Internship completion certificate

Internship completion certificate

Internship completion certificate
 ABSTRACT

Internship is necessary to bridge the gap between the Theoretical knowledge gained from the
classrooms and the practical world. Visit to the Kudremukh Iron Ore Company Limited
which produces iron ore pellets and pig iron ore are produced gave insights about the time
management and functioning of a real-world working industry. This internship report
summarizes on the different aspects learnt in the company for different weeks and also about
the company production rates and its sustainability with current scenarios with high on
machinery upgrade.

ABOUT COMPANY

KIOCL Limited, formerly known as Kudremukh Iron Ore Company Limited, is a

government-owned enterprise established on April 2, 1976, in Kudremukh, Karnataka. Its
main purpose was to mine and process low-grade iron ore. The company completed its 7.5
million tonne annual capacity project in Kudremukh and constructed a 110-kilometer slurry
pipeline and filtration units in Mangalore by August 1980. The first shipments were
dispatched in September 1980.

KIOCL has been a pioneer in iron ore mining, beneficiation, and pelletisation for over four
decades in India. Its Mangalore facility houses a Pellet Plant with a capacity of 3.5 million
tonnes per annum and a Blast Furnace Unit with a capacity of 2.16 lakh tonnes per annum.

However, the mining activities at the Kudremukh site, located 110kms from Mangalore, were
discontinued at the end of 2005, following the Supreme Court's confirmation of Kudremukh
National Park area status over the present mines.

Despite this setback, KIOCL products continue to be widely recognized and valued in both
domestic and international markets, and the company has established a strong brand
reputation.

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 VISION
To emerge as a world class mining company with the highest international standards of
Quality, Productivity, Customer Satisfaction, Safety, Health and Environment Management,
Corporate Social Responsibility and Care for Employees technological & environmental
excellence and also as a leader in Beneficiation & Palletisation Industry in India and establish
a global credence.

MISSION
• Lasting relations with customers and Vendors to ensure smooth supply chain based on
trust and mutual benefits.
• Business with ethics & integrity.
• To thrive to improve the socio economic condition in the neighbourhood of
Company’s production centre.
• Continuous learning.
• Adaptability to Technology and changing Global Scenario.
• Growth, recognition and reward for employees..

TRAINING FACILITIES
KIOCL has a well-developed Training centre where Training initiatives are carried out.

• Orientation Training

• Fire Fighting -Live & Class Room Lecture

• Skill Development Training

• Behavioural Training

• First Aid Training

• Vocational training for college students

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 POLLUTION PREVENTION & SAFETY MEASURES
KIOCL is fully committed to ensuring the safety of its employees and engineers working
across all departments of the company. To this end, the company has implemented several
measures to safeguard its workers. These include:

• Compulsory use of hand gloves while working in repair units.

• Mandatory shutdown of the entire plant when repairing any machinery to prevent
accidents for the personnel carrying out the repairs.
• Posting safety slogans throughout the campus, such as "PRODUCTION IS
MUST,BUT SAFETY IS SUPER MOST."
• Installation of warning boards near every machine to prevent hazards.
• Keeping a fire brigade constantly prepared to respond to fire accidents.
• Enforcing the wearing of helmets in all sections of the industry.

By adopting these safety measures, KIOCL has significantly reduced the number of accidents
in the working area. The company has also established a dedicated department to oversee the
proper implementation of safety measures and ensure a safe working environment for its
employee.

COMPULSORY SAFETY EQUIPMENTS

fig 1 Safety Gloves Fig 2 Safety Shoes

Fig 3 Safety Helmets Fig 4 Safety Earplugs

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LIST OF FIGURES

Figure no Description Page no

Figure 01 Safety gloves iii
Figure 02 Safety shoes iii
Figure 03 Safety helmet iii
Figure 04 Safety earplugs iii
Figure 05 Iron ore pellet 4
Figure 06 Belt conveyor 7
Figure 07 Ball mill 9
Figure 07.1 Ball mills 10
Figure 07.2 Three ball mills 10
Figure 08 Vacuum disc filter 12
Figure 08.2 Horizontal pressure filter 13
Figure 09 Agitator tank 14
Figure 10 Coke 15
Figure 11 Limestone 16
Figure 12 Bentonite 16
Figure 13 Quick lime 16
Figure 14 Pelletization process flow chart 17
Figure 15 Mixing of ore 17
Figure 16 Mixing of ore 18
Figure 17 Pellet disc 20
Figure 18 Division of undersize, oversize 21
Figure 19 Oscillation bed roller conveyor 22
Figure 20 Pellet cars 23
Figure 21 Heater 24
Figure 22 Plant control room 25
Figure 23 Turbocharger 27
Figure 24 Schematic diagram of diesel engine 29
Figure 25 Diesel generator room 30
Figure 26 Storage tank of coolant,lubricator 31
Figure 27 Draft fans of heating zones 31
Figure 28 Exhaust of diesel engine 32
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 INDEX

SL.No CONTENT PAGE NO.

1 Abstract i

2 Vision ii

3 Safety Measures iii

4 Brief About KIOCL Ltd. 1

5 Products 4
6 Port Facilities 5

7 Storage area 6

8 Reclaimer 7

9 Conveyor & tripper 7

10 Screening 8

11 Ball mill 9

12 Filter 14

13 Agitator 16

14 Pellet Plant 18

15 Material composition 19

16 Pelletizing 20

17 Baking 28

18 Scrubbing 30

19 Captive Power Plant 32

20 Engines 34

21 Conclusion 41

22 Reference 42

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 BRIEF ABOUT KIOCL

HISTORY OF KIOCL LIMITED

• KIOCL Limited (Formerly known as Kudremukh Iron Ore Company Limited), a

Flagship Company under the Ministry of Steel, Govt. of India was formed on 2 April
1976 for Mining and Beneficiation of low grade iron ore at Kudremukh, Karnataka,
India.
• KIOCL has been a pioneer with over four decades of experience in operating Iron Ore
Mining, Beneficiation and Iron–Oxide Pelletisation in the Country. KIOCL is having
facilities to operate 3.5 MTPA Iron-oxide Pellet Plant, Blast Furnace Unit to
manufacture 2.16 lakh tonnes per annum Pig iron at Mangaluru, Karnataka.
• KIOCL is an EoU and a profit making, continuous dividend paying Company with a
positive net worth and Mini Ratna Category I PSU is also an ISO9001:2015, ISO
14001:2015 and ISO 45001:2018 certified Company. The Corporate office is at
Bengaluru, Karnataka.

Operational Performance of Pellet Plant

• KIOCL is producing both BF and DR grade pellets with excellent chemical &
physical specifications to suite for Blast furnaces and direct reduction plants.
• The Company has taken up many initiatives like handling both Magnetite and
Hematite types of ores through in-house R&D, sourcing from both domestic and
global markets through long term contracts,100% utilization of coastal transportation,
Indigenization of equipments/spares etc.,

Make in India initiatives

• KIOCL is making continuous efforts to go for higher volumes in order to improve its
capacity utilization and also earn foreign exchange for the country through ‘Make in
India’ initiatives. Under the aegis of this, Pellet Plant is also being used as a tolling
plant to optimize the production capacity by converting imported iron ore/ concentrate
into pellets and exported the same.

Current Verticals

• The company entered into Mineral Exploration and is currently carrying out activities
in the field of Iron, Manganese, Limestone, Nickel, Chromium etc.

• Erection & Commissioning, Operation & Maintenance of Iron-Ore, Chromium

Beneficiation, Pellet Plants etc.

• Green energy through Solar Power Plant for captive purpose.

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New Verticals

• Entering into Ductile Iron Spun Pipe manufacturing through Backward and Forward
integration of Blast Furnace Unit

• Joint Venture with sister PSUs for setting up of Pellet Plants

• Development of Devadari Iron Ore mines for captive purpose

POLICIES

INTEGRATED MANAGEMENT SYSTEM POLICY

We are committed to serve the steel and foundry industry by

• Deriving Total Customer Satisfaction through supply of quality Iron ore pellets & Pig
iron terms of timely delivery and at competitive price.

• Preventing pollution of Air ,Water and Land and minimizing waste.

• Preventing injury and ill health due to work environment.

• Complying with applicable legal and statutory requirements, safety rules and
regulations and other requirements.

• Conserving natural resources like Water, Energy and Oil.

• Providing safe working environment and work practices to reduce risk to people,
property and surrounding areas.

• Striving for continual improvement in all spheres of our activity, products and
services.

• Promoting sustained developments.

INTEGRATED MANAGEMENT SYSTEM OBJECTIVES

• Achievement of product requirements and supply on time as per contract

specifications.

• Continual reduction in number of accidents and man days lost due to accidents.

• Complying with applicable legal and statutory requirements, safety rules and
regulations and other requirements.

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 • To continue to invest in capacity building of personnel for improving the knowledge,
skill and attitude.

• Continual reduction of specific consumption of resources and hazardous waste

generation.

• Continual reduction of occupational health to improve the helath of the personnel.

• Growth through expansion and diversification

• Explore new markets and segments

• Be competitive through cost reduction by change in processes

• Open new vistas of business by creating diversified Business Units

• To continue to invest in the capacity building of personnel for improving the

knowledge, skill & attitude

MAINTENANCE
Because of the plant's continuous operation, it requires frequent maintenance; otherwise, the
plant's equipment and machinery may fail. This can be accomplished through a planned
maintenance schedule.

TYPES OF MAINTENANCE

Maintenance is classified into three types

Scheduled Maintenance: It is done once in a year according to manufacturer’s

recommendation. It also depends upon the hours of operation in which the worn -out parts are
replaced along with the other modifications that needs to be done.

Breakdown Maintenance: It is done only when there’s a failure in the equipment. Here the
equipment’s are checked to find any wear or breakdown and replaced if it’s necessary.

Corrective Maintenance: It is done by simply checking for a problem. This is done for any
critical equipment. Any time if there’s a breakdown or shutdown due to any reason, Routine
check-up is made before switching ON the machine.

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 PRODUCTS

IRON ORE PELLET

KIOCL’s Iron Ore Pellets conform to international standards at the size of 9-16 mm in
diameter, making them ideal for hi-tech steel plants anywhere in the world. As a result of the
latest production techniques and constant Research and Development efforts and adopting
innovative technology to improve quality, the KIOCL product is the choice of quality-
conscious consumers.

KIOCL’s total quality movement is an assurance to the very best it can offer. Right from the
beginning what set KIOCL was its commitment to quality and customer satisfaction. It is this
consciousness for quality that propelled KIOCL to achieve ISO certifications. KIOCL sells
pellets in Domestic (DTA) markets through Sea and Road among impanelled customers.

Fig 5. Iron ore pellet

PORT FACILITIES
KIOCL Limited at its port facilities department has iron ore grinding unit, filtering unit and
loading system for handling the panama vessels for cargo loading at a draft depth of 13 mtrs.
The iron ore fines received by rail and ship are subjected to grinding after primary screening.
Through three nos. of ball mills, the ore is ground by way of wet grinding process.

The ore thus ground is subjected to screening and then filtration. Highly efficient screens are
used for screening the ground iron ore with size separation. For filtration of the ground slurry,
vacuum disc high pressure filters are used. The filtered material will have a moisture of
around 8.5-11%. This is then carried to a closed storage shed of 2 lakh tonnes capacity. From
the storage shed, the ore is fed to the pellet plant using a bridge reclaimer.

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The company has another shed for storage of pellets. About 2.5 lakh tonnes of pellets can be
stockpiled there. A bucket-wheel reclaimer is used to load the pellets to conveyors to further
carry the pellets to ship, anchored in the berth dedicated to KIOCL Ltd. This can load 5000
tonnes per hour.

The pellets are then cooled to a suitable temperature for transporting to a load out facility.
Both processes recycle the heat from the pellet back through the process to aid in energy
efficiency and decrease fuel usage.

A storage silo of 8000 tons capacity for storing iron ore fine with connected conveyors is
integrated with the grinding and filtration plant. With this system iron ore fines will be stored
in the silo and fed to ball mills through an apron feeder, grizzly screen and feed conveyors.

STORAGE AREAS
• SHED 1
Grinded and filtered Iron Ore is stored in Shed 1 which is called as Iron Ore Concentrate
(IOC) of size 100-200 mesh which is the raw material for pellet. Capacity of 2.5 lakh tons.

• SHED 2
Raw material from the ship and truck is stored in the shed 2 which is called as Iron Ore Fine
(IOF) of size 3mm to 10mm which fed into ball mill for grinding and filtration through
conveyors. Capacity of 2.5 lakh ton.

• SHED 3
The final product (pellet) from the Pellet Plant is stored in shed 3. From there it is been
loaded to the ship. Capacity of 2.5 lakh ton.

RECLAIMERS
A heavy-duty stacker reclaimers handles material ranging from coal to iron ore pellets found
in steel mills, coal yards, and transfer stations, primarily functioning for stacking and
reclaiming materials.

Stacker reclaimer machines typically have a boom that is capable of reaching over the top of
the stack of materials used for reclamation and a bucket or claw that can grab the material
and stack it.

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Types of Stacker Reclaimers

There are two types of stacker reclaimers: bridge type and bucket-wheel.

• Bridge-type stacker reclaimers have a bridge that spans the width of the stack. They
are used for stacking and reclaiming material in a single row or stack.
• Bucket-wheel stacker reclaimers, on the other hand, have a bucket wheel that spins
around a central axis, intended for stacking and reclaiming material in multiple rows
or stacks.

Stacker Reclaimers are common in various industries, such as mining, power generation, and
port operations. They are typically used to stack material on one side of a stockpile and
reclaim it from the other side.

Bucket wheel Reclaimer:

• 10 Buckets in a wheel.
• Capacity of 100 tons/hour.
• Power consumption 40kW/hr.

Barrel Reclaimer:

• It has 70 buckets.
• The overall Capacity of 1000tons/hour
• Power consumption 10kW/hr.

CONVEYOR AND TRIPPER

Conveyor Systems are mechanical devices or systems that efficiently convey materials. A
belt conveyor system comprises of two or more pulleys (also known as drums) that revolve
around a closed loop of carrying medium (the conveyor belt).

A tripper conveyor is a form of conveyor belt used in construction, mining, and other large-
scale earth-moving businesses. Depending on the height of the pillars, tripper conveyors are
capable of large quantity stockpiles. Some common applications include stockpiling for
winter, discharging to bins or ships and linear stockpiling inside storage buildings.

Belt Tripper Conveyor System Application

Belt Tripper can be used in stockpile bulk materials into open-pit, in-plant warehouse, silo,
bins, bunker, etc. The materials can be Biomass materials, Limestone, Gypsum, Potash,
Sulphur, Coal, Fertilizers, Wood Chips, Clinker, Aggregates, Petroleum Coke, mineral ore,
Other Bulk Solids…

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Belt Tripper Conveyor System Solutions

For applications where more than one conveyor discharge position is required, belt trippers,
belt plows/belt diverters, and reversing belt conveyors. A reversing belt with discharges at
both ends, filling multiple bins along the length of the conveyor, or you need to create a long
continuous pile such as in filling a bulk storage building, bulk material handling needs
covered.

Advantages

• Can build large volume, linear stockpiles with limited real estate
• Can build a linear surge pile over reclaim tunnel conveyor
• It will help you fill bunkers inside a building
• It can be engineered to your application
• It can meet very strict environmental regulations.
• Long working life, heavy duty truss frame construction, designed around capacity
requirements.

Maintenance

• Inspection of conveyor drive components.

• Oil analysis on large conveyor gearboxes.
• Inspect belt wash/ scraper system regularly.
• Inspect conveyor harden or crack change the belt if necessary.
• Inspect belt slippage.

Fig 6. Belt conveyor

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SCREENING
DERRICK STACK SCREEN

Derrick Stack Screen is a multi-layer vibrating fine screen is a wet fine-grained material
screening equipment developed through the introducing of advanced technology from abroad.
It adopts advanced multi-layer design, which can realize five-way parallel feeding with small
area and large processing capacity. It adopts original imported vibrating motor, international
advanced linear motion track, repeated pulping technology, fast material transfer speed and
high screening efficiency. The screen frame adopts the original imported spring suspension
support of low noise, low power consumption, small equipment dynamic load and long
service life; flexible polyurethane anti-blocking screen mesh is of high open porosity, high
grading efficiency, and long wear-resistant service life. Consisting of up to five individual
screen decks positioned one above the other and operating parallel. The slurry will undergo
screening after coming out of the ball mill. Inspection and changing of nylon cloth which is
used for screening of slurry. Inspection of feeders should be monitored.

BALL MILL
A ball mill is a type of grinder used to grind or blend materials for use in mineral dressing
processes, paints, pyrotechnics, ceramics, and selective laser sintering. It works on the
principle of impact and attrition: size reduction is done by impact as the balls drop from near
the top of the shell.

A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shell
may be either horizontal or at a small angle to the horizontal. It is partially filled with balls.
The grinding media are the balls, which may be made of steel (chrome steel), stainless steel,
ceramic, or rubber. The inner surface of the cylindrical shell is usually lined with an abrasion-
resistant material such as manganese steel or rubber lining. Less wear takes place in rubber
lined mills. The length of the mill is approximately equal to its diameter.

In case of continuously operated ball mill, the material to be ground is fed from the left
through a 60° cone and the product is discharged through a 30° cone to the right. As the shell
rotates, the balls are lifted up on the rising side of the shell and then they cascade down (or
drop down on to the feed), from near the top of the shell. In doing so, the solid particles in
between the balls and ground are reduced in size by impact.

• Raw material from shed 1 through conveyor comes to ball mill for grinding purpose.
• Water is mixed with iron ore fine before entering ball mill.
• Slurry is feed into the ball mill.
• Ball mill consist 0f 60mm chromium-Steel balls.

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There are two types chromium balls:

• Low Chromium Ball- Consisting of 15% chromium.

• High Chromium Ball- Consisting of 28% chromium.

• Initially, a 50 bar high-pressure pump is utilised to pressurise the lubricating oil in

order to raise the ball mill, which aids in rotation.
• A 50 bar high-pressure pump is used to pressurize the lubricating oil and raise the ball
mill, aiding in its rotation.
• The pressure is then reduced to 10 bars and the pump is turned off, allowing the ball
and slurry within the mill to rotate as the drum does.
• A tube is inserted into the ball mill, connecting the outer part of the drum to the
outside of the mill.
• Filling the tube with air causes the drum to revolve along the outer section of the mill.
• The ball travels halfway before falling to the ground due to gravity.
• When the ball collides with the slurry, grinding occurs, which is commonly referred
to as hammering.

Maintenance

• Measuring the tolerance slide ring and slide shoe.

• Checking for hydraulics and lubricants.
• Inspection of separator.
• Inspecting the wear of grinding balls.
• Inspection of gear

Fig 7,Ball Mills

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Fig7.1 Ball Mills

Fig 7.2 Three Ball Mills

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FILTERS
Iron ore is ground to finer particle sizes through different grinding systems. Large grinding
mills using grinding ball media are one of the most common and particularly in pelletizing
plants where finer particle size are required for the pelletizing process. Those large mills
operate either with water mixed in with the ore – called wet grinding – or without water - dry
grinding.

A fair amount of water is used in the wet grinding process. The material exiting the mills is
in form of slurry with water content typically ranging from 30 to 50 %. The surplus of water
should be removed prior to the balling process through dewatering equipment given that
pelletizing requires a much lower moisture content (from 8 to 10 % for most plants).

We find few de-watering technologies in the industry, but slurry filtering through vacuum
disc filters is still the main equipment seen in pelletizing operations.

There are two types of filters

• VACUUM DISC FILTER

In paper mills, Rotary Vacuum Disc Filters, also known as Sector Disc Filters or Save
All Filters, provide good filtering area while taking up the least amount of space.
Several discs, connected to a central barrel and spinning through slurry, open air, and
the discharge zone, stand in front of one another.

• It consists of 12 disc filter.

• Slurry from storage tank is pumped to the vacuum disc filters.
• These filters suck the slurry with the help of vacuum pump.
• The water from the slurry gets separated and dry IOC is obtained.
• Snap blow pump blows air into the filter and makes the IOC to fall on the conveyor
below it from which is stored in shed 1.
• The filter material is nylon cloth.
• Capacity of 1 filter is 200tons/hr.
Maintenance

• Inspection of centre shaft for any hole.

• Inspection of agitator shaft
• Inspection of Agitator shaft sleeve wearing
• Journal bearing wear out
• Ridge plate wear out
• Vacuum hose leakage
• Inspection and changing of nylon cloth
• Agitator shaft bearing wear out

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 • HORIZONTAL PRESSURE FILTER
• Pressure leaf filters are excellent for applications that need high flow rates and a low
solids content. They work in batches, with the filter cake being discharged and the leaf
being cleaned while the filter is turned off. Depending on how the cake will be utilised
or disposed of, the filters can handle both dry and moist cake output.

• Depending on the cake forming qualities and the vacuum's capacity to hold a thick
and heavy cake to the vertical leaf surface, the distance between the leaves can range
from 30-100 mm. The spacing is determined at the bottom end by the filter necks of the
leaves and at the top end by spacers.

Maintenance

• Inspection and changing of cloth.

• Seal changing.
• Roller changing.
• PCV changing.
• Inspection of plate.
• Inspection of choke in the hose.

Fig 8. Vacuum Disc Filter

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 Fig 8.1 Horizontal Pressure Filter

AGITATORS
An agitator is a device or mechanism to put something into motion by shaking or stirring.
There are several types of agitation machines, including washing machine agitators (which
rotate back and forth) and magnetic agitators (which contain a magnetic bar rotating in a
magnetic field). Agitators can come in many sizes and varieties, depending on the
application.

AGITATOR TANK

• Slurry from the ball mill comes to the agitator tank.

• It is passed through a process called cyclone before it is stored.
• Cyclone separate heavy slurry particle to move down and heavier particle on the top.
• The heavy particle is stored in the agitator tank.
• Lighter ones are moved to thickener where it is kept for some time for settlement of
fine particle.

Maintenance

• Inspection of gear box oil.

• Inspection of gear box oil pressure, temperature.
• Strainer cleaning.
• Gearbox greasing.
• Agitator shaft greasing.

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Fig 9 .Agitator tank

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 PELLET PLANT
A 3.5 MTPA Pellet Plant based on LURGI Straight Grate process is in operation at
Mangaluru, since 1987. The process of palletization involves mixing of Iron Ore Concentrate
with Limestone, Bentonite, and Coke as additives for improving the Physical and
Metallurgical properties of Pellets.

The mixed material is fed to pelletizing discs of 7.5 meter dia for production of green pellets,
which are screened on Double Decker roller screen to remove the un-sized material.

The sized green pellets are fed to the indurating machine of 492 Sq. meter grate area. The
green pellets are dried, pre-heated fired at high temperature and cooled in the indurating
machine. The pellets after screening to remove the undersized materials are conveyed to a
stockpile.

MATERIAL COMPOSITION

• Iron Ore Concentrate (IOC) :

Before entering the Pellet Plant (PP) is mixed with Additives to form the raw material for PP
plant. These additives are

• Coke
• Limestone
• Bentonite
• Quick lime

COKE

The coke is burned by hot air forced into the furnace, which functions as both a source of
heat and an oxygen reducer.

Fig 10.Coke

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LIME STONE

The primary source of CaO in palletisation is limestone. Its calcination occurs at a high
temperature during pellet induration, releasing CaO to generate a variety of calcium
containing slag phases (Ca-ferrites or silicates), which improves slag bonding and pellet
characteristics.

Fig 11. Lime stone

BENTONITE

Bentonite is a traditional metallurgical pellet binder, which ensures that the dry and roasted
pellets have certain strength properties that meet transportation requirements.

Fig 12. Bentonate

QUICK LIME

It is used to remove moisture content in the iron ore concentrate.

Fig 13. Quick lime

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 Fig 14. Pelletization process flow chart

PELLETIZING
Pelletizing is the process of compressing or moulding a material into the shape of a pellet. A
wide range of different materials are pelletized including chemicals, iron ore,
animal compound feed, plastics, waste materials, and more. The process is considered an
excellent option for the storage and transport of said materials. The technology is widely used
in the powder metallurgy engineering and medicine industries.

Pelletizing iron ore is undertaken due to the excellent physical and metallurgical properties of
iron ore pellets. Iron ore pellets are spheres of typically 9–16 mm (0.24–0.63 in) to be used as
raw material for blast furnaces. They typically contain 64–72% Fe and various additional
materials adjusting the chemical composition and the metallurgic properties of the pellets.
Typically limestone, dolomite and olivine is added and Bentonite is used as binder.

The process of pelletizing combines mixing of the raw material, forming the pellet and a
thermal treatment baking the soft raw pellet to hard spheres. The raw material is rolled into a
ball, then fired in a kiln or in travelling grate to sinter the particles into a hard sphere.

The mixed material containing IOC and Additives are loaded onto a conveyor belt by a
Feeder/Bin. From the conveyors, the mixed material is made to fall into bins with the help of
deflectors and there are a total of 6 bins.

Fig 15. Mixing Of Ores

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DEFLECTORS
In order for the pellet mill to express its maximum production capacity, the product to be
pelletized must be distributed regularly and uniformly on the perforated surface of the die.
The deflectors are used to collect the product that passes from the conveyor to the rotary feed
cone and distribute it on the perforated surface of the die.

The deflectors are made of AISI 340 steel (the cylindrical shank) and C40 (the blade). The
deflectors are adjustable and the correct adjustment of their inclination guarantees perfect
product distribution and consequent regular consumption of the die. The “hardened by flame”
blade is shaped with a particular parabolic profile designed to adapt to the profile of the
rotary feed cone.

Nylon Liners are used to make the deflectors, and there are a total of 5 deflectors. These
deflectors aid in the separation of mixed materials into certain containers. The mixed material
is weighed in these bins, and a certain weighed amount of material is made to fall onto a
Weighing Conveyor. Large Pelleting Discs receive the material from the weighing conveyor.

Fig 16. Mixture of Ore

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PALLETING DISCS
Pelletizing discs are used in the agglomeration process to form fine iron ore into uniform
green iron ore pellets. Green pellets are fed to a travelling grate or grate kiln. Disc pelletizers
utilize a non-pressure (tumble growth) approach to agglomeration and work by tumbling
material on a rotating disc, with a binding agent and feedstock being continuously added. The
binding agent causes the fines (or seed pellets, when utilizing a pre-conditioning step) to
become tacky and pick up additional fines as the material tumbles against itself. This causes a
“growing” action referred to as coalescence. Once pellets have reached the desired size, they
exit the rotating disc via centrifugal force.

Pelletizing discs are the equipment of choice when uniform pellet size and ease of control are
important for converting fine ores into round spherical pellets up to 20 mm in diameter.Pellet
size influenced by disc angle, disc speed and location of solid and liquid feed, is
automatically controlled through the operational flexibility of pelletizing discs. Laboratory
and pilot scale tests will determine optimum flow schemes, equipment sizing and scale-up.

All inner disc bottoms are lined with “expanded metal” and the disc rim is lined with
polyethylene plates to reduce abrasive wear. The base and scraper support provide maximum
stability while allowing disc angle adjustment, without the need for separate scraper
adjustment.

Individually mounted vane-type ploughs easily control and maintain the product layer over
the disc’s entire surface. The pivot base, a rotating part, is mounted on heavy-duty anti-
friction bearings.

Advantages

• Adjustable inclination during operation (40°-60°)

• Variable speed control during operation via a frequency converter (5-11 rpm)
• Adjustable disc height - Highly wear-resistant lining of disc
• Highly wear-resistant bottom, side and rim scrapers
• Water spraying system

There are a total of 6 pellet discs whose diameter is about 7.5 meters and each disc having a
capacity of 140Tons-160Tons/hour. The Pellet Discs are made to continuously rotate at an
angle of 47° from the ground and the mixed material is fed to it.

When the material is fed to the rotating discs, water is sprayed on top of the material through
a tiny sprinkler in order to retain the required amount of moisture in the material so that the
balls are formed. The sticking of balls onto the disc surface is prevented by the use of a
component called scrapper.

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 Fig 17. Pellet Discs

SCRAPPER
Scrapes the material from the Pellet Disc surface to keep it from clinging to the discs. Pellet
Disc has three different sorts of scrappers.

• Bed Scrapers (Total of 3 )

• Side Scraper (Total of 1)
• Lip Scraper (Total of 1 )
The balls come out of the Pellet Disc due to the centrifugal force produced on the balls by the
revolving disc, and the balls that come out of the rotating discs are now known as Green
Pellets. Roller-Screening is applied to these green pellets.

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 Fig 18. Division Of Undersize and Oversize

ROLLER-SCREENING
The process involves a set of rollers that rotate in the same direction, creating space between
them to separate undersized and oversize green pellets from the correctly sized ones. The
correctly sized pellets are directed onto a conveyor placed beneath the rollers. The conveyor
then leads to a secondary screening process, known as Double Deck Screening.

During this process, oversized and undersized green pellets are discarded, while the correctly
sized ones continue on the conveyor belt. The discarded pellets are then recycled using
another conveyor belt. After the Double Deck Screening process, only the correctly sized
pellets are transported forward through the conveyor belt.

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Finally, the green pellets are moved onto a hydraulic/oscillating conveyor through conveyor
CBG-2026.

Fig 19. Oscillating Bed Rollers Conveyor

HYDRAULIC/OSCILLATING CONVEYORS
The Hydraulic/Oscillating Conveyor's function is to disseminate the material dropping
through the conveyor's oscillator action along the sides. The right-sized pellets are moved to
another conveyor from the Hydraulic conveyor/Oscillating conveyors. Pellet Cars are
impacted by the scattered pellets on the conveyor.

PELLET CARS
The Pellet Cars are used to carry the green pellet through the furnace where the baking of
pellet occurs. Before loading the green pellets onto the pellet car, a series of baked pellets are
placed in an order on top of the cart to increase the porosity for the heat to travel evenly
between the pellets and to prevent the green pellets from sticking to the Pellet Car, as well as
to act as a cushioning for the falling green pellets to prevent them from breaking at impact.

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The green pellets are placed onto the pellet cart after these two Hearth layers have been laid
down on the pellet cart. The green pellets from the pellet cart are baked in the furnace.

Fig 20. Pellet Cars

BAKING
The furnace has five areas:

• Up-Draft Zone.
• Down-Draft Zone.
• Pre-Heating Zone.
• Firing Zone.
• Cooling Zone.

Up-Draft Zone:

An Up-Draft furnace pulls in air from the bottom of the unit and sends the heated air upward
into the duct system. In this process, the pellets gets dried from the bottom side and the hence
both the sides gets dried. The Temperature in this zone ranges from 260°C to 280°C.

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Down-Draft Zone:

Down-Draft furnace pulls in air from the above, heats it, and sends it out to the Duct work
that rests below the unit. The wet pellets that are sent to the furnace gets dried from the Top
due to this process. The temperature in this zone is around 360°C.

Pre-Heating Zone:

After the drying zone, the pellets now move to Pre-Heating Zone. The temperature in this
zone is below the melting point of the pellets at 1300°C.In this temperature range, crystal
growth begins. This is useful to prevent the formation of Thermally Cracked Pellets.

Firing Zone:

To obtain High-Strength and abrasion resistance, pellet temperatures of 1260°C to 1320°C

are necessary. Clinkering of the pellets will occur if the pellet temperature is raised above the
prescribed limit owing to charge fusion.

Cooling Zone:

In this Zone, the temperature of the pellets are brought down from the 1320°C to 400°C
before letting it to be cooled in the outer shed 2. The pellets after cooling will have a carrying
capacity of 250Kg /pellet.

Fig 21. Heater

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CONTROL ROOM
Role & responsibilities

• Monitor pellet production rate to meet shift target

• Smooth operations of mixing, balling & indurating machine through DCS
• Maintain Pellet CCS, TI, Basicity & porosity
• Maintain and control: Power consumption and Heat in-put
• Ensure uninterrupted Operations
• Co-ordination with CAPTIVE POWER PLANT & PF for day-to day operations
• Handling emergency situations
• Shift Reporting
• Safety/Environment Norms Compliance
• Involvement in Kaizen & QC
• Maintaining daily shift targets in respect of Pellet quality, production and cost
• Planning of shutdown activities and handling emergency situation

Fig 22. Plant Control Room

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 CAPTIVE POWER PLANT

DIESEL GENERATOR ENGINES

• The Wartsila 12V46 four-stroke diesel engine is used to generate electricity in the
captive power plant.
• CPP is able to generate the power with the help of a marine engine Wartsila which is
made a company based in Finland.
• There are a total of 3 engines in CPP plant in KIOCL, Panambur. These engines were
commissioned in the year of 1996.
• These engines are also called DCG’s (Diesel Generator Sets).
• It is a four-stroke compression ignition engine and a 12V46 engine i.e. A V-12
Cylinders Engine with bore diameter of 46mm.
• It is generally operated with furnace oil of viscosity 10 times that of diesel i.e., 150
centistokes. (Viscosity of diesel is 15 centistokes).
• Each DCG is capable of producing 9 mega-watts of power.
• The engine runs at a Maximum RPM of 500 and power output is 10860kW.
• The capacity is 20 litres.
• The Separator is used to separate oil from water.
• Storage tank is externally connected for lubrication and is run by electric motor
separately.
• Coolant tank is externally built for hot and cold waters.
• Turbo Chargers are used for Cold Start.

TURBO CHARGERS
As the name suggests, it's a device that adds air to a combustion chamber to improve fuel
combustion and power output. In addition, it runs on the exhaust gases of the cylinder, which
it uses to provide fresh air to the engine. As a result, it has separate valves for this.

Advantages(Air System):

• It is not mechanically driven system.

• The furnace oil cost is lesser and production cost is lesser.
• Maintenance is easy compared with other fuels
• Boiling Point is very high
• Suitable for long machining hours

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 Fig 23. Turbocharger

FILTERS
• There are a total of 7 filters.
• When one filter is choked, DP charge on which diverts the path of flow of the oil from
choked filter to other working filters.
• Residues are cleaned frequently

ALTERNATORS
A permanent magnet is mounted on the same shaft as the engine in the alternator. The main
alternator is AC, which is powered by a brush rotation stem with rotating rectifiers. The
output voltage and load variations are controlled by the AVR panel. When the load on the
engine increases, the voltage variation to the engine causes the speed to decrease.

SEPARATORS
There are two types of separators

• HFO separator
• LFO separator.

The purpose of the separator is to separate the moisture from the furnace oil and the
impurities along with moisture falls into the sludge tank which has a capacity of 10kL.

Maintenance:

• Cleaning of sludge tank when it fills up to a certain height

• HFO seperators are cleaned every 400 hrs & LFO seperators cleaned every 1000 hrs.

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 • ENGINE COOLING SYSTEM
There are two cooling system that is LT and HT cooling.

• LT cooling is used to cool the engine.

• HT cooling is for cooling the auxiliary equipment like turbochargers.

The hot water is exchanged and is cooled outside the building area. In order to cool the
system, two cooling Medias are provided

• Internal Cooling Media.

• External Cooling Media.

Internal Cooling Media is used for the engine and the turbochargers.

Total Power required to operate PP and PF is 32MW

• 20MW is required by PF
• 10MW is required by PP
• 2MW is required by other accessories

Governor will reduce the speed of the DG to reduce the frequency of power when required
DG supplies the power to the Main bus.

During emergencies, Moto-Weightier is used as backup engines which uses diesel as its fuel.
The storage unit of furnace oil has a capacity of 3200kL.

OPERATIONS
• Start the compressor air
• Fill the top of the piston head and make air pressure about 20kg /cm2 in the bottom
• Start Pre-Heating the lubricating oil pump and fill gravity tank
• When 20kg /cm2 pressure is reached, do a blow-off. Hence it removes water or
moisture present above the piston and also helps to rotate the crank-shaft or start the
DG
• Check control box then start the LT pump (Lubrication) and HT pump (Furnace oil).
• Reset the DG
• The DG is ready to start; By loading at the circuit. The DG is started when there is a
green indication indicating to start the DG
• The DG’s rotate at a speed of 500RPM
• The Voltage is now set as per the KPTC requirement
• In synchronising blocks, observe the Synchronoscope. This is done to the
Synchronize DG with KPTC smoothly
• Initiation of load command (Increase the load on DG’s)
• The power generated is supplied to PF and PP

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MAINTENANCE OF THE ENGINE:
During design and development, the engine manufacturers emphasised the necessity of easy
maintenance.

Wartsila 12V46 engine maintenance principle is sustained by the following:

• Cylinder Head with 11 fixing studs and simultaneously hydraulic heightening of all 4
studs
• A hydraulic jack for the main bearing: vertical uniform one cylinder camshaft pieces
• Fittings are used wherever possible
• Every 200 hours, the scheduled maintenance is done
• 250 bar of pressure is maintained inside the valves in order to check for any leakage
in the oil
• Cam-Shaft valve greasing with oil
• 500 hours, 1000 hours are the maintenance hours

Fig 24. Schematic diagram of Diesel Engine

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Fig 25. Diesel Generator Room

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Fig 26. Storage Tanks Of Coolants, Lubricants

Fig 27. Draft Fans of Heating Zones

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 Fig 28. Exhaust

Port Facilities, Pellet Plant, Captive Power Plant

Working Videos On Field (Kindly Scan QR Code)

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33
 CONCLUSION
Industrial training is significantly beneficial to all concerned parties in contributing towards
the development of the nation. Being a student, one can acquire Industrial experiences and at
the same time familiarize themselves with the real working environment at the Industrial
training site. This opportunity also enabled us to further expand our creativity while seizing
the profession ethical values as basis to venture into professional career in the future.
Therefore, we students must develop ourselves to become a valuable asset to the esteemed
organization or industry.

In the meantime, the industry or organization shall be able to recognize, assess and guide
their potential future employees. For some organizations, the students undertaking the
Industrial training have in fact overcome the scarcity of professional workforce within the
organization. On top of that, the industry/organization may also indirectly acquire
professional consultation from the Faculty Supervisor during their visits to the organization.

On the other hand, the Faculty Supervisors, apart from guiding, supervising and assessing the
students, may also obtain enormous information on the current developments in the
industry/organization, which will enrich themselves as academic staffs. By realising the
advantages and the limitless amount of benefits that can be accomplished by all parties
through this Industrial training, the excellent collaboration between the University and the
industry must be greatly considered. We the students and the Faculty Supervisors as the
unification chain between the University and the organization must play their considerable
parts so that the Industrial training will turn out as the most awaited activity by all parties in
order to achieve common aims and aspirations.

During one semester training period, a lot of experience, knowledge and exposure that have
gained by us.. All disclosures were awakening us in a boost of self-confidence to face life
more challenging now. Practical is a complement to the science or theory learned. This is
clearly the concept of science and charity, where they have learned without practice will be
lost and will not give anything - what effect. So if we do without the knowledge of course
there will be problems in terms of grip and stance ever - changing.

During our industrial training, there were many changes from the point of learning
environments and discussion among colleagues. It can directly increase the dedication and
rational attitude towards us. However, there are still some weaknesses that can be improved
in the future. Therefore we conclude that the industrial training program has provided many
benefits to students even if there are minor flaws that are somewhat disfiguring condition , so
that this weakness can be rectified in the future. We conclude that the training we received
through this industry has given us a lot of exposure in the computing world. We would like to
thank KIOCL for giving students to find their own experience with having Industrial Training
like this.

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 REFERENCES

• https://www.wikipedia.org/
• https://kioclltd.in/
• https://ibm.gov.in/
• Old Reports
• Google.in
• Youtube

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