION Mechanism

• Standard PUSHING – 1. Batteries 10 &11 – 147 2. Batteries 8 & 9 - 134

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DOOR CLEANING UNIT/SYSTEM• In TATA STEEL – Jamshedpur , Coke oven batteries- 8,9 and 10,11 are currently using two types of cleaning system in their SCP Machines. • The two types of DOOR CLEANING SYSTEM are - 1. HIGH PRESSURE WATER JET RECTANGULAR MOTION SYSTEM 2. HIGH PRESSURE WATER JET CIRCULAR MOTION SYSTEM• The mechanism of the above two door cleaning system is similiar, their operation and functions are exactly same.• The major difference lies in the motion of the nozzle.• In HIGH PRESSURE WATER JET RECTANGULAR MOTION SYSTEM, the nozzle along with MOTOR unit slides horizontally and up-down following the perimeter of a rectangle.• Whereas , in HIGH PRESSURE WATER JET CIRCULAR MOTION SYSTEM , the nozzle while moving horizontally follows a CIRCULAR ARC and while moving up-down follows a STRAIGHT LINE.• HIGH PRESSURE WATER JET RECTANGULAR MOTION SYSTEM is more advantageous than the CIRCULAR MOTION SYSTEM ,because for cleaning purposes ,the former can generate pressures upto 600 BAR , whereas the latter can generate pressures upto 300 BAR.

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DOOR CLEANING UNIT/SYSTEMPARTS/COMPONENTS:

1.NOZZLE

DIMENSION OF ORIFICE – Diameter =5mmAREA OF ORIFICE = 3.14 X 25/4= 19.625 mm^2

STEEL COVERING DIAMETER = 25-30mm

2.NOZZLE HOLDER 3.SOLID SHAFTS

2 in number - The MOTOR and CLEANING unit slides on these shafts

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DOOR CLEANING UNIT/SYSTEMPARTS/COMPONENTS:4.PLUMMER BLOCK/CLAMPS

PLUMMER BLOCK PLASTIC CLAMPS

Plummer block is used for supporting shaft on the unitPlastic clamps helps in easy sliding of unit over shaft.

5.HORIZONTAL/VERTICAL MOTOR 6.CHAIN-SPROCKET

Horizontal Motor

SPROCKET

3 in number chain –sprocket system

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DOOR CLEANING UNIT/SYSTEMFRONT VIEW REAR VIEW

Nozzle Protective STEEL COVERING

DC POWERBOX (2)

WATER INLET FACET

Electric connection pipes

CARRIAGE - on which unit slides horizontally

CHECKER PLATE – for supporting motors unit

SHAFT (2)

PLASTIC CLAMPS (4)

Horizontal Motor

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DOOR CLEANING UNIT/SYSTEMSCHEMATIC VIEW:

BOOSTER PUMPMAIN PUMP

CONTROL UNIT DOOR CLEANER

CLEANING UNIT

OVEN DOOR

HIGH PRESSURE DOOR CLEANER -

• The HP water door cleaner can be anintegrated part of the SCP or CP-Machineor can be installed in the battery line asstationary cleaning system.

• The small size enables a space-saving integration even under limited assembly preconditions.• Fully automated door cleaner provides a innovative way towards non-polluting coke ovens with a pressure up to 600bar.

• Low water consumption and low maintenance, low operating costs.

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DOOR CLEANING UNIT/SYSTEMOPERATION/PRINCIPLE:• Since, the fluid used for cleaning is WATER ,it must have provision for storing.• During the time of feeding of coal from COAL TOWER, water is also taken and stored in a RESERVOIR (70 L) in SCP Machine.• The water is supplied through pipes when required.• Since the CLEANING UNIT supplies water at a very high pressure ( 600 BAR) ,there must be a system for pressurazing water.• The EXTERNAL PART of UNIT consists of a system of two PUMPS-• 1. BOOSTER PUMP - smaller in size – used for initial pressurazing water to a low pressure of about 300 BAR.• 2. MAIN PUMP - larger in size- used for final pressurazing water to a high pressure of about 600 BAR.• Both these pumps are connected to each other by a shaft.

BOOSTER PUMP

MAIN PUMP

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DOOR CLEANING UNIT/SYSTEMHow the cleaning unit works :• The water from the MAIN PUMP is supplied through the INLET FACET to the NOZZLE via a shaft connecting the two.• The unit consists of both VERTICAL and HORIZONTAL Motor for providing 2 types of motion – SLIDING & ROTATING• The VERTICAL Motor helps in rotating the NOZZLE Shaft via a CHAIN-SPROCKET 2 , which then helps in driving CHAIN-SPROCKET 3 connected to front.• The HORIZONTAL Motor is connected to a shaft ,it is connected to CHAIN-SPROCKET 1 ,where the sprocket slides horizontally on a CHAIN provided on the CARRIAGE.• The 2 Motors are supported on a CHECKER PLATE.• The 3RD Motion consists of lifting up and lowering down the entire UNIT ,whenever required depending on CYCLE of operation.• All these 3 Motions occurs simultaneously – one-by-one.• The 3RD Motion is carried by a HOSE CHAIN (very high load carrying capacity),and is driven electrically.• The movement of unit is completely electrical , no man-power is required , since each motion is detected by SENSORS and ENCODERS fitted for every motion.

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DOOR CLEANING UNIT/SYSTEMCYCLES OF OPERATION :

1. CYCLE 1- Nozzle at 0 degrees is made to slide horizontally from left to right , without nozzle rotation.

2. CYCLE 2 – Nozzle is made to rotate by 90 degrees , and HOSE CHAIN lifts the unit up ,cleans the door vertically.

3. CYCLE 3 - Nozzle is rotated by 180 degrees, along with slides horizontally from right to left.

4. CYCLE 4 – Nozzle is rotated by 270 degrees, HOSE CHAIN moves the unit down vertically.

DOOR CLEANING UNIT

INSPECTION PLATFORM

NOZZLE

HOSE CHAIN

0.45 m

6 m

1

2

3

4

DOOR CLEANER( FRONT VIEW)

Dimensions of a STANDARD OVEN DOOR – 0.45 m x 6 m

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DOOR CLEANING UNIT/SYSTEMSIDE VIEW :

INLET FACET

VERTICAL MOTOR

Front view of vertical motor

CHAIN- SPROCKET 2

HORIZONTAL MOTOR

NOZZLE

CHAIN-SPROCKET 1

CHAIN-SPROCKET 3

CHECKER PLATE

SHAFT – connecting inlet facet to nozzle

LIMIT SWITCH

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DOOR CLEANING UNIT/SYSTEMMODIFICATION :• The CHAIN-SPROCKET DRIVE used in door cleaner may lead to many problems with continued usage.• Some of the DISADVANTAGES of chain-drive system are – 1. It requires precise alignment of shaft. 2. It is not suitable for non-parallel shaft. 3. More wear at joints,if not well lubricated. 4. High initial cost.• Also ,the CHAIN used over sprocket is made of STEEL, which has the chances of DAMAGE , cracks may develop , proper lubrication is needed.• Lubrication is done by DIESEL , slightly with more usage , deposits may develop.• Also , the CHAIN carry maximum load while in operation , their STRENGTH should be more.• CHAINS are unable to transmit HIGH POWER.

• ROLLER and HAULING CHAINS are able to transmit LOW & MEDIUM POWER.• Only , POWER TRANSMISSION CHAINS transmit HIGH POWER , but they are very costly.

• Loosening the chain drive system could dismantle the MOTOR unit.

• Also , CHAIN DRIVES takes up a lot of space , not COMPACT.

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DOOR CLEANING UNIT/SYSTEMMODIFICATION :

• Keeping in view all factors discussed in previous slide , we can a suitable GEAR –DRIVE system in place of CHAIN-DRIVE system.• GEAR-DRIVE has many ADVANTAGES over chain-drive : 1. More compact ,needs less space. 2. It transmits same velocity ratio. 3. Smooth operation. 4. Less maintenance required. 5. It transmits a relatively higher power. 6. It has high transmission efficiency. • The compactness of the unit could be maintained by using a GEAR-DRIVE in place chain-drive system.• Both SPIRAL and HELICAL GEARS are suitable for use.• SPIRAL gears are gears in which TEETHS are PARALLEL, only one teeth remains in MESH with one teeth, no END THRUST is present.• HELICAL gears are gears in which TEETHS are incline by HELIX ANGLE , - End THRUST is present – small disadvantage - Low impact stress - Greater LOAD carrying capacity.• However since the gears are made up of STEEL , they must be covered by a PLASTIC COVERING from avoid getting RUSTED.• A suitable GEAR TRAIN may even be used – either SIMPLE or COMPOUND GEAR TRAIN , depending on direction of ROTATION required.

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DOOR CLEANING UNIT/SYSTEMMODIFICATION :

CHAIN-SPROCKET 3

NOZZLE

NOZZLE HOLDER

- Rotation in Same direction- More SPACE

SPIRAL GEAR-DRIVE

- Rotation in Opposite direction Also possible- More COMPACT

TUMBLER GEAR ARRANGEMENT

IDLER GEAR

LEVER

1

2

• When lever is at 1 – a & c – opposite motion• When lever is at 2 – a & c - same motion

a

c

MULTIPLE GEAR-DRIVE

-Enables multiple nozzle arrangement

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DOOR CLEANING UNIT/SYSTEMMODIFICATION :CHAIN – DRIVE

SystemsGEAR –DRIVE

Systems GEAR -TRAINS

Could be replaced by

Spiral ,Helical, Bevel gears

Depending on direction of ROTATION required

Simple GEAR-TRAIN

But GEARS must be covered by a PLASTIC INSULING

DIVERGING NOZZLE CONVERGING-DIVERGING NOZZLE

Could be replaced by

REASON –

DA/A = DP/P ( 1/M^2 – 1),where M = Mach numberDA/A = Change in areaDP/P = Change in pressure

(1 ) (2)

Mach number in 2 > 1 ,Because initial pressure Wont be zero ,because Of THROAT presence

M<1 M>1

THROAT – M=1

Higher M ,more exit speed

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DOOR CLEANING UNIT/SYSTEMMODIFICATION :Square METAL

CLAMPSPlastic ROUND

CLAMPSMore efficient

movement

Could be replaced withfor

• Square METAL CLAMPS used for supporting the MOTOR unit ,helps in sliding motion of unit along SHAFT.• Since they are made up of METAL , with continued usage ,they may get CORRODED from inside.• They must be replaced by ROUND CLAMPS with BALL LINING.• BALLS helps in easy rotation of SHAFT and allows smooth sliding.• They also need a small LUBRICATION for their maintenance.

• Effective for LONG-TERM usage.

BALL LINING

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DOOR CLEANING UNIT/SYSTEMCONCLUSION:• Therefore , it is suitable to use GEAR-DRIVE in place of CHAIN-DRIVE system , however it has not been use in recent days• It is possible to use it in future.• Instead of using SQUARE CLAMPS for motion of shaft, we can switch to CIRCULAR CLAMPS for more rigidity.• All desired CALCULATIONS and PART SPECIFICATION are specified in word document provided.

INSPECTION:• When the DOOR CLEANER comes for repairing, maintenance , each individual component must be inspected• Individual part should be checked whether there is a CRACK or not.• CHAINS must be checked for SLACK and TIGHT conditions.• If cracks occurs , it should be repaired ,if it cant be repaired ,then discarded.• LUBRICATION must be done with DIESEL or GREASE ,wherever required.• Parts must be WELDED ,if crack occurs at JOINTS.• PLUMMER BLOCK should be crack-free.

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THANK – YOU