1. PROJECT REPORT
This project report is prepared as part of B-Tech Internship
curriculum. Project is prepared on the study conducted on
the business process of M/s Namo Alloys Pvt. Ltd.
Author & Conducted by:
Pranav Bhardwaj, 2nd
Year, B.Tech (Hons.)
Dept. of Metallurgical & Material Engineering
National Institute of Technology,
Jamshedpur
3. 2
ABOUT NAMO ALLOYS
M/s. Namo Alloys was established by its chairman Sh. Anand Parkash Jain as
‘NAVEEN JAIN METAL UDYOG’ in the year 1966. With his sheer hard-work and
dedication, the courage to stay-with untiring enthusiasm, he led the organization
to heights of success and carved out a niche market for the organization….not only
in scrap but also in the field of NON-FERROUS METAL ALLOYS.
Organization’s Managing Director, Mr.Naresh Jain, is a true visionary and has
always strived hard to ensure that group reaches the pinnacle in the field of
nonferrous metal alloys. He has ensured a constant growth of the group under his
able leadership which resulted in vertical increase in the annual turnover of the
organization.
Its Director, Mr. Neeraj Jain – strongly believes in having “Systems to international
standards” with proven technologies. Maintaining superior quality and technology
has remained the main principles of the organization to achieve best CSAT level, to
understand their needs and delivering accordingly.
VISION
NAMO ALLOYS seeks for continuous improvements in every operational activity that it
undertakes creating a great tomorrow based on the never stopping efforts of today.
To achieve economics of scales,
to meet the emerging challenges of open market and
to be globally competitive,
Striving to become market leader in the Metal Alloys Manufacturing companies in India
MISSION
“NAMO ALLOYS is committed to be an innovative leader in aluminum die casting that provides
value in an engineered approach to extend product life and meet customer’s expectation in a
global market place”.
BELIEVES
The group believes that ‘Excellence’ is not merely a work ethic, it is an invisible code in-built into
human factor, which is in harmony with a basic human value; “Do Your Best”
4. 3
NAMO GROUP OF COMPANIES
This group consists following 2 independent companies:-
NAMO Alloys Pvt. Ltd.
AKSHAY Aluminium Alloys Pvt. Ltd.
NAMO Alloys owns 2 plants in:-
Prithla, Haryana
Manesar, Haryana
5. 4
Organizational Structure
Plant Head
Manufacturing Head
H.O.D Quality
H.O.D DispatchIncharges
Materials Head
H.O.D Materials
Supervisors SupervisorsSupervisorsSupervisors
Workers
Supervisors
Supervisors
Workers
Supervisors
Supervisors
Workers
Supervisors
Supervisors
Workers
Supervisors
Supervisors
6. 5
Business Process Flow
Cont…
Charging
Batch Charge Preparation
MeltingTemperature (750-850 degree Celsius) Tempof moltenmaterial (710+/-30degree Celsius)
SaltAddition&Mixing
Launder coating & Pre-heating
Moltentransferto HoldingFurnace
Chemical compositioncheckingatfiring
stage
Fluxing&Drossing
Chemical Composition
Alloying
Melting Exhaust Temperature up to 850-950 degree Celsius
Final Material Charging
Fluxing & Drossing
Incoming Inspection
Receiving Raw Material
Material Sorting
Ok
7. 6
Scrap is bought from the vendors with the prior information of impurity level. When a container
arrives, an incoming report is made to compare the impurity percentage as against the
purchase order terms. Once it is found as per norms, scrap (raw material) is sent for
DegassingbyNitrogen
Hydrogentest
Final composition and temp 710+/-20
degree Celsius
Filtration
Casting starts
Skimmingof oxide layers
Batch identification
Visual inspection
NotOk Ok
Reject Dispatch to store
Not Ok
Not Ok
Weighingof Ingots
Dispatch according to daily plan
Grade wise Storage
8. 7
segregation where impurity like Copper, Zinc, Magnesium, Rubber, Iron etc. are separated and
aluminium is sent for melting. A batch charge report (Instruction) is prepared for the operators
working on the furnaces. The operators charge the furnace accordingly. After alloying, drossing
and degassing, bath (molten material) is sent for casting through the launder and poured into
the moulds. The hot ingots are allowed to cool and then are collected and packaged by the
dispatch department.
The process is explained in detail below:-
1. Materials Dept.
2. Manufacturing Dept.
3. Quality Dept.
4. Dispatch Dept.
9. 8
Materials Department
This department of the company looks after the receiving of raw material from vendors and
segregation of the raw material. Raw material for the company is different types of aluminium
scrap, namely
1. Tense (automobile parts)
2. Burada (fine aluminium scrap)
3. Section (aluminium bars)
4. Wheel
5. Troma (wheel parts)
6. B.B.S (aluminium sheets)
7. Zorba (mixed scrap)
Organization Structure
Materials Head
H.O.D
Supervisors (8)
Workers (~200)
10. 9
Activity Flow
Scrap is bought from the vendors with the prior information of impurity level. When a container
arrives, an incoming report is made to compare the impurity percentage as against the
purchase order terms. Once it is found as per norms, scrap (raw material) is sent for
segregation where impurity like Copper, Zinc, Magnesium, Rubber, Iron etc. are separated and
aluminium is sent for melting.
Incoming Report
Around one ton of scrap is taken out from the container for the preparation of incoming report.
The sorters separate the scrap in different heaps depending upon the scrap types (few are
listed in the report format in annexure 1). The heaps are weighed and it is noted down in the
report next to its category.
Impurity percentage is then measured by separating the impurity from different heaps either
by cutting, hand sorting, visual inspection or burning.
For Iron Attached scrap, a melting report is also prepared to note the exact amount of attached
iron impurity. In a melting report, a sample from the respective heap is melted to measure the
iron content.
Incoming Report
Segregationprocesses
If ok
Raw Material
received
11. 10
For Rubber Attached scrap, oil is sprayed on the heap after weighing and then it is burnt. It is
again weighed and difference shows the weight of impurity (rubber).
For Rubber and Iron attached scrap, impurity percentage is taken out after seeing the
percentages of above two samples and doing the visual inspection of the samples by the expert.
For zinc, copper and brass attached scrap, cutting is used to separate them from aluminium.
At the end, total impurity is weighed and total impurity percentage is calculated.
If the impurity percentage is less than or equal to what was agreed then the container is passed
for sorting.
Places of sorting:
On Rotary Sieve machine
On Vibrating screen
On small conveyer
On table
1. Rotary Sieve machine
Rotary is mostly used for scraps like Zorba, Troma. It separates out less than 8 mm size
material from other material. These separated out material exits from the bottom of rotary
and rest of material are passed onto the conveyer which transfers it over to another one
where sorting is done.
The sorters only allow pure aluminium scrap or the ones with iron as attachment. All other
materials are stocked in different heaps according to the impurity. Iron attached aluminium
scrap is allowed to pass, and as the roller that moves the conveyer belt is electromagnetic,
it helps to separate those scrap from pure ones mechanically. The sorters also separate the
“section” as they are aluminium rich.
Other aluminium scraps are sent for cutting to detach the attached elements like zinc,
copper, brass etc. The detached elements are stocked separately to be sold/used and the
aluminium obtained from the process, are separately stocked with pure tense, B.B.S or
section accordingly. Elements like lead and magnesium that are found separately in the
scrap, are also stocked separately.
12. 11
*If the scrap on conveyer belt increases drastically then it is made sure that zinc is
separated and rotary is switched off.
*Big scraps like wheel, cooker, etc. are not put into rotary or through any other processes.
2. Vibrating screen(washing machine)
The below 8 mm sized materials are segregated on this machine. A continuous flow of
water is maintained on this machine. From top corner, the feed is supplied into the system.
Here heavy materials fall from the nearest opening and the opening is named as No.1.
Aluminium scrap being lighter falls from other openings. Heavy metals from No.1 opening is
transferred onto another screen for further segregation as some aluminium scrap may have
passed with the heavy metals. Again heavy metals pass through the nearest opening. Then
the heavy metals are hand sorted by a worker and stocked in different piles.
3. Small conveyer
The process is similar to what is done on the conveyer of rotary sieve but here only dust is
separated by the dry vibrating screen connected to the conveyer and there is no rotary in
this system.
4. Table
The left over scrap from rotary and small conveyer is sent to the tables. Each sorter is
assigned 1 table each to hand sort the scrap. The expectation of the company from each
table is to sort approx. 500kg of scrap.
Sorting Parameters
Magnesium is lighter than aluminium scrap and produces white streak on scratching it on
the floor with soft hands.
Lead is blackish in nature and does not produce sound on being dropped on floor.
Copper is of red colour and brass is of golden colour. Brass produces golden streak on
scratching it on floor.
Zinc is heavy and does not produce any specific streak. It would be silver-grey in colour and
produces characteristic sound on being dropped. Zinc is also stored to melt to make zinc
ingots.
Iron would have rust on it and is magnetic in nature.
Steel is lustrous and heavy.
Section is white in colour. They are aluminium bars and are very ductile.
B.B.S is aluminium sheet with high ductility.
Tense are automobile parts.
13. 12
Manufacturing Department
The company deals with Aluminium and Zinc alloys ingot manufacturing. This department
manufactures different grades of aluminium and zinc alloys ingots according to the customer
requirement. The major grades manufactured by the company are mentioned as below:-
ADC-12
AC-4B
AS9
ZAMAK-3
ZAMAK-5
Organizational Structure
Activity Flow
MANUFACTURING HEAD
Incharges
Supervisors
Workers
Charging
Batch Charge Preparation
14. 13
Contd………
MeltingTemperature (750-850 degree Celsius) Tempof moltenmaterial (710+/-30degree Celsius)
SaltAddition&Mixing
Launder coating & Pre-heating
Moltentransferto HoldingFurnace
Chemical compositioncheckingat firing
stage
Fluxing&Drossing
Chemical Composition
Alloying
Melting Exhaust Temperature up to 850-950 degree Celsius
Final Material Charging
Fluxing & Drossing
DegassingbyNitrogen
Hydrogentest
Final composition and temp 710+/-20
degree Celsius
Filteration
Castingstarts
Skimmingof oxide layers
NotOk
NotOk
15. 14
A batch charge report (Instruction) is prepared for the operators working on the furnaces. The
operators charge the furnace accordingly. After alloying, drossing and degassing, bath (molten
material) is sent for casting through the launder and poured into the moulds. The hot ingots are
allowed to cool and then are collected and packaged by the dispatch department.
Furnaces
The company owns 11 furnaces, which are mentioned below:-
Tilting Rotary Furnace(TRF)
5 metric ton Skelner Furnace (5 MT SF)
6 metric ton Skelner Furnace (6 MT SF)
10 metric ton Skelner Furnace (10 MT SF)
14 metric ton Skelner Furnace (14 MT SF)
3 Pit Furnaces (For Aluminium)
3 Crucible Furnaces (For Zinc)
Working of TRF
Its name Tilting and Rotary Furnace describes the movement of this furnace. It is mostly used to
melt the slag (a.k.a Dross, processed), light weight metals (e.g. UBC) which wouldn’t give good
recovery in Skelner furnace due to the direct flame. This furnace is used only for melting
purpose and not alloying.
Batch identification
Visual inspection
Notok ok
Reject Dispatch to store
16. 15
Prior to charging feed to the furnace with the help of a crane a salt solution (NaCl) is prepared,
and its uses are listed below.
The charge doesn’t come in direct contact of the flame.
Doesn’t let molten aluminium stick to the inner walls of TRF.
NaCl solution doesn’t let the bath to get oxidized.
It cools the Dross.
Steps involved in TRF operation:-
Furnace is charged very quickly using the large charge opening.
Melting is done by burner arrangement while maintain approx. temperature of 710
degree Celsius.
Salt addition is done to cool the dross.
The furnace is tilted to pour the aluminum out. The dry slag remains in the furnace.
The furnace is rotated at high speed for 5 minutes in each direction-using burner if
required.
More aluminium is poured out of the furnace. Repeat the above 2 steps until no further
aluminum is obtained.
The furnace is tilted and rotated simultaneously to tip out the dry salt slag. Amount of
slag greatly reduced because a liquid slag is not needed. Faster rotation-better
separation of aluminum from slag.
After each cycle furnace is quickly cleaned, avoiding the need for a weekly salt wash.
While working on the TRF, operator is required to fill the production sheet for TRF (format is as
attached below).
The molten metal from TRF is poured onto the trough (launder) through which it goes to
holding furnace (Skelner furnace) for alloying. While transferring 2 button samples are taken for
spectrometry test to know the composition.
A certain amount of oxygen is introduced in the enclosed environment within the TRF. This
oxygen is used for combustion as it enhances the efficiency of furnace oil ( hereafter F.O.) used
as a fuel (80% F.O. is burnt). F.O. is kept under 2-2.5 atm pressure and at a temperature
approximately equal to 80 degree Celsius.
Cleaning of TRF:-
17. 16
Manual chipping is done to remove the aluminium and dross which sticks onto furnace’s
inner lining.
If the TRF is closed for more than 24 hrs. then a salt wash is given, where only salt is
charged and melted to prepare the furnace for operation.
Working of Skelner Furnace
Skelner furnace are non-rotating furnaces, they have vertical and tilting motion to assist the
operator in charging. The input for these furnaces is heavy material e.g. ingots, tense, etc. They
can be used for whole smelting process which was not in the case of TRF. The tapping is done
from behind by opening the plug at the back but before tapping drossing should be done.
Steps involved in operating a Skelner Furnace:-
The feed is charged into the furnace in either solid or liquid form depending on what the
density of the scrap. Liquid form is transferred from TRF.
When charging is completed, solids are allowed to melt while keeping the temperature
between 750-850 degree Celsius.
After melting cover flux is added, this process is known as Fluxing. Cover flux increases
the temperature at that instance and that place forcing solid aluminum stuck to dross to
melt.
After fluxing, a process named Drossing is carried out where dross is skimmed out by the
operators using the long handle apparatus made up of iron.
Then 2 button samples are taken for spectrometry test to know the chemical
composition of the bath.
Then according to spectro-result and the grade we are supposed to make, alloying
elements like Cu, Fe, Si, etc. are charged and exhaust temperature is raised to 950-1000
degree Celsius according to the element/s added.
The next steps are fluxing and drossing.
Again 2 button samples are taken to check whether the composition is as required or
not. If not then above 2 steps are carried out again.
Degassing is done by nitrogen for 5-10 min. to remove any gas dissolved in the bath and
for proper mixing of alloying element/s.
Degassing is followed by Hydrogen test to check where a sample is taken to check
whether there is gas present in bath or not.
If the test results are okay then spectrometry test is done for the last time and
temperature is brought down to 710 +/- 20 degree Celsius otherwise degassing is
repeated.
If ok, then back plug is opened to pour the bath towards the casting and if not then
alloying is done again.
While working on the SF, operator is required to fill the production sheet for Holding Furnace
(format is as attached below).
18. 17
In these furnaces, air is used to help the F.O combust properly (60% F.O. is burnt). Oxygen is not
used instead of air as it is costly, repeated opening of furnace lid increase the loss of oxygen
and oxygen may oxidize the bath. F.O is kept under 2-2.5 atm pressure and at a temperature
approximately equal to 80 degree Celsius.
Working of Pit Furnace
These furnaces are made by digging a pit in the ground and lining the walls by thermal
insulating material. Our company has 6 such structures of 100 kg capacity each. The burners are
fitted around the walls of furnace and they heat the walls which in turn melt the alloy. The
speed of production for this furnace is slow but the recovery is over 95%.
Steps involved in operating a Pit Furnace:-
Furnace is preheated for about 10-15 min. at about 300 degree Celsius for aluminium
alloy and about 150 degree Celsius for Zinc alloy.
Charging is done by shovel.
Temperature is increased to about 700 degree Celsius for aluminium alloys and up to
450 degree Celsius for Zinc alloys.
Then the lid is covered.
Sample is then taken for spectrometry test and alloying is done accordingly.
After alloying spectrometry test is conducted.
Then with a long handled cup the furnace is emptied in moulds.
Casting
Temperature in the Skelner furnace is adjusted according to the length of launder (pouring
trough) so that the temperature at distributer is approx. 720 degree Celsius. Before pouring
launder is coated with a coating to smoothen it for the flow of molten bath. When the molten
metal comes out of the furnace it passes through 200 and 60 mesh size screen to filter any
leftover dross. After passing through the filter it goes to the distributer on launder. The
distributer is a circular apparatus with many holes on regular interval at the circumference for
molten metal to pass; it pours the molten metal to different molds below it. The molds are
attached to a conveyer which moves at about 1m per min.
19. 18
After pouring of molten metal into the mold, oxide layer starts to form over the liquid. The
oxide layer and dross is immediately skimmed by men standing near the distributer.
The conveyer is about 10m in length and one end is below the distributer and at the other end
workers take out the solid ingots from the moulds and put them in a pile. The temperature of
solid ingots at the other end is approx. 250 degree Celsius. While stocking workers remove de-
shaped & ingots with visible dross.
After this a visual inspection of piles are carried out by an expert to see whether they are as
required by the customer or not. Few ingots are also sent to lab while casting to see the
physical properties of the ingots. After cooling, the finished stock is sent to the dispatch section.
Parameters for rejection of ingot:
Presence of gas bubbles in the ingot.
Presence of large dross lumps on the surface of ingot.
Cold lap indicating rapid drop in temperature while casting.
White surface indicating oxide formation.
Coarse fracture indicating improper mixing of alloying elements.
Presence of shrinkage/inclusion.
Dross Processing
Our Company also recycles dross produced by the furnaces. It also buys black dross to be
recycled in TRF. Dross produced by TRF and SF are kept separately.
Dross produced from TRF is processed by following procedure:
TRF dross is cooled down by spreading it in open.
Then it is sent through Dross cooling machine which separates Cyclone (waste), Small
Dana (to be sold) and Maal (Dheema+Al).
Maal is then sent to pulverizer for screening. It hammers the aluminium into ball shape
and Bada Dana (>2 mm dia), Small Dana (<2mm dia) and Under Challi (waste).
Small Dana is sold but Under Challi is thrown as wastage.
Bada Dana is sent to TRF for melting.
Dross produced from Skelner Furnace is processed in 2 ways:-
In Pulverizer
In DPM (Dross Processing Machine)
1. In Pulverizer
After cooling, iron is separated from dross using a hand magnet. Then dross is sent to
pulverizer and iron is processed in drum roll where iron separates from attached aluminium
20. 19
which falls down as Al kitta (it is sold). Then same steps are followed as in processing of TRF
Dross except that Under Challi for this dross is sold.
2. In DPM
After cooling, iron is separated from dross using a hand magnet. Then dross is charged into the
machine which is hemispherical in shape. Cover flux is also added (10% by wt). Company owns
2 DPMs and each produces about 25 kg Aluminium ingot for every 100 kg Dross.
21. 20
QUALITY DEPARTMENT
This department looks after the quality of the ingots produced and also sees to equip the
company with better technology and development of the processes. It sees to various defects
in the products and amends the processes accordingly. It is the responsibility of this
department only to make a batch charge (format attached). Major tests that are done in the
company lab are as following:-
Spectrometry test
Tensile test
Fracture test
Hydrogen test
Our lab is equipped with following equipments:-
Spectrometer Lab Model M8
Microscope Image Analyser
Universal Testing Machine
Mobile degassing equipment
Rockwell Hardness Tester
Organizational Structure
Quality Head
Supervisor
Lab Attendant
22. 21
Spectrometry Test
Optical emission spectroscopy using arc and spark excitation (Arc Spark OES) is used for trace
metal analysis to determine the chemical composition of metallic samples. This process is
widely used in the metal making industries, including primary producers, foundries, die casters
and manufacturing. Due to its rapid analysis time and inherent accuracy, arc spark optical
emission spectroscopy systems are most effective in controlling the processing of alloys.
Arc spark spectrometer is used for many aspects of the production cycle including incoming
inspection of materials, metal processing and quality control of semi-finished and finished
goods.
Principle of Optical Emission Spectrometry
Optical emission spectrometry involves applying electrical energy in the form of spark
generated between an electrode and a metal sample, whereby the vaporized atoms are
brought to a high energy state within a so-called “discharge plasma”.
These excited atoms and ions in the discharge plasma create a unique emission spectrum
specific to each element, as shown at right. Thus, a single element generates numerous
characteristic emission spectral lines.
Therefore, the light generated by the discharge can be said to be a collection of the spectral
lines generated by the elements in the sample. This light is split by a diffraction grating to
extract the emission spectrum for the target elements. The intensity of each emission spectrum
depends on the concentration of the element in the sample. Detectors (photomultiplier tubes)
measure the presence or absence or presence of the spectrum extracted for each element and
the intensity of the spectrum to perform qualitative and quantitative analysis of the elements.
23. 22
Tensile Testing
Tensile testing, also known as tension testing, is a fundamental materials science test in which a
sample is subjected to a controlled tension until failure. The results from the test are commonly
used to select a material for an application, for quality control, and to predict how a material
will react under other types of forces. Properties that are directly measured via a tensile test
are ultimate tensile strength, maximum elongation and reduction in area. From these
measurements the following properties can also be determined: Young's modulus, Poisson's
ratio, yield strength, and strain-hardening characteristics.
Principle of Universal Testing Machine
The most common testing machine used in tensile testing is the universal testing machine. This
type of machine has two crossheads; one is adjusted for the length of the specimen and the
other is driven to apply tension to the test specimen. There are two types:
Hydraulic powered machines
Electromagnetically powered machines.
The machine must have the proper capabilities for the test specimen being tested. There are
four main parameters: force capacity, speed, precision and accuracy. Force capacity refers to
the fact that the machine must be able to generate enough force to fracture the specimen. The
machine must be able to apply the force quickly or slowly enough to properly mimic the actual
24. 23
application. Finally, the machine must be able to accurately and precisely measure the gauge
length and forces applied; for instance, a large machine that is designed to measure long
elongations may not work with a brittle material that experiences short elongations prior to
fracturing.
The test process involves placing the test specimen in the testing machine and slowly extending
it until it fractures. During this process, the elongation of the gauge section is recorded against
the applied force. The data is manipulated so that it is not specific to the geometry of the test
sample. The elongation measurement is used to calculate the engineering strain, ε.
Universal Testing Machine
Fracture Test
This test is done to see whether the bath is properly mixed.
Random ingots are selected and are broken. The inner surface is observed to see following:-
Coarse fracture showing that mixing is not done properly.
Fine fracture showing that mixing is properly done.
Porosity, only 1 % porosity is accepted by international standards.
Shrinkage and inclusion.
To see porosity, sample is polished & etched and then is viewed under microscope.
25. 24
If the test comes to be negative then casting is immediately stopped and degassing is done
again or the heat is discarded and reused.
Rapid Pressure Test (Hydrogen Test)
It is done to check whether gas is present in the bath or not. Mostly the gas present in the bath
is hydrogen. Hydrogen forms whenever molten aluminium comes into contact with water
vapor, and easily dissolves into the melt. The gas tends to come out of the solution and forms
bubbles when the melt solidifies.
Operating principle of Rapid Pressure Test
A sample is taken from the furnace after degassing to check whether degassing is done properly
or not. The closed loop recirculation is a proven method of directly monitoring hydrogen in
molten aluminium. A small volume of carrier gas, usually nitrogen, is brought in contact with
the melt by means of an immersed probe, and is continuously recirculated in the closed loop
until its hydrogen content reaches equilibrium with the vapor pressure of H2 in the melt. The
H2 concentration in the gas is measured and converted into a reading of the gas concentration
in the metal. This method is fast, reproducible and accurate, and can be used “on-line” on the
cast shop floor.
If after testing, surface of the sample comes out to be convex then the sample is ok but if it is
concave then gas is present in sample so degassing of bath has to be done.
1. (B)
Test samples (A) solidified under atmospheric pressure and (B) solidified under vacuum.
27. 26
DISPATCH DEPARTMENT
This department looks after the storage, dispatch and transport of verified ingots. It also looks
after the colour coding of ingots according to the customers.
Organizational Structure
Dispatch Head
Workers
Supervisor
28. 27
Activity Flow
The cold ingots are collected by the dispatch department and are weighed. They are stored
grade wise and then are separated and coloured according to the colour codes of different
companies.
Each bundle is made up of 110 ingots and then is tied by synthetic ropes. The consignment is
dispatched along with
1. Customer order copy
2. Excise slip
3. Packing slip (format is attached below)
4. Spectrometry test report
5. Button sample if asked for.
The company owns following equipments:-
1. Roof-attached crane
2. Trucks (2)
Extra vehicles required for transportation are hired from Transportation Company.
Incoming of Ingots
Weighingof Ingots
Dispatch according to daily plan
Grade wise Storage
29. 28
Suggestions
1 Keep the raw materials in separate section according to their avg. chemical report with
+/- 3% change in their composition. This can save time, wastage of materials and
reduce chances of human error in adjusting the chemical composition thus profiting
the company.
2 Installation of Tap in the back of TRF for pouring. The advantages of this modification
are listed below:-
2.1 Lid is now not required to open for tapping thus tapping temperature can be controlled.
2.2 The production of Dheema can be reduced as launder’s length would be reduced
drastically.
2.3 Dross emission can be controlled thus much purer molten material would pass onto the
holding furnace.
3 After 1st tapping, rotate the furnace for about 10 min at a very high speed and fire the
burner according to the temperature required. Retap to remove additional molten
aluminium. Thus the dross production is reduced.
30. 29
Incoming Report Format
S.NO QTY.(kg) %AGEIMPURITYUTY(kg)
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
Total
CAPACITOR
WASTE MATERIAL
DUST
PANEL BOARD
IMPURITIES
IRON
iron+rb att zinc
RED CUTTING MATERIAL
RUBBER+IRON@MG
IRON@ZINC
ZINC
LEAD
MAGNESIUM
GREEN PLATE
AL. CAPACITOR
PVC COPPER WIRE
BRASS
IRON @COPPER /BRASS
COPPER RADIATOR
OTHER MATERIALS
STEEL
COPPER
HARDDISK
IRON+RB ATT CASTING
IRON+RB ATT SEC/BBS
IC
RUBBER@TENSE/BBS/SECTION/TWITCH
BRASS/COPPER@TENSE/BBS/SECTION/TWITCH
MIX MATERIAL BELOW 8MM
ATT. MATERIAL
IRON ATT. TENSE/TWITCH
IRON ATT. BBS/SECTION
FOIL
DHUMMA
CLEAN BBS
AL RADIATOR
UBC
CLEAN MATERIAL
CLEAN TENSE/TWITCH
CLEAN SECTION
PARTY NAME RECEIVED DATE
CONTAINER NO. REPORT DATE
MATERIAL
ITEMS REMARKS
