1. INTERNSHIP REPORT
January 2015
Hi Tech Carbon [Aditya Birla Nuvo, Ltd] Gummudipoondi,
Tamil Nadu
2015
Student
Program
Department
Internship Supervisor
Sahil Ali Tonse [4MW12ME082]
B.E. [Mechanical Engineering]
Shri MAdhwaVadiraja Institute of
Technology & Management, Bantakal.
Mechanical Engineering
Mr. Prajwala Sameera, Frontline Engg.

2. ADITYA BIRLA GROUP
A US $40 billioncorporation,the AdityaBirlaGroupisinthe League of Fortune 500. It is anchoredbyan
extraordinaryforce of over120,000 employeesbelongingto42 differentnationalities.The Grouphas
beenrankedNumber4in the global 'Top CompaniesforLeaders'surveyandrankedNumber1inAsia
Pacificfor2011. 'Top CompaniesforLeaders'isthe mostcomprehensive studyof organisational
leadershipinthe worldconductedbyAonHewitt,FortuneMagazine,andRBL(a strategicHR and
LeadershipAdvisoryfirm).The Grouphastoppedthe Nielsen'sCorporate Image Monitor2012-13 and
emergedasthe Number1 corporate,the 'Best inClass'
Over50 per centof the AdityaBirlaGroup'srevenuesflow fromitsoverseasoperations.The Group
operatesin36 countries–Australia,Austria,Bangladesh,Brazil,Canada,China,Egypt,France,Germany,
Hungary,India,Indonesia,Italy,IvoryCoast,Japan,Korea,Laos,Luxembourg,Malaysia,Myanmar,
Philippines,Poland,Russia,Singapore,SouthAfrica,Spain,Sri Lanka, Sweden,Switzerland,Tanzania,
Thailand,Turkey,UAE,UK, USA,and Vietnam.
Aditya Birla Group – The Global Scenario
Aroundthe world,we're knownfor:
 A metalspowerhouse, amongthe world's mostcost-efficientaluminiumandcopperproducers.
Hindalco-Novelisisthe largestaluminiumrollingcompany. Itisone of the three biggestproducers of
primary aluminiuminAsiawiththe largestsingle locationcoppersmelter
 No.1 inviscose staple fibre
 No.1 incarbon black
 The fourh-largestproducerof insulators
 The fourh-largestproducerof acrylicfibre
 Amongthe top 10 cementproducers
 Amongthe bestenergy-efficientfertiliserplants
 The largestIndianMNC withmanufacturingoperations inthe USA
Aditya Birla Group – The Indian Scenario
In India,here'swhatwe have accomplished:
 The largestfashion(premiumbrandedapparel)andlifestyle player
 The second-largestmanufacturerandlargestexporterof viscose filamentyarn
 The largestproducerinthe chlor-alkali sector
 Amongthe top three mobile telephony companies
 A leadingplayerinlifeinsuranceandassetmanagement
 Amongthe top twosupermarketchainsinthe retail business
 The largestmanufacturerof linen fabric
Rock solidinfundamentals,the AdityaBirlaGroupnurturesa culture where successdoesnotcome in
the way of the needto keeplearningafresh,tokeepexperimenting.

3. BIRLA CARBON
Hi-Tech Carbon, the carbon black business of Aditya Birla Nuvo, caters to the tyre and non-
tyre industry with a vision to be the most respected, green, globally-advanced fillers
business.
With manufacturing plants at Renukoot in Uttar Pradesh, Patalganga in Maharashtra and
Gummidipoondi in Tamilnadu, Hi-Tech Carbon is the second largest producer of carbon black in India,
covering approximately 40 per cent of the domestic market share. The combined capacity stands at
314,000 mtpa including recent greenfield capacity expansion at Patalganga.
The carbon black business under the umbrella of Aditya Birla Nuvo enjoys a satisfied customer base.
Both the units are ISO/TS 16949 and QS 9000 certified for advanced quality management, ISO 14001
certified for environment management, OHSAS 18001 certified for occupational health and safety and
IQRS 7 for International Quality Rating System. The laboratory located at Gummidipoondi unit is
approved by NABL (ISO 17025 Certified). The R&D Centre ABFRI located at Gummidipoondi unit is
approved by the Department of Science and Technology, Government of India. The compa ny has
internalised management techniques such as 5-S, QSS, KSS, Mentor, IQRS, Six Sigma and Total
Productive Maintenance (TPM) practices to enrich operational performance.
Hi-Tech Carbon is also the first Carbon Black plant to be certified with OHSAS-18001 for occupational
health and safety. Hi-Tech Carbon, Gummidipoondi has been conferred the coveted Deming Award for
Quality (2002) by the Deming Prize Committee (JUSE), Japan. The NECA award was conferred on this
unit for energy conservation. The unit has also won the Greentech Safety Award and Greentech
Environment Excellence Award for outstanding achievement in safety and environment. The IMC
Ramkrishna Bajaj National Quality Award was presented to this unit for excellence in quality.
The company is one of the lowest cost producers and has the locational advantage of being near the
sea coast. The company also gets value contribution from energy sales.
The company prides itself on its consistent product quality and environmental safety standards. Hi-
Tech Carbon uses the most modern technology, operated through the Distributed Control System
(DCS). This process automation ensures quality and consistency in the manufacturing of Carbon Black.
The manufacturing process also envisages conserving heat energy for productive utilisation through
downstream processes.
The AdityaBirlaGroup isthe No.1producerof carbon blackinthe world.Internationally,the Grouphas
carbon blackfacilitiesatits AlexandriaCarbonBlack unitinEgypt, Thai Carbon BlackPublicCompany
LimitedinThailandand LiaoningBirlaCarbonBlack unitinChina.The Group derivessynergiesthrough
marketingunderthe brand‘BirlaCarbon’andcentral procurementof feedstock.
Research & Development
As the leadingCarbonBlackCompany,ResearchandDevelopmentatBirlaCarbonis focusedonthe
future bydevelopingandusingworld-classCarbonBlackTechnologyforthe benefitof itscustomers.
Withestablishedstate of arttechnologycenterslocatedin Taloja,Maharashtra(India) andMarietta,
Georgia(USA),andregional satellite laboratories,the growinganddynamicTechnologyGroupatBirla
Carbonis focusedoncontinual enhancementinCarbonBlackTechnologythroughitseffortsacross
ProcessTechnology,ProductTechnologyandTechnical ServiceCapability.BirlaCarbonforms
partnershipswithitscustomerstoensure thattheyobtainconsistentqualityandperformance.

4. Process Technology
The ProcessTechnologyGroupat BirlaCarbon is
leadinganddrivingthe processoperations
strategyof Environmental Stewardshipand
Sustainabilityforthe mostefficientand
advancedproductiontechnology.Utilizing
Computational FluidDynamics(CFD) andmany
yearsof toplevel engineeringexpertise,the
ProcessEngineerscontinuetopioneer
technologydevelopmentinthe manufacturing
plantsto deliverthe qualityandproductsthat
customersrequire inanefficientand
environmentallyfriendlymanner.Forexample,
BirlaCarbon takesadvantage of the additional
energyin Thierplantstoproduce electricityfor
local consumption,furtherreducingthe CO2
footprinttomeetthe energyneeds.
Product Technology
The Product TechnologyGroup,alongwiththe
Technical Service Capabilityineachregionof
the world,isleadingthe effortinensuringthat
customershave all of theirproduct-based
technical needsmet,includingquality,
performance andnewproducts.Inparticular
these groupsworkverycloselywiththe
customersona dailybasistoensure thatthey
have the technical supportrequiredtobe
successful andovercome theirproduct
challenges.
Laboratory Services
TheirTechnologyLaboratoriesinMumbai,India
and Marietta,Georgia(USA) are housedin
worldclasstechnical facilitiescontaining
modernlaboratoryequipmentandexperienced
scientistsandresearcherswithexpertiseinnot
justCarbon BlackTechnologybutalsoacross
Rubber,Plastics,InksandCoatingsTechnology.
These laboratoriesare available forthe benefit
of Thiercustomers,researching CarbonBlack.

5. Environment
BirlaCarbon’s businessdependsonlimitednatural resourcessuchasoil,gasand water,and they
recognize thatthey have a responsibilitytogrow Thierbusinessinawaythat usesthese resourrces
wisely. Thierenvironmental strategyfocusesonfourareas– energyand emissions,water,waste,and
responsible sourcingandconsumption.
Operatingefficientlyisvital toBirlaCarbon’scontinuedandsustainable success.They face anumberof
challengesinthisarea,includingmeetingstricterregulations,implementingthe latesttechnologyat
Thierplants,andattracting talentedpeople whocanoperate Thierstate-of-the-artplantsand
technology.We are committedtotacklingthese challenges,andthey plantodothis byimproving Thier
manufacturingefficiencythroughinnovationandsharedexpertise.Thisisall partof ThierSustainable
Operational Excellence approach,whichhelpsusimprove standards,operate efficientlyandminimize
Thierenvironmental impacts.
In FY2014 BirlaCarbon conducteda Life Cycle Assessment(LCA) tomeasure the impactsof their
feedstockandcarbonblack – fromcrude oil extractiontothe deliveryof carbonblackto thier
customers’gates.The assessmentwill helpthembetterunderstandthe impactwithregardto
CO2 emissionsandidentifyopportunitiestoreduce thier overallcarbonfootprint.

6. CARBON BLACK
Carbonblack (subtypesare acetylene black,channel black,furnace black, lampblackandthermal black)
isa material producedbythe incomplete combustionof heavy petroleumproductssuchas FCC tar, coal
tar, ethylene crackingtar,anda small amountfrom vegetable oil.Carbonblackisaform
of paracrystallinecarbonthathas a high surface-area-to-volumeratio,albeitlowerthanthat
of activatedcarbon.Itis dissimilarto sootinits muchhighersurface-area-to-volume ratioand
significantlylower(negligible andnon-bioavailable)PAH(polycyclicaromatichydrocarbon) content.
Carbonblack ismainlyusedasa reinforcing fillerintiresandotherrubberproducts.Inplastics,paints,
and inkscarbonblack isusedas a color pigment.
Practically all rubber products where tensile and abrasion wear properties are crucial use carbon
black, so they are black in color. Where physical properties are important but colors other than black
are desired, such as white tennis shoes, precipitated or fumed silica has been used as a substitute
for carbon black in reinforcing ability. Silica-based fillers are also gaining market share in automotive
tires because they provide better trade-off for fuel efficiency and wet handling due to a lower rolling
loss compared to carbon black-filled tires. Traditionally silica fillers had worse abrasion wear
properties, but the technology has gradually improved to where they can match carbon black
abrasion performance.
ITS USES
Total productionwasaround8,100,000 metrictons (8,900,000 shorttons) in 2006.[4]
The most common
use (70%) of carbon blackis as a pigmentandreinforcingphase inautomobiletires.Carbonblackalso
helpsconductheatawayfrom the treadand beltarea of the tire,reducingthermal damage and
increasingtire life.Carbonblackparticlesare alsoemployedinsome radarabsorbentmaterials andin
photocopierandlaserprintertoner,andotherinksandpaints.The hightintingstrengthandstabilityof
carbon blackhas alsoprovideduse incoloringof resinsandfilms. About20% of worldproductiongoes
intobelts,hoses,andothernon-tire rubbergoods.The balance ismainlyusedasa pigmentininks,
coatingsand plastics..
Carbonblack fromvegetable originisusedasa foodcoloring,inEurope knownasadditive E152. It is
approvedforuse as additive 153(Carbonblacksor Vegetablecarbon)[6] in AustraliaandNew Zealand[6]
but hasbeenbannedinthe USA. Additionally, the color pigment Carbon Black has been widely used
in food and beverage packaging around the world for many years. It is used in multi-layer UHT milk
bottles in the US, parts of Europe and Asia, and South Africa, and in items like microwavable meal
trays and meat trays in New Zealand.
The highest volume use of carbon black is as reinforcing filler in rubber products, especially tires.
While a pure gum vulcanizate of styrene-butadiene has a tensile strength of no more than 2.5 MPa,
and almost nonexistent abrasion resistance, compounding it with 50% of its weight of carbon black
improves its tensile strength and wear resistance as shown in the below table. It is used often in the
Aerospace industry in elastomers for aircraft vibration control components such as engine mounts.

7. SKI CARBON BLACK-GUMMUDIPOONDI
SKICarbon Black,Gummudipoondi wasestablishedinthe year1998, howeverthe productionwas
startedin2000.Birla Carbon produces andsuppliesacomplete line of highqualityASTMgradesfortire
producersunderthe brand‘BirlaCarbon’and has developedperformance carbonblackgradestailored
to improve tire performance fortreadlife. The annual Carbonblackproductionof the plantis1.6 Lakh
MTPA(MetricTonnesPerAnnum).The charge usedisCarbonBlack FeedStock(CBFS) Oil importedfrom
the UnitedStates.The plantalsohosts a 33.7 MW captive powerplantwhichusesthe off gas(CO) as
fuel.ThisplantatGummudipoondi runson WorldClassManagementStandards[ISO27001/SA 8000,
ISO/TS16959,Deming TPM/WCMSilverAward,IQRS Level 7,ISO 9002/ISO14001/QS9000/OHSAS18001,
SSQ6 KSS] .The plantalsohousesa Master batch plantproducingthe masterbatchrubberto meet
customerdemands. Atpresentthe typesof CarbonBlackbeingproducedatthe Gummudipoondi plant
were
 Hard Black(N220,N330,N347 Etc) - Alsocalledas the Tread Grade Carbon.Hard grades of
Carbon Black are usedin treads of tyres as these are highlyabrasion resistant.
 Soft Black(N660,N550,650 etc)-Alsocalledas the Carcass Grade Carbon Black. Soft gradesare
general purpose of fast estrudingCarbon Black and find theiruse inthe side walls of tyresand
in the manufacture of tubes.
Grade
Airbag
ConveyorBelt
Ext.Product
Footwear
Hoses
Ink
Mech.Goods
ModuledProd.
OTRTyre
Plastic
Pigments
RailwayPad
Retread
Rubbersol
Tubes
TyreCarcass
TyreTread
V-Belt
Wire/Cable
N 220 X X X X X X
N 330 X X X X X X X X X X X X X
N 347 X X X X
N 550 X X X X X X X X X X X
N 650 X X X X X X X X
N 660 X X X X X X X X X X X

8. FUNDAMENTAL MECHANICAL DEVICES USED IN THE PLANT
1. COUPLING
A couplingisa device usedtoconnecttwo
shaftstogetherattheirendsfor the purpose of
transmittingpower.The primarypurpose of
couplingsistojointwopiecesof rotating
equipmentwhilepermittingsome degreeof
misalignmentorendmovementorboth.By
careful selection,installationandmaintenance
of couplings,substantial savingscanbe made in
reducedmaintenance costsand downtime
Figure 1-FLANGE COUPLING
Shaft couplings are used in machinery for several purposes. The most common of which are the
following.
 To provide for the connection of shafts of units that are manufactured separately such as a motor
and generator and to provide for disconnection for repairs or alterations.
 To provide for misalignment of the shafts or to introduce mechanical flexibility.
 To reduce the transmission of shock loads from one shaft to another.
 To introduce protection against overloads.
 To alter the vibration characteristics of rotating units.
 To connect driving and the driven part.
Basicallythere are twotypesof couplings-RigidandFlexiblecouplings.A rigidcouplingisaunitof
hardware usedto jointwoshaftswithinamotoror mechanical system.Itmaybe usedtoconnecttwo
separate systems,suchasa motor and a generator,orto repaira connectionwithinasingle system.A
rigidcouplingmayalsobe addedbetweenshaftstoreduce shockandwearat the pointwhere the shafts
meet.
Whenjoiningshaftswithinamachine,mechanicscanchoose betweenflexible andrigidcouplings.While
flexible unitsoffersome movementandgive betweenthe shafts,rigidcouplingsare the mosteffective
choice forprecise alignmentandsecure hold.
Commontypesof couplingsthatwere usedinthe site are flange couplingsforlightapplicationsand
gear couplingsforheavydutyapplications.
2. BEARING

9. A bearing is a machine element that
constrains relative motion and reduces friction
between moving parts to only the desired
motion. The design of the bearing may, for
example, provide for free linear movement of
the moving part or for free rotation around a
fixed axis; or, it may prevent a motion by
controlling the vectors of normal forces that
bear on the moving parts.
Many bearings also facilitate the desired motion as much as possible, such as by minimizing friction.
Bearings are classified broadly according to the type of operation, the motions allowed, or to the
directions of the loads (forces) applied to the parts.
Bearings can be classified into various types depending on several parameters.
 Dependingonwhetherthe ball orrollerisusedbetweenthe twobearingringsitcan be classified as
Ball Bearing and Cylindrical Bearing.
 Dependingonthe load exerted on the bearing they can be classified as Radial Bearings and Thrust
Bearings.
 Special types of bearings include Spherical Bearing, Tapered Bearing, Needle Bearing Etc.
Types of bearings which could be seen in the plant are Cylindrical roller bearings, Ball bearings and
NU Type bearings.
3. PLUMMER BLOCK
A pillowblock,alsoknownas a plummer blockor bearinghousing,
isa pedestal usedtoprovide supportfor a rotatingshaftwiththe
helpof compatible bearings &variousaccessories.Housing
material fora pillowblockistypicallymade of castironor cast
steel.
Figure 2 PLUMMER BLOCK
The fundamental applicationof bothtypesisthe same whichistomount bearingssafelyenabling
theirouterringto be stationarywhile allowingrotationof the innerring.The housingisboltedtoa
foundationthroughthe holesinthe base.Bearinghousingsare eithersplittype orunsplittype.Split
type housingsare usuallytwopiece housingswherethe capand base can be detached,while certain
seriesare one single piece housings.Varioussealsare providedtopreventdustandother

10. contaminantsfrom enteringthe housing.Thusthe housingprovidesacleanenvironmentforthe
expensive bearingstofreelyrotate,hence increasingtheirperformance anddutycycle.
The Plummerblockswere seenhousingthe shaftsof boosterfans,blowersandotherheavyduty
shafts.
4. AIR COMPRESSORS
An air compressoris a device thatconverts
power(usuallyfromanelectricmotor,a
diesel engine oragasoline engine) into
kineticenergybycompressingand
pressurizingair,which, oncommand,canbe
releasedinquickbursts.
There are numerousmethodsof aircompression,dividedintoeitherpositive-displacementor
negative-displacementtypes.
 Dependingonthe discharge pressure
1. Low-pressure aircompressors(LPACs),whichhave adischarge pressure of 150 psi or less
2. Medium-pressure compressors,whichhave adischarge pressure of 151 psi to 1,000 psi
3. High-pressure aircompressors(HPACs),whichhave adischarge pressure above 1,000ps
 Dependingonthe principleof operation
1. Positive displacementCompressors.
2. Centrifugal Compressors.
 Dependingonthe numberof stages
1. Single stage Compressors.
2. Multistage Compressors.
Air compressors have a wide application in every industry specifically in Birla Carbon plant the
Multistage positive displacement compressors with intercoolers were used to generate compressed
air which was stored in pressure vessels which could be used later for the operation of various
valves and other pneumatic devices.

11. 4. PUMPS
A pump isa device thatmovesfluids
(liquids orgases),orsometimes slurries,by
mechanical action.Pumpsoperate bysome
mechanism(typically reciprocatingorrotary),
and consume energy toperformmechanical
work by movingthe fluid.Pumpsoperatevia
manyenergysources,includingmanual
operation,electricity, engines,orwind
power,come inmanysizes,from microscopic
for use inmedical
applicationstolarge industrial pumps.
Figure 3 PUMPS
Mechanical pumpsserve ina wide range of applicationssuchas pumpingwaterfromwells, aquarium
filtering, pondfilteringandaeration,inthe car industry forwater-coolingandfuel injection,in
the energyindustry forpumpingoil andnatural gas or for operatingcoolingtowers.
The typesof pumpsusedat plantsite were Centrifugal Pumpsforwaterlikethe feedwaterpumps,RO
waterpumps,Condenserpumpsandthe Charge pumpswere Screw pumptype.
5. AIR BLOWERS
A centrifugal fan isa mechanical devicefor
movingairor othergases.The terms
"blower"and"squirrel cage fan"(because it
lookslike ahamsterwheel) are frequently
usedas synonyms.These fansincreasethe
speedof airstream withthe rotating
impellers.
Theyuse the kineticenergyof the impellers orthe rotatingblade toincrease the pressure of the
air/gasstreamwhichin turnmovesthemagainstthe resistance causedbyducts,dampersandother
components.Centrifugal fansaccelerate airradially,changingthe direction(typicallyby90o
) of the
airflow.Theyare sturdy,quiet,reliable,andcapable of operatingoverawide range of conditions.
Main parts of a centrifugal fanare:

12. 1. Fan Housing
2. Impellers
3. Inletandoutletducts
4. Drive Shaft
5. Drive mechanism
Othercomponentsusedmayinclude bearings, couplings,impellerlockingdevice,fandischarge casing,
shaftseal platesetc.
Centrifugal fans or blowersare usedtosupplyairto the reactorsor combustionchambersalsoto
ensure flowof carbonparticlesasa booster fan.
6. HEAT EXCHANGERS
A heat exchangerisa piece of
equipmentbuiltforefficient heat
transferfromone mediumtoanother.
The mediamay be separatedbya solid
wall to preventmixingortheymaybe in
directcontact.
Theyare widelyusedin space heating,refrigeration,airconditioning,powerplants,chemical
plants,petrochemicalplants,petroleumrefineries,natural gasprocessing,andsewagetreatment.
The classicexample of aheat exchangerisfoundinan internal combustionengine inwhicha
circulatingfluidknownas enginecoolant flowsthrough radiatorcoilsandairflowspastthe coils,
whichcoolsthe coolantand heatsthe incoming air.
Heat exchangersfindawide applicationinindustrydue totheirpropertyof energy conservation,
they can be foundusedas AirPre-Heaters(APH),Oil Pre-Heater(OPH), Waste HeatBoiler(WHB),
SuperheaterEtc. Thus heatexchangeshelptoincrease the plantsefficiencybyutilizingthe heat
whichwouldotherwisegetwasted.
PRODUCTION

13.  OVERVIEW
Carbonis a rich elementpresentinthe crude oil. The low value carbon richresidue Carbonwhichisa
waste productfrom the fractional distillationprocessof crude oil isimportedfromUSA since the
domesticqualityof CBFSiscomparativelypoor.Itistransportedtothe plantsite bytrucks and storedin
large tankswhich are maintainedat 90 0
C withthe helpof steamcoil.There are a total of 3 production
linesatBirlaCarbon Gummudipoondi.The Carbonblackparticlesare filteredoutandfurtherprocessed
to getthe desiredproductwhereasthe off gas liberatedmaybe burntinthe combustorto produce flue
gases.These flue gasesare passedthroughawatertube boilerandthusthe generatedsteammaybe
usedto produce electricityusingturbineswhichmaybe usedfor in-plantrequirementsandexcessmay
be importedtothe grid. The Carbonblack isstoredin16 large silosandcan be packedintobags and
transportedbasedondemand.The Master batch product isproducedwhichisthe most fundamental
part of tire isalsoproducedat a on-site unittomake it convenientfor theircustomers. The plantfollows
highstandardoperationandmaintenance standardalongthe process.
 PROCESS

14. Figure 4-Carbon Black Production Process
1. REACTOR-Itisa cylindrical longmetal shelledchamber insidewhichthe preheatedCBFSoil is
subjectedtocombustionprocess.The CBFSisfedthroughnozzle gunsmountedatideal
inclination.The filteredandpreheatedaircreatesadraft,ensure flow of gasesandensure
combustionprocess.The oil ispartiallyburnttoproduce COgas whichcontainssuspended
carbon particles.Before the combustioniscompleted,itisquenchedwithwaterusingwater
guns.The temperature inside the reactorvariesfrom15000
C to 20000
C.
2. Air Pre-Heater (APH)-TheAirPre-Heaterisa‘Shell andTube type HeatExchanger’device.
The flue gasespassthroughthe smallertubesinside andthe airfromthe blowerflowsthrough
the shell.The hotflue gases whichare at about20000
C heatthe atmosphericairwhichisat 700
C
to about650 0
C -800 0
C whichisthenintroducedtothe reactor.
Steam at 2050

15. 3. Waste Heat Boiler(WHB)-Wasteheatboilerisasmall watertube boilerwhichisusedto
generate lowpressure steamatabout200o
C. Thisisjust a heatconservationdevice andthe
generatedlowpressure steamcanbe usedforvariousdomesticpurposeswithinthe plant.For
example,the steamcanbe usedtokeepthe CBFSin the storage tankswarm because itmay
solidifyatlowertemperatures.
4. Oil Pre-Heater-Justlike the APHandWHB,Oil Preheater isa device usedtoheatthe charge
CBFS whichisdeliveredtoitfromthe storage tanks viacharge pumpsof screw type.The oil at
the outlethasattaineda temperature of 2000
C. These heatconservationdeviceshelpin
improvingthe effecienyof the plantbyfacilitating ideal combustionprocess.Notonlythatbut
thisprocessof heat extractionalsocoolsdownthe flue gaswhichotherwisethe carbonparticles
wouldgetvanisheddue tohightemperaturesanalsodamage the further equipment.
5. Quenchtower-Afterthe heathasbeenextractedfromthe flue gasestoacertainextent
nowfurtherreductioninthe temoerature canbe obtainedbyquenchingthe gaswithwaterand
steam.Italsomoistensthe carbonparticlessothattheycan be easilytrappedinthe filterbags.
6. MainBag Filter(MBF)- Mainbagfilterisa huge chamberinwhichmany pocketsof filters
are placedinside.Whenthe gasesare blownthroughthemthe wettedcarbonparticlesstickon
the surface of the bags.The bags are so designedsuchthatonlythe off gas can pass throughit.
The bags are made to vibrate at curtainedintervalsusingthe reversedraftfansthusthe carbon
particleswill fall downonthe bottomof the container.
o Micro-pulveriser-Micro-Pulveriserisadevice whichfurtherbreaksdownthe Carbon
Black particlesintofineranduniformsizedgranules.Itisa highspeed,low clearance
hammermill withveryhighefficiencyandoutput.The methodof size reductionis
characterizedby relativelyhigh residence time,minimizingheat buildup duringthe milling
process.The micro pulveriserandrotorassembly fittedwithhammers.The grindingaction
takesplace due to impactbetweenthe rapidlymovinghammerandthe particle themselves.
o Booster fan-Itisa type of centrifugal blowerwhichisusedtoproduce aflow of Carbon
blackparticlescomingoutof the pulveriserandfedtothe Pelletizing unit.The impellerisa
forwardcurve type and drivenbya electricmotormounted onthe same shaft.
7. Pelletizer-The wetmixerpelletizerisusedtoconvertfluffycarbonblackintopelletedform.It
isa mill type of mixer, withanexternallyheatedjackettolimitcake formationinside the
pelletizer. The jacketof the pelletizerisheatedwiththe helpof steam. The jackettemperature
ismaintainedat100o
C to 120o
C. This tool isa set of spiral pinsattachedto a scraper bar,
allowingthe pelletizershafttobe supportsas itis pushedthroughthe shell. A mixtureof water
and molassesisaddedintothe wetmixer alongwiththe pulverizedcarbonblack.The pins
scrape off the carbonblack and resultinthe uniformsizedcarbonblackpelletsatthe otherend.

16. Figure 5 Pins inside the pelletizer unit
8. Rotary Dryer-isatype of industrial dryeremployedtoreduce orminimize the liquidcontent
of the material byindirectheatingwithflue gasgeneratedfromthe Combustor.The dryeris
made up of a large rotatingcylinderwhichslopesslightlysothatthe discharge endislowerto
conveythe material undergravity. It isof an indirectlyheatedtype.Hotflue gasesfromthe
combustionfurnace flowsthroughthe dryeraroundthe dryercylinderthusheatingthe dryer
cylinderexternally. The hotflue gaseswill flow outthroughthe exhaustopeningonthe furnace
to a stack.
9. Conveyers-
Bucketconveyerisa type of mechanical
equipmentusedtoconveythe product
fromdrierdischarge to a cross conveyer
fromwhichit will be fedintothe silos
for coolingandstorage. The dried
carbon blackpelletscomingoutof the
rotary driernowneedtobe cooledand
stored. Since the particlesare smaller
sized,bucketelevatorsare the most
suitable.The crossconveyerisof a
screwtype.
10. Storage
Silois a vertical cylindrical vesselwhichactsasa place forstorage as well ashelpsincooling
downthe particlesbefore packaging. The silosfromthe drierare elevatedbybucket elevators
and throughscrewtype cross conveyersare dischargedintothe respective silothoughlogic
controls.There are a total of 16 silosatthe plantsite. Basedon customerdemandsthe product
can be packedintobagsand dispatched.

17. CAPTIVE POWER PLANT
The captive powerplantat the plantsite has a total capacity to produce 33.MW of electicity outof
which9MW is requiredforworkingof the plantwhereasthe excesspowerissuppliedtothe Tamil Nadu
ElectricityBoard[TNEB].For3 operationlinesthere isone watertube boilereach.The COgas whichisa
off gas tappedfromthe bag filterisfurtherburntinthe combustorto generate hightemperature CO2
whichisa flue gas.Thishotflue gas generatedismade topassoverthe watertubesinthe boilerand
steamisgenerated.The unitalsohousesa superheaterto furtherincrease the temperature of steam.
An airpreheatertoachieve efficientcombustionaswell asaneconomizertopreheatthe boilerfeed
water.These componentsincreasethe overallefficiencyof the boiler.
The superheated steamnowpassesthoughthe sheetmetal pipes intothe turbine unit.Turbine unitsare
controlledbyturbine governorwhichregulate the amountof inletsteam. Inletsteamhasa pressure of
48 Kg/cm2
andtemperature of 4150
C. The Turbine shaftiscoupledtothe Electricgeneratorsviaa
gearbox whichfacilitatedthe reductioninshaftspeed while increasingthe torque. There are atotal of
fourturbineswhose specificationsare aslistedbelow-
o 2.5 MW Turbine manufacturedbyTriveni Turbines,Bangalore.
o 6 MW Turbine manufacturedbyTriveni Turbines, Bangalore.
o 8 MW Turbine manufacturedbyTriveni Turbines,Bangalore.
o 17.2 MW Turbine manufacturedbyShinNippon,Japan.
The feedwaterusedisRO purifiedanddemineralizedbefore use inthe boiler.Almost95% of the water
usedinthe processis recovered.The condenserunitconsistsof 3Fan Cooledcondensersandone water
cooledcondenser. The cooledwaterispumpedbackintothe circuit. Afterthe heathasbeenextracted
fromthe flue gasesupto the maximumpossible extent,theyare letoff tothe atmosphere throughthe
boilerstacks.
Off gas

18. MASTERBATCH UNIT
Master Batch is the mostbasic componentof rubberusedespeciallyforthe productionof tires.Here,in
thisplantthe rubberand otheradditivessuppliedbythe customersare mixedwiththe carbonblack
producedonsite toobtainthiscompound. RubberCompoundMasterBatchesare a blendof rubber
polymersandcarbonblack alongwithotherrubberchemicalsandadditives.
These MasterBatches can be made by blendinganyrubberpolymerasa base like Natural Rubber/
SyntheticRubber/Butyl / EPDM etc. or in combinationof few of these.PetroleumderivativeCarbon
Black isusedas a reinforcingfillertoadd to the basicstrengthto the Polymer.Otheradditivessuchas
Stabilizersandadditivesare added alongtogeta properblendof anyrubbercompounded master
batches. The combinationusedinthisunitconsistsof 60% rubber,35% Carbonand 5% of Additives.
The above saidingredientsare blended&mixedtogetherinanadvanced&powerIntegratorsystem
that iselectronicallycontrolledinhighpoweredmixers.The ingredientsare addedinstageswithatime
and temperature basedmixingcycles,ensuringthe consistencyinweightsandinthe rightmixingtime
cycles& temperatures.A temperatureof 160 to 170 ismaintainedbythe exothermicreactionbetween
the ingredients.Thisensuresthe consistencyinthe batch-to-batchoperationsresultingina
Homogenousdispersionof all andtomake a qualitymix foruse inany desirednextstage of production.
Mixedrubbercompoundsare againblendedinanopenmill usingoverheadblenderstofurtherimprove
the Homogeneitytothe highestlevel,toachieve the bestmixedmasterbatchcompounds.The roller
millsalsoeliminategenerationof airbubblesorcavitydefectsInthe sheets.ThesemixedMasterbatch
compounds are dippedina compatible Anti tackliquid&cooledtoambienttemperature bysheeting
out ina continuoussheetform.The sheetsare of a uniformthicknessvaryingfrom6mmto 8mm
dependingoncustomerrequirements.
Figure 6 Master batch sheets

19. CONDITION BASED MAINTAINANCE TECHNIQUE
ConditionBasedMaintenance (CBM) isamaintenance strategythatusesthe actual conditionof the
assetto decide whatmaintenance needstobe done.CBMdictatesthat maintenance shouldonlybe
performedwhencertainindicatorsshow signsof decreasingperformance orupcomingfailure.Checking
a machine forthese indicatorsmayinclude non-invasive measurements,visualinspection,performance
data and scheduledtests.Conditiondatacanbe gathered at certainintervals,orcontinuouslyCBMcan
be appliedtomissioncritical andnon-missioncritical assets.CBMaimsat extendingthe machine life,
improvingproductivityandtakingmachine healthtonextlevel forthe lifetimeof equipment.This
Technique followedbythisplantincreasesthe safety,enhancesproductionandalsoreduces
maintenance expenditure inthe plant. Unlike inplannedscheduledmaintenance (PM),where
maintenance isperformedbaseduponpredefinedscheduledintervals,conditionbasedmaintenanceis
performedonlywhenitistriggeredbyassetconditions.Comparedwithpreventativemaintenance,this
increasesthe time betweenmaintenance tasks,becausemaintenance isdone onanas-neededbasis.
Benefits of ConditionMonitoring
o No surprise breakdowns
o Increased“uptime”
o Minimize maintenance resource
o Improvesequipmentreliability
o Improvesworkersafety
The 3 Phases of ConditionBasedMaintenance
o Surveillance - monitoringthe equipmentconditiontodetectdevelopingproblems
o Diagnosis- isolatingthe rootcause of the issue anddevelopingacorrective planbasedon
priority,equipmentconditionanditsremaininglife
o Remedy- performingthe corrective action.
TypesofConditionBasedMaintenance
o Vibrationanalysis – rotatingequipmentsuchascompressors,pumps,motorsall exhibita
certaindegree of vibration.Astheydegrade,orfall outof alignment,the amountof vibration
increases.
o Temperature gun. Noncontacttype of temperature measuringdevicetocheckthe temperature
of componentssuchasmotors,bearingsetc.
o Infrared – IR cameras can be usedto detecthightemperature conditionsinenergized
equipment.
o Acoustic - Usedto detectgas,liquidorvacuumleaks.

20. MANTAINANCEPRACTICES CONDUCTED DURING THEINTERNSHIP PERIOD
1. Maintenance of Process water pump-
Pump Specifications
o Model- WK65-4
o Type- Multistage with4 impellers
o Capacity- 45 m3
/Hr
o Speed- 2950 RPM
o Head- 168m
Actions Performed-
o LubricatingBall bearingatnon-drivenend
o LubricatingNU Type bearingonthe drivenend
o Lubricatingthe Flange Type coupling
2. Maintenance of Booster fan
The boosterfan isa device withforwardcurvedvane usedtoblow the CarbonBlack
enteringfromthe micro-pulveriserintothe pelletingunit.Itisconnectedtoanelectric
motor viaa gear couplingandPlummerBlockwhichhousesthe bearings.
Actions Performed-
o Changingof SS 500 oil lubricatingthe plummerblock.
o Checkingforconditionandclearance of Spherical rollerbearings.
o Checkfor conditionof Bolts
o Checkfor shaftalignment
o Lubricationof Gear couplingandcheckfor brokendebris
o Inspectionof blowercavityanddamage of impellers