This document provides information about Hindalco Industries Limited's reduction plant located in Renukoot, Uttar Pradesh, India. It includes a plant layout map and lists the primary products manufactured as primary aluminum, alloy ingots, billets, slabs, sheets, wire rods, doors, cans, and blister packs. The document consists of sections describing the crane, compressor, bath crushing, alumina transfer system, dry scrubbing system, and integrated control module at the reduction plant.

1. ON
REDUCTION PLANT
HINDALCO INDUSTRIES LIMITED
RENUKOOT, SONEBHADRA U.P
Guided by: Submitted by:
Mr. R.K Yadav Shivam Singh Chandel
(Senior Manager) Mechanical Engineering
Mr. Abhineet Singh Raj Kumar Goel Institute
(Assistant Engineer) Ghaziabad, U. P
1

2. N S
ASSEMBLY POINT MAIN GATE
ADM.OFFICE
BAUXITE FIRE
COAL TIPPLER
COAL YARD SEFTY&HRD
FIRST AID
WORK SHOP
Train. Cent.
WASHER CYOLITE POTROOM COMP.
AREA
STORE
TO MUD YARD PETROL PUMP
PLANT–I -STORE PROJECT DIV. GAS YARD
ASSEMLY POINT
LIME PLANT R–
DIGESTION BAUXITE
TIPPLER
1-ASSEMBLY
2- “
3- “
4-SAFETY OFFICE
5- “
6- “
7- “
8- “
I.T
DEP.
CARBON
PLANT
BF
BF
R
O
D
D
I
N
G
P
O
T
R
O
O
M
BFL
A
B
CANTEEN
DESIGN OFFICE
DISPOSAL
W
S
H
EGSC
GSC
PPT
QQ
BO
IL
ER
COGEN.
P
O
T
R
O
O
M
P
L
A
N
T
|
I
I
CASTER
C
O
L
D
M
I
L
L
B .FURNACE
CAST HOUSE
BULLET
CASTING
PLANT LAYOUT OF HINDALCO INDUSTRIES:
2

3. PRODUCT MANUFACTURED IN HINDALCO:
1. 2. 3.
Primary Aluminium Alloy ingots
Billets
Ingots
4. 5. 6.
Slab Aluminium sheet
Wire rods sheet
7. 8. 9.
Door Can
Blister Pack
3

4. Table of Contents
1. Preface
2. Acknowledge
3. Company Profile
4. Project Synopsis
5. Reduction Plant – II Details
6. Crane
7. Compressor
8. Bath – Crushing
9. Alumina Transfer System
(A.A.F.S/H.D.P.S)
10. Dry Scrubbing System (D.S.S)
11. I.C.M
4

5. PREFACE
In this era of globalization and liberalization of economy, the
technology is changing at a swift rate and in this process of revolution
one needs to keep up with the world to strive for excellence and to
meet the global standards.
Giving this due consideration practical training schedules have been
inducted in the curriculum of technical studies as they give a practical
exposure to the actual conditions, irrelevant of the field.
In this context I got an opportunity to undergo practical training of 30
days at Hindalco Industries Limited, Renukoot (U.P).
During the training I was asked to study about “Reduction Plant- II”
in details and it was a great experience for me working on this project
under the guidance of the professional’s.
5

6. Acknowledgement
I would like to take this opportunity to express my sincere thanks to
Hindalco Management and special thanks to our respected mentor Mr.
R. K Yadav (Senior Manager- Potroom Maintenance, for all the
guidance and support he provided me while this project was being
conducted.
I would like to thanks Mr. Abhineet Singh (Assistant Engineer) for
assigning me with the task and the valuable support he has provided to
me.
I would also like to thanks Mr. S.K. Das (G.M. Training Dept.
Renukoot), and other staff members for their help, support and
guidance they provided to us.
I would also like to thanks my maternal uncle Mr. D. K Singh who has
suggested me to do training in the worldwide renowned company
‘Hindalco’.
Last but not least I would like to thanks almighty God who has given
me strength to perform the task given to me. I would also like to thanks
my parents, my sister and brother in law, my teachers and friends and
all other member who is directly or indirectly related with this project.
6

7. HINDALCO – It is made by joining three words, when dissolved it
comes:
“HIND” – Hindustan,
“AL” – Aluminium (Since Al is the chemical formula of
Aluminium in Chemistry),
“CO” – Corporation
7

8. Lying in the foothills of the Vindhya Range, Renukoot is about 180 km
From Varanasi, and 300 km from Allahabad. It is well connected to
these cities by beautiful metallic roads passing through green forests.
Phone : (05446) 252077/8/9
Fax : (05446) 0252107
Email : hindalco.rkt@adityabirla.com
HISTORY OF HINDALCO:
Hindalco was set up in collaboration with Kaiser Aluminium and
Chemicals Collaboration, USA, in a record time of 18 months. The
plants started its commercial production in the year 1962 with a
capacity of 20,000 tonne per annum (TPA).
The company is managed by Board of Directors, with Shri Kumar
Mangalam Birla as the chairman of the Board of Directors. Day to day
affairs of the company is managed by a team of professionals
Executives headed by Shri Ratan Shah as the Director (Whole Time).
HINDALCO TODAY:
Aluminum has turned out to be the wonder metal of the industrialized
world. No other single metal can do so many jobs, so well, and so
economically.
Aluminum growth rate is the highest amongst the major basic
metals today. HINDALCO ranks as the largest Aluminium producer in
India, whose more than 58% sales is in value-added product and has
8

9. more than 40% in total market share. The company’s fully integrated
aluminum operations consists of the mining of Bauxite, conversion
of Bauxite into Alumina, production of primary aluminum from
Alumina by electrolysis and production of Properzi redraw rods,
rolled products, extrusions and value-added products like Foil and
Wheel at Silvasa. HINDALCO’s integrated operations and
operational efficiency have enabled the company to be one of the
world’s lowest cost producers of Aluminum. The company cost
efficiency has helped it to record on outstanding performance in the
face of adverse market conditions.
HINDALCO also owns a large captive THERMAL POWER PLANT
at Renusagar that meets the power requirement of the company very
effectively.
HINDALCO has embarked upon a Rs 18 billion brown field
expansion project which will Smelter capacity by 100000MTPA,
refining capacity by 210000MTPA, and captive Power Generation to
769MW in the year 2000, HINDALCO acquired Alcon’s 54.6
majority stake in another Indian aluminum major Indal. This was
followed by public offer for an additional 20% stake the
acquisition makes possible and excellent synergistic fit Indal.
Strength in Aluminum and downstream, products dovetail
admirably with HINDALCO strong presence in metal.
9

10. An ISO 9002 and 14001 certified company, HINDALCO achieved
significant export in the year 2001-02 & so on……., and is registered
on the London Metal Exchange. HINDALCO also has star trading
house status. HINDALCO products range includes Primary Aluminum,
Ingot, Alloy Ingot, Billets, Cast Slabs, Alloy Wire Rod, Sheet
Products, Extruded Profiles, Conform Products, Foil and Allow.
HINDALCO POLICY HIGHLIGHT:
Vision
To be a premium metals major, global in size and reach, excelling in
everything we do, and creating value for its stakeholders.
Mission
To relentlessly pursue the creation of superior shareholder value, by
exceeding customer expectation profitably, unleashing employee
potential, while being a responsible corporate citizen
Values
10

11. 11

12. HINDALCO INDUSTRY – OVERVIEW:
Type Product
Industry Metals
Founded 1958
Headquarters Mumbai, India
Area served Worldwide
Key people Kumar Mangalam Birla (Chairman)
Products Aluminum and Copper products
Revenue 750.77 billion (US$ 12.38 billion) (2013)
Operating Income 66.82 billion (US$ 1.12 billion) (2013)
Net Income 35.79 billion (US$ 599.19 million) (2013)
Total assets 589.32 billion (US$ 9.866 billion) (2013)
Employees 19,341 (2013)
Parent Aditya Birla Group
Website www.hindalco.com
MILESTONE OF HINDALCO:
Year Event
1958 Incorporation of Hindalco Industries Limited.
1962
Commencement of production at Renukoot (Uttar
Pradesh) with an initial capacity of 20,000 mtpa of
alumina.
1965
Downstream capacities commissioned (Rolling and
extrusion mills at Renukoot).
1967
Commissioning of Renusagar power plant.
1995
Mr. Kumar Mangalam Birla takes over as Chairman of
Indal Board.
12

13. 1998 Hindalco attains ISO 1401 EMS certification.
1999
Brownfield expansion of metal capacity at Renukoot to
242,000 TPA.
2000
Acquisition of controlling stake in Indian Aluminium
Company Limited (Indal) with 74.6 percent holding.
2001
Hindalco enters ‘The Asia Top 25’ list of the CFO Asia
Annual Report Survey, the only Indian company in 2001.
2002
Amalgamation of Indo Gulf Corporation Ltd. copper
business, Birla Copper, with Hindalco with effect from 1
April 2002.
2003
Scheme of arrangement announced to merge Indal with
Hindalco
Copper smelter expansion 250,000 TPA.
2007
Novelis became a Hindalco subsidiary with the completion
of the acquisition process.
2011
Refinance of Novelis debt US$4 billion to lend strategic
flexibility to grow.
Achieved financial closure of two projects through debt
financing – Utkal Alumina for Rs. 4,906 Crore and Mahan
Aluminium for Rs. 7,875 Crore.
13

14. SELF OWNED & JOINT VENTURE COMPANIES OF
ADITYA BIRLA GROUP:
 • Around 34000 workforce • 15 + nationalities

Key products and brands Locations Capacities Country
Hindalco Industries Ltd.
Alumina Chemicals Renukoot (Uttar Pradesh),
Muri (Jharkhand), Belgaum
(Karnataka)
1,160,000 tpa India
Primary Aluminium Renukoot, Hirakud (Orissa),
Mahan Aluminum
489,000 tpa
Extrusions Renukoot, Alupuram 27,700 tpa
Rolled products Belur(West Bengal),
Taloja(Maharashtra), Renukoot,
Mauda(Maharashtra)
200,000 tpa
Wire rods Renukoot, Alupuram(Kerala) 64,400 tpa
Indal (subsidiary of Hindalco)
Foil Rolling Kollur (Andhra Pradesh) 4,000 tpa
Key products and brands Locations Capacities Country
Birla Copper (Hindalco Industries Ltd.)
Copper cathodes Dahej (Gujarat) 500,000 tpa India
Continuous cast copper rods 97,200 tpa
Sulphuric acid 1,670,000 tpa
Phosphoric acid 180,000 tpa
Gold (Birla Gold) 15 mt
Silver (Birla Silver) 150 mt
DAP&complex(Birla Balwan) 400,000 tpa
14

15. Hindalco Industries Ltd. (Aditya Birla Minerals Resources Pty. Ltd.)
Copper cathodes Nifty mines 25,000 tpa Australia
Copper in concentrate Mt. Gordon mines 40,000 tpa Australia
Power Mt. Gordon mines 28MW Australia
Key products and brands Capacities Country
Grasim Industries Ltd.
White cement Birla White 475,000 tpa India
Grey cement UltraTech
Cement (formerly
Birla Plus), Birla
Super
13.12 mtpa
UltraTech Cement Ltd.
Ordinary Portland cement, Portland
Blast furnace slag cement, Portland
Pozzolana cement and grey
Portland cement
17 mtpa
Key products and brands Capacities Country
SKY INVESTMENT PVT LTD
Carbon black Birla Carbon 84000 mtpa India
Thai Carbon Black Co. Ltd.
Carbon black Birla Carbon 220,000 mtpa Thailand
Alexandria Carbon Co. S.A.E
Carbon black Birla Carbon 285,000 mtpa Egypt
Liaoning Birla Carbon Co. Ltd.
Carbon black Birla Carbon 55,000 mtpa China
15

16. key products and brands Capacities Country
Pulp
Grasim Industries Ltd.
Rayon grade pulp 70,000 tpa India
AV Cell Inc.
Softwood / hardwood pulp 122,500 tpa Canada
AV Nackawic Inc.
Dissolving pulp 189,000 tpa Canada
Fibre
Grasim Industries Ltd.
Viscose staple fiber (VSF) Birla Viscose 270,100 tpa India
Thai Rayon Public Company Ltd.
VSF Birla Viscose 110,000 tpa Thailand
PT Indo Bharat Rayon
VSF Birla Viscose 155,000 tpa Indonesia
Thai Acrylic Fibre
Acrylic fiber Texlan 100,000 tpa Thailand
Alexandria Fiber Company, S.A.E
Acrylic fiber 18,000 tpa Egypt
Yarn
Viscose filament yarn Ray One 16,400 tpa India
SKY INVESTMENT PVT LTD (Jaya Shree Textiles)
Flax yarns 15,340 spindles India
Worsted yarns 25,548 spindles
PT Indo Liberty Textiles
Rayon yarn, polyester,
Blended yarn
45,120 ring spindles Indonesia
PT Elegant Textile Industry
Rayon, polyester, rayon-
Polyester blended spun
Yarn
168,088 spindles Indonesia
PT Sunrise Bumi Textiles
Viscose rayon, polyester viscose, spun polyester,
Polyester combed cotton, anti pill yarn, sewing
Thread, high twist yarn, reverse twist yarn, flame
Retardant yarn, rayon cotton blended yarn, micro
Denier polyester rayon yarn, rayon silk yarn, slub
Yarn, lycra core spun yarn
89,376 spindles Indonesia
16

17. Indo Phil Acrylic Manufacturing Corporation
High bulk acrylic dyed yarn, non-bulk acrylic dyed
yarn
3,700 mtpa Philippines
Indo Phil Textiles Mills Inc
Poly viscose blended yarn, poly cotton blended yarn,
Polyester yarn
13,500 mtpa Philippines
Indo Phil Cotton Mills Inc
Cotton yarn 10,000 mtpa Philippines
Indo Thai Synthetics Co. Ltd.
Synthetic yarns 98,568 spindles Thailand
Fabrics
Grasim Industries Ltd.
Fabric - polyester, viscose, silk and wool blends 146 looms India
Uncrushables, Ice Touch, Purista, and CleanFab 18 million meters
SKY INVESTMENT PVT LTD
Pure Linen and Linen
Blends
Linen Club 107 looms India
Flame Retardent Fabrics Pyroguard
Branded apparel
SKY INVESTMENT PVT LTD (Madura Garments)
Ready-to-Wear Garments Louis Philippe,
Allen Solly
Van Heusen, Peter
England
India
Key Products and Brands Capacities Country
Indo Gulf Fertilisers Ltd.
Urea Birla Shaktiman 864,600 mt India
Birla Copper (Hindalco Industries Ltd.)
DAP/NPK complexes Birla Balwan 400,000 tpa India
Key Products and Brands Capacities Country
Grasim Industries Ltd.
Caustic Soda 258,000 tpa India
17

18. SKY INVESTMENT PVT LTD
Caustic Soda 82,125 tpa India
Liquid Chlorine 50,340 tpa
Hydrochloric Acid ,475 tpa
Tanbac Industries Ltd.
Aluminium Fluoride 17,000 tpa India
Hydrofluoric Acid 17,000 tpa
Bihar Caustic and Chemicals Ltd.
Caustic Soda Lye 92,750 mt India
Liquid Chlorine 65,785 mt
Hydrochloric Acid 29,040 mt
Sodium Hypochlorite 1,800 mt
Compressed Hydrogen 17,42,400 nm3
Aluminium chloride 12000 tpa
Captive Power Plant 30 MW
Aditya Birla Chemicals (Thailand) Ltd.
Sodium Triployphosphates,
Tetrasodium Pyrophosphate,
Sodium Hexametaphosphate,
Sodium Acid Pyrophosphate,
Monosodium Phosphate,
Disodium Phosphate,
Trisodium Phosphate,
Speciality Phosphates
Epoxy Resins (bis-a and bis-f),
Diluents, Curing Agents
and Allied Products
Sodium Sulphite, Sodium
Metabisulphite,
Sodium Bisulphate
Epichlorohydrin
Caustic Soda
Chlorine
Polyphos®
Epotec
Birlasulf-SS,
Birlasulf-SM,
Birlasol 35
Thailand
Thai Peroxide Co. Ltd.
Hydrogen Peroxide, Peracetic
Acid, Calcium Peroxide
Encare, Ecare,
Aqua-x,
Birlox 5,
Birlox 12,
Ocare
15,000 mtpa Thailand
PT. Indo Raya Kimia
Carbon Disulfide 50,000 tpa Indonesia
18

19. Key Products and Brands Capacities Country
Essel Mining & Industries Ltd
Iron and Manganese Ore 15 million tons India
Key Products and Brands Capacities Country
Pan Century Surfactants Inc.
Fatty Acids 55000 mtpa Philippines
Fatty Alcohol 30000 mtpa
Glycerin 6500 mtpa
Key Products and Brands Capacities Country
Aditya Birla Insulators
Insulators 38,800 tpa India
Key Products and Brands Capacities Country
PSI Data Systems Ltd. (subsidiary of Aditya Birla Nuvo Ltd.)
IT solutions (banking, finance and insurance) India
Key Products and Brands Capacities Country
Aditya Birla Minacs Worldwide Limited (subsidiary of Aditya Birla Nuvo Ltd.)
BPO / ITES 9,089 seats India
19

20. Key Products and Brands Capacities Country
Birla Global Finance Company Ltd.
Financial Services India
Birla Sun Life Insurance Company Ltd.
Insurance Solutions India
Birla Sun Life Asset Management Company Ltd.
Mutual Funds India
Birla Sun Life Distribution Company Ltd.
Investment Planning Services India
Birla Insurance Advisory Services Ltd.
Non-Life Insurance Advisory Services India
Key Products and Brands Capacities Country
Idea Cellular
Cellular Services Idea 21 million subscriber base India
Key Products and Brands Capacities Country
Aditya Birla Retail Limited
Multi-Format stores 170 retail outlets India
20

21. REDUCTION PLANT – II DETAILS
Aluminium (Al) is usually produced by decomposing Alumina
(Al2O3) dissolved in a bath of molten Cryolite (Na3AlF6) by means of
an electric current. The molten mass lies in the Crucible Box lined
with Carbon, where the lining acts as cathode. The anode is also made
of carbon and is fed down into the molten mass from above. Metal is
produced by Alumina being dissolved in the molten salt and
decomposed, thus enabling the Al
3+
ions to migrate to the cathode
where they are supplied with electrons and they are reduced to
elementary metal on contact with the cathode. Point Feeder is used for
feeding additives such as Aluminium Oxide or Fluoride to
Aluminium electrolysis cells. The additives are fed to the electrolytic
bath of the cell through a hole in the bath crust, which hole is made by
means of a centre punch.
The process used in Reduction Plant is ‘Hall-Herault Process’. There
are two design principles for Hall-Herault Process. Thus, the
electrolysis cells can be provided with self-baking anodes, then so
called ‘Soderberg Anodes’, which are continuous, or with readily
baked anodes of carbon, so called pre-baked anodes, which have to be
exchanged during the electrolysis process as they are generally
consumed.
The electrolytic bath comprises Aluminium Oxide dissolved in melted
Cryolite with the small amount of additives, basically Aluminium
Fluoride (AlF3) and Calcium Fluoride (CaF2). During the
electrolysis process, the Aluminium Oxide is used as it is decomposed
to Oxygen, which immediately reacts with Carbon of the anode, and
Aluminium, which due to the gravitational force to the bottom of the
cathode. The other additives are to some extent also used, and to
maintain the chemical balance in the electrolytic bath, new additives
have to be supplied to replace the ones being consumed.
21

22.  Potroom Mechanical Maintenance:
• Point Feeder
• Fume Treatment Plants ( D.S.S)
• Crust Breaker
• Crane (Electric Overhead Crane)
• Automatic Alumina Feeding System (AAFS)
• Belt and Conveyor
• General Maintenance
 Hindalco Renukoot Unit Is broadly
classified into following main plants:-
• Alumina Plant: The raw material, Bauxite (Al2O3.3H2O) is
converted to Alumina (Al2O3) by ‘Bayer’s Process.’
• Reduction Plant: Alumina is taken as input and is reduced to
Aluminium in Smelter Pots by ‘Hall-Herault’s Process’.
2 Al2O3 + 3C  4Al + 3CO2 (960°C)
(Dissolved) (Solid) (Liquid) (Gas)
Aluminium is deposited at cell bottom. Some Al gets dissolved in
the electrolyte
• Fabrication Plant: The Aluminium produced in the smelter plant
is fabricated into finished goods (like heat sinks, roofing sheets,
checkered sheets etc.) or semi-finished goods (like coils, wire
rods, circles etc.).
22

23. CRANE
• Crane: It is equipment used for material handling in the industry
and organization.
• Types of Crane: It is basically of three types:-
1. Electric Overhead Travelling (E.O.T) Crane.
2. Mobile Crane (e.g. Fork Lift).
3. Jib Crane.
• In Hindalco Industries, Electric Overhead Travelling (E.O.T)
Crane are widely used.
• E.O.T Crane:
The crane moves on the gantry rails, fixed on top of the gantry
girders. In this type generally three motions are incorporated,
namely Hoist, Cross Traverse and Long travel. At times
according to the customer’s requirement Auxiliary Hoist and
micro motion are also incorporated. The Hoist and Cross travel
machineries are fitted on a common frame called the “Crab or
Trolley” which moves on rails fixed on the Crane Girders.
• Main Parts of the E.O.T Crane:
1. Long Travel (Bridge): This type of crane travel takes place in
horizontal direction for over a long distance.
2. Cross Travel (Trolly): This type of travel takes place on crane to
move load from one end to other on crane itself.
23

24. 3. Hoist Travel (Hoist): This type of travel is used for uplifting and
lowering of load vertically upto a desired height (not more than
12.8 meter).
• According to Bridge Drive:
1. Single Motor Drive Crane.
2. Double Motor Drive Crane.
• Major Parts of E.O.T Crane:
1. Long Travel Drive Mechanism.
2. Trolly Assembly.
3. Bridge Girders.
4. End Carriages.
5. Platforms.
6. Operator’s Cabin.
7. Trolly Power Supply Arrangement.
• Advantages of E.O.T Crane:
1. They eliminate the need for wide passages and do not block any
space at ground level.
2. They cover the entire working area without limiting the layout.
3. Operating costs are very low, since it needs only one operator,
require very little maintenance and consumes a very little electric
power.
24

25. • Brakes in E.O.T Crane:
1. Bridge : Foot Operated Hydraulic Brake.
2. Trolly : NIL.
3. Hoist : D.C Electro Magnetic Brake.
• Safe Working Load (S.W.L) of E.O.T Crane:
Weight: 7.5 Metric Tonne
Height: 12.8 Meter
• Power Supply In Crane:
415 Volt 3 Phase Power Supply
Crane moves on ‘Current Rail Path (C.R.P)’.
• The following are the given capacity and drive of cranes fitted
in various lines of Reduction Plant:
Pot Line Makers Safe Working
Load
Drive
Line 1 P & H 6.0 MT Single Drive
Line 2,3 P & H 7.5 MT Single Drive
Line 4 A.C.C 7.5 MT Single Drive
Line 5 W.M.I 7.5 MT Double Drive
Line 6 to 11 MUKAND 7.5 MT Double Drive
B/F # 1 to 3 W.M.I 6.0 MT Double Drive
B/F # 4 CIMMCO 6.0 MT Double Drive
Maintenance W.M.I 7.5 MT Single Drive
25

26. Area
• To avoid electric spark in Potroom Cranes, Hook insulator in
bottom block assembly are used. So ‘Thrust Ball Bearings’ are
used in Hook Insulator.
• Hoist Maximum Lift:
1. Line 4 5.0 MTR.̶
2. Line 5 to 8 5.8 MTR.̶
3. Line 9 to 11 6.1 MTR.̶
4. B/F # 4 4.9 MTR.̶
 Wire Rope:
• Wire Rope Material: Ungalvanized Steel.
• Wire Rope Construction:
16 mm is diameter of one string of wire.
19 string is aligned together to make one core, and
6 core combines together to form one wire rope.
Length of wire rope varies from 38 – 48 MTR, depending on use.
Line 4 16 mm Diameter * 6 * 19 * 38 MTR̶
Line 5 to 8 16 mm Diameter * 6 * 19 * 42 MTR̶
Line 9 to 11 16 mm Diameter * 6 * 19 * 48 MTR̶
B/F # 4 - DO -̶
Maintenance Area 16 mm Diameter * 6 * 19 * 38 MTR̶
• Ultimate Tensile Strength ̶ 180 MPa.
• Breaking Strength 16500 kgs.̶
26

27.  Hook Material:
Fully Killed Low Carbon Steel
EN – 3ASIS; 1875 Grade 2
1. Original opening of hook is 78 mm (allowable opening of hook is
10%of the original opening =7.8mm. so max. hook opening
85.8mm is allowable)
2. hook thickness is 105 mm (max wear is 10% i.e.10.5mm
allowable)
 Pot Room Crane Speed:
• Bridge Speed : 122 MTR/MIN
• Trolley Speed : 58 MTR/MIN
• Hoist Speed : 12.8 MTR/MIN
 Procedure to Start the Crane:
1. Check Crane and craneway for any obstructions.
2. Release all ‘locking device’.
3. Check that parts needing lubrication have required quantity of
lubricants.
4. Ensure that no item is lying loose on the crane and the trolly.
5. Check for neutral position of all ‘control gears’.
27

28. 6. Switch on the ‘Crane protective gear’.
7. Check signals and wiring devices.
8. Check ‘brake and limit switches’ for their proper functioning.
 Procedure to Stop the Crane:
1. Run empty hook and the trolly to the specified resting position.
2. Run Crane to the access point.
3. Set the ‘master controllers’ in neutral position.
4. Switch off lights.
5. Press the OFF push button provided in the cabin/pendent.
6. Switch OFF the isolating switches.
7. Actuate locking devices if any.
8. Lock ‘Operator’s cabin’.
 Precautions on Use of Crane:
1. Make sure of the operation of safety device before hand.
2. Do not load beyond the ‘safe working load’.
3. Do not use crane beyond it’s designed ‘duty cycle’.
28

29. 4. Do not use Crane in lower notches of master controller for long
period.
5. Do not use creep speed for continuous/long operation. The creep
speed is only for spotting the load.
6. Avoid quick ‘deceleration’.
7. At the end of shift, inspect the crane and prepare for the next
shift.
 More details about E.O.T.Crane maintenance:
Wheel Wear
Due to presence of aluminum in the atmosphere the wear on the wheel
tread is rather fast. Whenever there is wear, the worst about it is that
there is unequal wear on specially the two side driving wheels. This
results in unequal diameter on two sides of the crane. If a crane with
unequal diameters diameter runs, it is likely to get tilted. As a distance
covered increases the tilt also would increase but, the crane runs on
wheel collars and this result in undue collar wear. The tilting of crane
is called “Crossing of Crane”.
29

30.  Reason For Crossing of Cranes Leading
To Frequent Shoe Out :
1. Unequal wheel wear specially in lines 1,2,3 and 4 where we have
single motor drive. Wherever there is a wear, it is unequal wear
and there is crossing of the crane. We have seen that difference of
more than 1.5 mm causes jamming, shoe out etc. due to crossing
of cranes.
2. Loose driving shaft keys/keyways or excessive play in the geared
couplings will cause jerky start on one side and causes crossing
of the cranes.
3. Excessive dusting in the pot room also causes crossing of the
crane.
4. Damaged bearings of the bridge drive gear box causes crossing of
the cranes.
5. Defective rail or rail joint with unequal gap at to ends may cause
crossing of the cranes .difference in heights of the rail at the joint
may also cause crossing of the cranes.
6. Failure of the rail /crane girder holding to the main roof columns
causing the crane girder to bend horizontally or vertically may
also lead to crossing the cranes.
7. Misalignment of the wheels may also leads to crossing of the
cranes. The problem is most when the wheels are changed for
maintenance purpose.
30

31.  General Checking In Pm:
• Oil Level, Oil Leakage & Base Bolt Of Gear Boxes
• Brake Drum & Brake Unit Of Hoist & Bridge
• Foot Brake (Master Cylinder)
• Wheels, Bearing & Housing
• Base & Coupling Bolt Of Motor
• Coupling & Coupling Bolts Of All Shaft
• Rope Drum & Rope
• Bumper Block & Stopper
• Hoist & Bridge Lever & Controller
• Base & Coupling Bolt Of Motor
• Coupling & Coupling Bolts Of All Shaft
• Rope Drum & Wire Rope (If 10 Wire Broken In 01 Ft Of 6/19 Wire
Rope)Then Wire Rope Should Be Changed
• Hoist & Bridge Lever & Controller
Pantograph/Shoes & Flexible
 Main Problems occurred in the Crane:
1. Current Rail Path (C.R.P) Tripping Trouble.
2. Collector Shoe out Trouble.
3. Bridge Jamming Trouble.
4. Hoist Brake Slipping Trouble.
5. Foot Brake Trouble.
6. Wire Rope Sparking.
31

32. 7. Hook Insulator Sparking Trouble.
8. Hook Jamming Trouble.
9. Wire Rope Broken Trouble.
10. Trolly Derailment.
 Cause of C.R.P Trouble:
1. Collector Shoe out.
2. Defective C.R.P Joints.
3. Crossing of Crane.
4. Misalignment of Pantograph.
5. Defective Track Rail Joints.
 Some Important information regarding
Crane:
• We change ‘roller wheel’ of Crane with the help of jack.
• The material used in roller wheel is of ‘Mild Steel’.
• ‘Slip Ring Induction Motor’ is used to drive the rope attached
with hook.
32

33. • Every motor of a Crane has a specific designation by which it is
differentiated.
e.g 15 C 300
15 – Horse Power.
C – Pole.
300 – Motor Number.
• In Hindalco industries the motor used is of ‘C Pole’.
• When Motor has some problem then for its repairment it is send
to ‘Electrical Repair Shop (E.R.P) Department’.
• In E.O.T Crane 4 wheels are mounted.
Two wheels are ‘Supporting Wheel’.
Two wheels are ‘Idler Wheel’.
And Power is always given to Idler Wheel.
• Formula to calculate the speed of motor:
Speed (N), rpm = 120 * f/P
Where, f = frequency, (50 Hz)
P = Number of Poles (6)
33

34.  Some Important Questions related to
Viva and Interview:
• Why only D.C Electromagnetic Brake is applied on Hoist
Travel, why not A.C?
∗ We all know that Alternating Current (A.C) is in pulsed form
and it has variations, sometime it is positive for short time it is
zero and then negative. This will lead to the up and down motion
of hook even after application of brake which can cause serious
injury and accidents in industry, so this is reason why we use
Direct Current (D.C).
• How does E.O.T Crane moves?
∗ In Crane no any wire is attached then also it moves and this is
possible due to ‘Current Rail Path (C.R.P)’ which have three
phase and is attached with platform and provide it supply of
current on which Crane moves.
• What are Lubricant applied in Wire Rope and Roller Wheel?
∗ ‘Servomess 175’ lubricant is used in Wire Rope.
‘Grease’ is used as lubricant in Roller Wheel.
34

35. COMPRESSOR
• Compressor supplied to Hindalco Industry is by ‘K.G
KHOSLA Compressor Limited’.
• Intercooler:
Pipe Length – 135 cm
Pipe Outer Diameter – 192 m/m
Pipe Inner Diameter – 185 m/m
• Aftercooler;
Pipe Length – 135.7 cm
Pipe Outer Diameter – 252 m/m
Pipe Inner Diameter – 237 m/m
 General Description:
‘KHOSLA – CREPELLE’ air compressors are of double acting
horizontal crosshead type and are built in one, two and three
rows. Each row consists of two opposed cylinders. The
compressor is driven by an ‘Electric Motor/Diesel/Turbine’
through V-Belts or Direct drive.
Each row has two crankpins arranged at 180°. This type of
compressor is balanced because two pistons of each row move in
opposite direction. The primary and secondary component forces
nullify each other and suppress all possibilities of vibration. The
efforts of each opposing crankpin are equal and create an axial
couple without reaction on the bearings.
35

36.  INTRODUCTION:
∗ Compressors are machines designed for compressing air or gas
from an initial intake pressure to a higher discharge pressure.
 APPLICATIONS:
Compressors are used in wide variety of applications as follows:
• For operating Instruments
• For operating Pneumatic Tools, gates, damper through
• Pneumatic cylinder.
• It is substitute for Steam, electricity in operating tools, drills etc.
• For agitation of Liquid in tanks.
• For burner firing through atomization.
 CLASSIFICATIONS OF COMPRESSORS:
1. Reciprocating
2. Rotary Vane
3. Screw
4. Turbine
5. Centrifugal
∗ Single Acting, Double Acting, Single Stage, Multi stage, Two
Stage, Single Cylinder, Multi Cylinder, Water Cooled, Air
Cooled, Electrical, Diesel, Gas, and Steam.
36

37. 37

38. 38
AIR FLOW IN RECIPROCATING COMPRESSOR
L.P. Cylinder
L.P. Piston
Piston Rod
Crank Shaft
Cross
Head
Connecting
Rod
Crank
Case
H.P.
Cylinder
H.P. Piston
Inter Cooler

39.  MAIN PARTS OF RECIPROCATING COMPRESSORS:
• Crank Case: Heavy duty grain cast iron frame. It also serves as
lubricating oil reservoir.
• Crank Shaft: Made of drop forged steel is provided with bolted
counter weights.
• Connecting Rod: Made of nodular gray iron or forged alloy
steel and are provided small & big end bearing.
• Cross Head: Made of nodular gray iron and is designed to
ensure true running of piston rod.
• Cylinder: Made of graded close grain cast iron. These are
provided with water jackets to ensure efficient cooling of the
surface that comes in contact with hot compressed air.
• Piston: Made of nodular gray iron or high grade aluminum alloy
& having the same weight i.e. L.P Piston hollow & H.P Piston
solid.
• Oil Pump: Gear pump is driven from the free end of crank shaft
for lubrication of parts.
• Inter Cooler: It is device for removing the HEAT OF
COMPRESSION of the air between consecutive stages of
multistage compressors.
• After Cooler: These are meant for removing the heat of
compression of the air after Compression is completed. These are
also used for removing moisture from compressed air.
• Air Receiver: It is used to store the air and help to eliminate
pulsation in the discharge line.
• Valves: Each cylinder is provided two suction & two delivery
valves for the upper and lower compression. The Valve is opened
and closed by means of the pressure difference occurring in the
cylinder.
39

40.  Details of Equipment:
1. Name of Equipment – KHOSLA Compressor (1 No to 6 No).
2. Year of Installation – 1991.
3. Manufacturer – M/S K.G KHOSLA Comp. Ltd.
4. Capacity/Speed – 1070 CFM/970 RPM.
5. Model – 2 HA 4 TER.
6. Type – Reciprocating Horizontal Balanced
7. Discharge Pressure – 7.0 kg/cm2
.
8. Load/Unload Pressure – 4.5 kg/cm2
, 6.0 kg/cm2
.
9. Inter Stage Pressure – 1.2-2 kg/cm2
.
10. Intercooler/Aftercooler – Water from shell, Air from Tube.
11. Low pressure cylinder diameter – 310 mm ¢ * 2.
12. High pressure cylinder diameter – 185 mm ¢ * 2.
13. Piston Ring Quantity (L.P) – 02Cast Iron.
14. Piston Ring Quantity (H.P) – 03Cast Iron.
15. Cylinder/Valve – Lubricated.
16. Oil Used – Servosystem – 121.
17. V-Belt Size/Quantity – D-238/11 Nos.
18. Motor Power/ Motor Speed – 250 H.P./1400 R.P.M.
19. Motor Type – Induction.
∗ CFM – Cubic Feet per Minute.
R.P.M – Revolution per Minute. *
 Single Stage Compressor:
Each cylinder is fitted with ‘suction and delivery valve’. The
suction air filters are mounted on both the cylinders, so that air
can enter at both ends of the piston during the forward and
backward stroke. As the piston is moving in the cylinder, quantity
of air sucked at the front side is compressed to the required
pressure when the piston travels towards the front end cover and
40

41. similarly when the piston moves towards the rear end of the
cylinder.
After compression the air passes to the header (if fitted), through
the delivery valve. The header works as an auxiliary air
receiver, thereby the temperature of air is reduced to some extent
and pulsations are damped. Finally, air passes to air receiver or
delivery pipe line.
 Two Stage Compressor:
After compression, the air from the first stage cylinder passes
through delivery valve to the water cooled heat exchanger
provided in between the first and second stage. There it is cooled
very near to the atmospheric temperature and is sucked by the 2nd
stage through the suction valves. In the second stage cylinder the
air is compressed again to the required pressure and then to the
Aftercooler, if provided and finally to the air receiver.
In compressor having more than two stages the air from the
second stage enters the next intercooler and a similar operation as
stated above is repeated till the air reaches to the final stage. It is
passed to the Aftercooler, if provided and finally to the air
receiver.
 Centrifugal Air Compressor:
The ‘Centac Compressor’ is designed to provide oil free
compressed air. The atmospheric air being compressed via
suction filters enters the compressor through the machine
mounted inlet control device and flow to the first stage where
impellor imparts velocity to the air. The gas proceeds to the
stationary diffuser section that converts velocity to pressure. The
built in air cooler removes the heat of compression and the air
41

42. then passes through the moisture separator in a low velocity zone
to remove condensate. This process continues in all subsequent
stages.
 DESCRIPTION:
 The Centac compressor is a centrifugal compressor driven by an
electric motor. The compressor and driver are direct coupled.
The Compressor Contains:
• A main driver that directly drives a bull gear that is common to
all stages.
• Compression stages consisting of an impeller mounted on its own
shaft, enclosed with in a common cast iron casing.
• Rotors consisting of an integral pinion gear driven at its optimum
speed by a common bull gear.
• An intercooler that is mounted after stage of compression.
• A moisture separator and a moisture removal system are fitted
after each cooler to remove condensate.
 CENTAC Compressor Details:
1. Manufacturer – Ingersoll Rand (I) Pvt. Ltd.
2. Number – Comp # 20, 21, 22.
3. Equipment – “CENTAC” Centrifugal Compressor.
4. Model – C55MX3EXT.
5. Drive – Electrical Motor.
6. Stage – Three.
7. R.P.M – Stage 1– 39,000, Stage 2 – 44,000
8. Type – Centrifugal.
9. Capacity – 6092 CFM.
10. Discharge Pressure – 7.0 kg/cm2
.
42

43. 11. Intercooler/Aftercooler – Air through Shell, Water through
Tube.
12. Tube Specification – Copper, with 5/8” O.D * 18 DWG.
13. Type of Lubricant – Servoprime-32.
14. Oil Pump (2 Nos) – Pre oil pump & Main Oil Pump.
15. Air Filter – Primary, Secondary (6 Nos.).
 Motor Side:
1. Manufacturer – BHEL (Bhopal).
2. Frame Size – 1LA 7636-2.
3. Applicable Standard – IS 325-1978.
4. Type – Induction Motor.
5. Service – Outdoor.
6. Duty Cycle – Continuous.
7. Rated Power – 950 kW.
8. Ambient Temperature – 55°C.
9. Rated Speed – 2978 R.P.M.
10. Rated Voltage – 6600 V ± 10.
11. Rated Frequency – 50 Hz ± 5.
12. Full Load Current – 96.6 Ampere.
13. No Load Current – 21.9 Ampere.
14. Efficiency – 95 %.
15. Total Weight – 5300 kg.
 Compressor Operating Parameters:
1. Inlet Cap – 6092 ICFM.
2. Discharge Pressure – 7.0 kg/cm2
.
3. Discharge Pressure Oil Filter – 0.3 to 0.8 kg/cm2
.
4. Seal Air Pressure – 0.5 to 1.8 kg/cm2
.
5. Instant Air Pressure – 4.2 to 8.4 kg/cm2
.
6. System Oil Pressure – 1.8 to 2.1 kg/cm2
.
7. System Oil Temperature – 43°C to 46°C.
43

44.  Cooling Water:
1. Pressure – 2.5 to 5.0 kg/cm2
.
2. Temperature – 28°C to 30°C.
3. Pressure Drop, Temperature Rise – 0.7 kg/cm2
, 8.3°C.
4. Vibration Stage – 0.05 to 0.50.4
5. Stage 3rd
Temperature – 40°C ± 10.
6. Motor Wind, BRG Temperature – 90°C ± 10, 70°C ± 10.
 Compressor Parts:
• Rotor Assemblies
• Bearing
• Seals
• Diffusers
• Intercoolers
• Moisture Separators
• Vibration Probes
• Casing
• Compressor Driver
• Lubrication System
1. Diffusers: A diffuser, located between each impeller and cooler,
converts velocity energy to pressure energy.
2. Intercoolers & After coolers: The coolers are donut type, with
water over tubes and oil in shell.
3. Moisture separators: The moisture separator is a SS mesh
screen type construction located at points in the air compressor
where air velocities are relatively low permitting efficient
moisture separation.
44

45. 4. Vibration Probes: A non contacting vibration probe is mounted
on each stage next to the plain bearing to measure vibration of
each rotor assemblies. Each probe is connected to a vibration
transmitter.
5. Casing: The gear case consists of a casing and casing cover
jointed vertically by bolted assembly which is opened for
servicing the bull gear and its bearings.
6. Rotor Assemblies: Each rotor consists of an SS impeller and a
removable thrust collar mounted on a helical geared pinion shaft
each secured to the shaft by polygon splines, eliminating the need
of keyways.
7. Bearings: Each rotor assembly is equipped with a thrust bearing
near impeller and a plain journal bearing, Babbitt lined, near bull
gears for radial loads.
8. Seals: A single cartridge seal is mounted in the plain bearing
house behind each impeller. Each cartridge consists of three, one
piece, fully floating non contact carbon rings. One ring is used as
an air seal and the remaining two as oil seals. Buffer air is
supplied to the oil a seal assuring that lube oil is not drawn past
the seals, thus ensuring oil free air.
 Compressor Efficiency:
∗ Factors effecting the Compressors efficiency:
• Leaky Valve
• Too large piston ring gaps
• More clearance between cylinder and piston
• Leakage at piston rod
• Inadequate inter stage cooling ( inter cooler plugged)
• High Inlet air temp.
• Low water pressure
• High inlet water temp.
• Speed is less ( Prime mover)
45

46. • Chocking of Suction filter
• After cooler ineffective
• Moisture separator is not working properly ( moisture in air)
 Air Conservation/Efficient Air System:
• Inter cooler & after cooler must be perfect and to be cleaned
periodically.
• Threaded connections are to be avoided in air system.
• Tapping in air lines, receiver outlet should be from top to avoid
water moisture carry over.
• Auto drains are to provide for drain.
• Globe valves should never be used in air system as pressure drop
is very high. In 1” ø gate valve pressure drop is 1.14 ft of used
pipe where as in 1” ø globe valve is 30 ft of used pipe.
• Hydraulic testing of Receiver should be done on every year at 1.5
times the safety valve setting.
• Flow meters are to provide in air lines to control the air
consumption.
• The co lour coding of air lines are essential.
• Cleaning operation should be done with 30-40 psi air pressure
only to save air consumption. Pressure regulations are to be
provided.
• 1/2” ø pipe releases 308 cfm at 70 psi
• 1/2” ø pipe releases 200cfm at 40 psi
• Efficiency, flow measurement of compressors.
 Ratio of Compression: The rates of initial volume
to the final volume.
∗ Cylinder Ratio: r = P3 / P
Where r = Ratio of Compression
46

47. P3 = Absolute discharge pressure in psi
P = Atmospheric pressure in psi
∗ Inter Cooler Pressure: P1 = P X P3 / P – P
∗ Pressure Drop in Line: LV2
R x d5.3
x 35000
L = Length of Pipe in ft, V = Volume of free Air in CFM
R = Ratio of Compression, d = I D Of Pipe in ft
∗ Piston speed: 2 x Stroke length x rpm ; 12 Ft/min
∗ Displacement: It is the volume swept through by the piston with
proper deduction for the piston rod, Unit -CFM.
• Normal velocity in compressed air piping = 20 ft/ sec Max.
∗ Effect of Comparative pressure on Power Cost - Cost of air
generation is 7 % less at less at 6 kg / cm2
than at 7 kg / cm2
.
∗ Unloading Power of compressors in comparison to full load:
Unloading Power consumption should be 15 % to 18 % of full
load.
• Cost of air generation in Alumina Plant Rs. 5. 20 approx.
(Calculated.)
• Intake air temp. Decreases 3 degree C & due to this increase in
volume delivered by 1 %.
47

48.   Procedure to Start the Compressor:
1. Check that cooling water valve is opened.
2. Check for cooling water inlet pressure to be in between 2.5
kg/cm2
to 5.0 kg/cm2
.
3. Check for the difference in between inlet and outlet cooling
pressure and that should lie in between 0.8 kg/cm2
to 1.0 kg/cm2
.
4. ‘Sealed air pressure’ should be approx 0.5 kg/ cm2
.
‘Instrument pressure’ should be in between 4.25 to 8.5 kg/cm2
.
5. Check level of oil in oil receiver and ‘Motor Bearing Indicator’.
6. Start pressure lubrication pump with the help of ‘control button’
and maintain oil pressure near about 2.0 kg/cm2
.
7. Oil temperature should be in between 35°C to 50°C.
48

49. 8. Ensure that inlet valve is closed and ‘bypass valve’ is in open
stage and drain moisture with the help of ‘Moisture Drain
Valve’.
9. With the help of ‘Start Push Button’ start the compressor in
unload direction and ensure that oil pressure and temperature is
correct.
10. In every stage check ‘bypass’ situation and with the help of
‘load push button’ bring compressor in load condition.
11. At every cooler note the temperature of water and ensure
that in between inlet and outlet, temperature difference should not
be greater than 8.0°C.
12. Check the flow of ‘discharge air’ from the compressor.
 Procedure to Stop the Compressor:
1. With the help of ‘unload push button’, unload the compressor.
2. With the help of ‘stop push button’, stop the compressor and
hold it in the same condition for 20 to 30 minute.
3. With the help of ‘control button’ stop control supply and with
inlet-outlet valve, stop the supply of water.
 Some important questions related with
Viva and Interview:
49

50. • What will happen if air is not cooled in intercooler and is
directly ejected in ‘High Pressure (H.P) Cylinder’?
∗ Air (atmospheric) is at pressure of 1.0168 bar and it in ‘Low
Pressure (L.P) Cylinder’ is converted into 1.5 bar. Due to
increase in pressure the gas become hot and its temperature also
get increased, and we know the property of hot gas that it
expands and cover a large volume. When this hot air is directly
ejected into the H.P Cylinder the piston and piston rod will
become hot and more lubrication will be required and tendency of
compressor to produce ‘plant air’ will be decreased and hence
the efficiency of compressor will also decrease.
• If the pressure in H.P Cylinder will not lie in Safe Working
Level (5 kg/cm2
to 7 kg/cm2
) i.e. it will increase or decrease
then what will happen
∗ If this condition arises the ‘mechanical governor’ is fitted which
will do loading and unloading of compressor. If the pressure is
below 5 kg/cm2
then ‘unloading’ of compressor will take place
and if pressure is more than 7 kg/cm2
then ‘loading’ of
compressor will take place.
BATH CRUSHING
50

51. • In ‘Bath - Crushing’ the medium block of ‘Cryolite (Na3AlF6)’
is crushed in powdered form (generally below 19 mm diameter)
and is mixed with ‘Alumina powder’ and is sent to Potroom for
extraction of Aluminium metal.
• Cryolite is used to produce and maintain heat in pot.
• ‘50 HP Induction Motor’ is used to break the ‘Bath’ by rotating
‘Rotary Breaker’.
 9 * 15 Rotary Breaker:
The Model Number 9 * 15 Rotary Breaker is derived as
follows:
9 – 9 feet diameter (2745 mm) at the screen plates
15 – 15 feet internal length (4575 mm)
This 9 * 15 Rotary Breaker consist of a ‘Barrel’ supported on
‘Trunnion Rollers’. The Barrel is lined with perforated ‘screen
plates’ and is driven by a ‘Chain Drive Arrangement’.
The principle function of Rotary Breaker is as follows:
a) Break and separate the material through lifting and impacting
inside the Rotary Breaker, the impact reducing the material size
to allow to sized material to filter through screen plates.
b) The material not able to be broken, drown to pass through the
screen plates, unprocessed material is discharged through ‘refuse
chute’ and disposed, this operation requires the Barrel to be
rotated in the reverse direction.
 9 * 15 Rotary Breaker Equipment Data:
Duty: a) Capacity 40 M.T nominal
51

52. b) Material
c) Feed Size
d) Discharge Size
Aluminium Oxide,
Cryolite, Aluminium
400 mm
Max. Size < 22 mm
Machine Data: a) Gear Box Ratio
b) Breaker Drive
c) Drive Motor
d) Breaker Speed
e) Coupling Type
13.5:1
3.5” Pitch Drive
Chain
Supplied by Others
16 R.P.M
Fluid Coupling
Machine
Dimensions:
a) Overall Length
b) Overall Width
c) Height
d) Overall Mass
6650 mm
5410 mm
3985 mm
44,480 kg
Serial number:
Mc Lanahan
Reference:
20053100
B 040308:01
 Rotary Equipment Installation and
Alignment Procedure:
1. Inspect all footings and confirm foundation bolts are at correct
centre and level.
2. Install and align main support beams and Trunnion Frames.
3. Pre-assemble and install lower chain case assembly.
4. Place drive chain into the lower chain case. Extend one end
approximately 1 meter past the drive sprocket position and
extend the other end outside the far end of the chain case. Ensure
that the loose ends of the chains are secured in place.
52

53. 5. Pre-assemble the two lower sections of the dust housing with the
‘product chute’. Seal all the flanges to prevent ‘egress of dust’.
This assembly can then be installed onto the main support beams,
fit packing plates under the dust housing support legs at step 9
after installing the barrel at step 7 below.
6. Ensure thrust rollers are clear of the path of the cylinder tyres to
allow clearance to install the barrel assembly.
7. Install the pre-assemble barrel and Trunnion bases and position
onto Trunnion wheels and between the thrust rollers. Ensure
cylinder tyres edges are aligned with the Trunnion tyres edges
within 1 mm.
8. Adjust thrust roller to clear cylinder by 1 mm at each end.
9. Shim lower dust housing to ensure uniform clearance around the
dust housing and the barrel ‘assembly seal rings’.
10. Pre-assemble the 4 upper section of the dust housing. Seal
all flanges to prevent egress of dust.
11. Install the top dust housing assembly to the bottom half of
the dust housing. Seal all flanges to prevent egress of dust.
12. Install drive sub-base, align and level as per drawing. Do
not grout sub-base to concrete until drive assembly has been
installed and sprockets aligned.
13. Install drive-assembly. Ensure correct alignment of drive
sprocket and the cylinder sprocket.
 Sequence of Operation:
53

54. A. Start-Up:- before starting the Rotary Compressor, follow all
procedures as outlined:
1. Start the machine in an unloaded condition.
2. Supply raw material to the feed end of machine only after
machine is running at full speed.
B. Shut-Down:-
1. Discontinue feeding the machine.
2. De-energize the breaker, only after all material has been
discharged from the cylinder.
• The ‘Fluid Coupling’ applied in 9 * 15 Rotary Breaker is of
standard type:
HFN 10/20, HFN 20 and HFDD 20
 Trouble Shooting:
Trouble Area Probable Cause Corrective Actions
1.Machine Fails to
Start
Electrical Malfunction Check mains is
operational
Check electrical
isolations, etc.
2.Motor operating
but breaker not
A.Coupling Failure
B.Reducer Failure
C.Bearing Failure
A.Check coupling
connections
B.Refer reducer
section
C.Replace bearing
54

55. D.Cylinder Overload
E.Wedges remain
between tyres
F.Hydraulic system
Failure
D.Remove wedges
E.Inspect/Repair/Hyd.
System
3.Bearing hot to
touch
A.Inadequate
Lubrication
B.Bearing failure
A.Inspect lubrication
flow
B.Replace Bearing
4.Cylinder runs hard
to one end
A.Trunnion shafts
misaligned
B.Trunnion base
misaligned
A.Align Trunnion
shafts
B.Align Trunnion
base
5.Vibration/Noisy
Operation
A. Trunnion shafts
misaligned
B.Trunnion base
misaligned
C.Flat spot on tyres
D.Build up on tyres
A.Align Trunnion
shafts
B.Align Trunnion
base
C.Replace tyres and
re-align
D.Clean tyres faces
• Introduction:
The 9 * 15 Rotary Breaker is to be stored at site prior to erection
and during this time it is to be protected from corrosion and
generally dust and dirt.
The manufacturers recommend the following storage regime for
storage period of upto six months.
55

56. • Corrosion Protection:
The 9 * 15 Rotary Breaker machined surfaces are to be wire
brushed clean of surface rust as spray sealed to prevent further
corrosion.
The recommended sealent is ‘CRS Soft Steel’. It is petroleum
based long term indoor/outdoor corrosion inhibitor that seals out
moisture and corrosive contaminants by forming a dry,
transparent, amber film which is highly resistant to humidity, salt
water and salt spray. The spray which once sets provides a solid
film base. The film can easily be removed with petroleum based
product.
• Storage:
After application of corrosion protection the 9 * 15 Rotary
Breaker is to be stored in a clean dry facility and adequately
protected from water (rain, dew, heavy mist etc.) and dust and
air born dirt. The storage is to be preferably indoors, however
under canvas or an equivalent waterproof cover on a hard stand
free of ‘sweating’ is acceptable.
56

57. ALUMINA TRANSFER SYSTEM
• Its other name is HDPS (Hopper Dense Pressure System) and
also AAFS (Automatic Alumina Feeding System).
• Alumina Transfer System is the process by which ‘Alumina’ is
feeded to the pot with the help of various equipments such as
pipe, duct, conveyor and imparting various techniques such as air
slides, air lift blower, etc.
• Alumina powder flows in the pipe with the help of ‘Air Slides’.
Air slides work on the principle of ‘Potential-Fluidization’.
It is of two types:
1. Horizontal air slide.
2. Inclined air slide.
• Safe working pressure of Bag House – 4-6.5 kg/cm2.
Safe working pressure of Air Slides – 15-20 millibar (mbar)
• Alumina Produced (Alumina Plant) – 1900MT/Day
• Alumina Transferred to Plant-1 – 400 MT/Day
• Alumina Transferred to Plant-2 – 1500 MT/Day
• Conveyors
• Air Slides
• Air Lifts
• Tankers
• Elevators
57

58.  Plant Starting Sequence:
Long Conveyor – ‘should be in starting condition’
↓
TT – 5 BAG FILTER FAN [2A (6) or 2B (7)]
↓
TT – 6 AIR LIFT BLOWER [2A (17) or 2B (18)]
↓
TT – 5 AIR LIFT BLOWER [1A (24) or 1B (25)]
↓
TT – 5 AIR SLIDE FAN [2A (30) or 2B (31)]
↓
ROTARY AIR LOCK (R.A.L) TT – 5 BAG HOUSE [50, 51, 52,
53]; At the interval of 30 seconds.
↓
BELT CONVEYOR – 2 [32]
↓
TT – 2 BAG FILTER FAN [1A (37) or 1B (38)]
↓
AIR SLIDE FAN [1A (43) or 1B (44)]
↓
ROTARY AIR LOCK (R.A.L) TT – 2 BAG HOUSE [54, 55, 56,
57]; At the interval of 10 seconds.
↓
VIBRATING SCREEN [45], Gate should be placed in side of
vibrating screen.
↓
BELT CONVEYOR – 1 [47]
• PROCEDURE:
1. Before starting ‘Air Lift Blower’, check that outlet valve of
blower is completely open.
58

59. 2. Before starting ‘I.D Fan’ check that fan outlet gate is completely
open.
3. Before starting the circuit, shut off all R.A.L
4. E very gate and valve of ‘stand by equipment’ should be
properly closed.
5. If plant has to be shut down for more than 30 minute, then in that
situation TT-5 and TT-2. Bag house pulsing of air should be
closed. At the time of restarting of Bag House ‘Rotary Air
Lock’ should be start at a minimum interval of 30 seconds.
59

60.  FLUORIDE ADSORPTION:
∗ The fresh alumina injected into the reactors serves as an
adsorbent for the fluorides and it also helps in creation of a dust
layer on the filter bags in order to collect particles even smaller
than the fabric mesh itself.
 Factor affecting the pressure drop:
1. Gas flow per unit of time and filter area.
2. Dust, alumina load and its composition.
3. Pulse cleaning frequency.
4. Valve operating time.
5. Cleaning energy (pulse pressure).
6. Gas temperature
7. Gas humidity
 CLASSIFICATION OF FANS, BLOWERS AND
COMPRESSOR:
• Fan is used to develop pressure – Upto 2 psi
• Blower is used – From 2 – 10 psi
• Compressor is used – Above 10 psi
• Fans:
Throughput of centrifugal or axial fans can be changed by
varying the inlet or outlet dampers.
1. Axial fan is used, where air or gas moves parallel to the direction
of rotation of axis and to move large quantity of air at low
pressure.
60

61. 2. Centrifugal fan is used, where air or gas moves perpendicular to
the axis and for greater height.
 Centrifugal fans:
• Radial blade type
• Forward curve type
• Backward curve and backward inclined type
• Air foil centrifugal fans
• Tubular centrifugal fans
 Blowers:
∗ Blowers are generally single stage, high-speed machines or
multistage units that operate at pressure close to or in the range of
compressors.
 AIR LIFT BLOWER:
1. Name of Equipment – Air Lift Blower
2. Year of Installation – 2000
3. Manufacturer – KAY INTERNATIONAL LTD.
4. Lifting Weight – 25 meter
5. Model – AC-1030
6. Capacity – 100 Metric Tonne
7. Type – Twin Lobe Type
8. Discharge pressure – 3500 MMWG
9. Flow – 7000 M3
/Hrs.
10. Motor Power – 120 H.P/4 Pole
11. Motor Speed/Type – 1440 R.P.M/3 Phase
 SPECIFICATION OF FILTER BAGS:
61

62. 1. Diameter : I.D – 127 mm
2. Length : 6066 mm
3. No of bags / line : 3240
4. Top Design : S.S snap band for bag holding. Top open
5. Longitudinal seam : Triple stitch with polyester thread
6. Bottom height : Bottom closed double bottom upto100 mm
7. Fabric used : Polyester needle felt
8. Composition : 100 % Polyester
9. Weight : 550 gm / m2
10. Thickness : 1.9 mm
11. Air permeability : 140 L/dm2/mm at 200 Pa
12. Air to cloth ratio : 82 – 85 m3/m2/hr
13. Density of fabric : 0.29 g/ cm3
14. Gas temperature : 60 to 130°C
15. Tensile strength : 1275 N/m
16. Bursting strength : 18 Kg/cm2
17. Max dimensional change : < 1% in hot air at 150°C
18. Life guarantee : Min 24 months
19. Performance : SPM < 8 mg/Nm3
;HF <1.5 mg/Nm3
Equipment used for emission measurement: APM 620 supplied by M/S
Envirotech, New Delhi
ALUMINA (Al2O3) PROPERTIES
• Bulk density ~ 0.9 - 1.1 g/cm3
• Particle density ~ 3.0 - 3.3 g/cm3
• Specific surface ~ 40 - 80 m2/g
• Particle size D50 ~ 75 m
~ 10 - 150 m
62

63. DRY SCRUBING SYSTEM
∗ The Dry scrubbing system treats exhaust gas from Pots. This
treatment of gases is based on adsorption of gaseous fluoride by
means of injected alumina, which is followed by bag filter where
enriched alumina is collected and being sent to pots for alumina
feeding. This plant can also be named as Fume Treatment Plant.
∗ F.T.P. serves the two functions, first it reduces the emission of
the HF gas and the dust particulate into the atmosphere, and
secondly it recovers aluminum fluoride, which is an important
input to the pots. This reduces the consumption of ALF3, which
we purchase from outside party.
 NEED FOR D.S.S/F.T.P
∗ During the electrolysis process for producing aluminum, the
alumina (Al2O3) liberates oxygen and the metal Aluminum is
produced. The electrolysis process takes place in an electrolytic
bath consisting of Aluminum fluoride and some other chemicals.
During this process hazardous gases are emitted (mainly
consisting of Hydrogen fluoride and other fluorides).To prevents
these gases to escape into the atmosphere, it is mandatory to
install F.T.P. Since fumes are treated by adsorption of fluorides
gases into dry alumina, hence the system is called Dry Scrubbing
System. The F.T.P. treats exhaust gas from Aluminum reduction
cells by dry scrubbing process, followed by bag filter to collect
fluorinated (enriched) alumina. F.T.P. reduces the emission of the
HF gas and the dust particulate into the atmosphere.
63

64.  PROCESS DESCRIPTION
∗ The process description of the F.T.P. is divided into four main
sections:
1. Gas Ducting and Fan System
2. Bag Filter System
3. Alumina Handling System
4. Instrumentation and Electrical system
∗ Alumina consumed in the pots is transported from the belt
conveyors to the primary silo, through the F.T.P. During This
process the primary alumina is mixed with the pot gas in the
reactor and forms the enriched alumina. This enriched
(secondary) alumina in turn transported to the reduction pots
where aluminum metal is produced. Other particulates are
collected on the filter bags.
64

65.  GAS DUCTING AND FAN SYSTEM:
∗ The main ductwork is designed in such a way that it gives nearly
same velocity throughout the system. Each individual pot has the
branch duct having a manually adjustable damper. These dampers
are set in a fixed position after balancing, so that an even suction
is obtained from each pot.
∗ For the suction of the gas there are three main exhaust fans
(Centrifugal type) in each line. Each fan has inlet and outlet
damper. There are 6-filter unit in each FTP and each filter unit
comprises a reactor and a filter compartment.
Each filter unit can be isolated for maint jobs by the inlet duct damper
and outlet duct damper.
 DUCT CONNECTED WITH POTS:
65
AnodeAnode AnodeAnode AnodeAnode

66.  CLEANING OF THE FILTER BAGS
∗ The cleaning of the bags is accomplished by a pulse jet technique,
where a medium pressure pulse of air is introduced into the open
top of each filter bag through nozzle arranged on a nozzle header.
The pulse air enters the nozzle header through solenoid
diaphragm valve installed on pulse tanks. There are 30 rows in
each bag house and each row comprises of 18 bags. The injection
of pulse air results in a rapid expansion of the bags. Alumina and
dust having accumulated on the outside of the bags is dislodged
and collected in the hopper.
∗ One row in all the filter units is cleaned simultaneously. The next
row in line is cleaned after a set time interval has elapsed.
∗ The permeability of a new bag is very high, resulting in a low-
pressure drop. Fumes and alumina in the gas flow will increase
the pressure drop through the bags.
 BAG CLEANING PARAMETER:
∗ The bag cleaning process is controlled by the PLC installed in
control room. All filters are cleaned on-line. This on-line pulsing
indicates that one row of bags in each filter unit is cleaned
simultaneously. The gas flow, dust load and gas temperature are
normally given parameters .The pulse cleaning interval, valve
opening time and pulse air pressure for the bags can be varied
within limits for optimal operation of FTP.
∗ The pressure drop affects the power consumption of the fans
whereas bag-cleaning parameters may affect the life of the bags.
66

67.  PULSE SYSTEM:
 FILTRATION CYCLE:
 BAG HOUSE:
67
CLEACLEA
NN
BAGBAG
DURINGDURING
FILTRATIOFILTRATIO
NN
DURINGDURING
PULSINPULSIN
GG
JUST AFTERJUST AFTER
PULSINGPULSING
““PUFF”PUFF”
NORMALNORMAL
FILTRATIOFILTRATIO
NN

68.  ALUMINA HANDLING SYSTEM:
• Alumina transport to primary silo:
∗ The primary alumina is being feed to each FTP from the existing
conveyors through a diverter valve leading the alumina into air
slides (2 airsides / one standby) for filling of the primary alumina
silo (Cap – 350 tons).
An emergency airlift is also provided for filling the primary silo.
 PRIMARY ALUMINA HANDLING:
68

69. ∗ The primary alumina silo (350 Ton) is equipped with two
manually operated discharge valve, one (Bypass) leading directly
to the distribution box , the other feeding air slide to a feed box
with loss- of –weight control system.
∗ Two blowers are being used to supply fluidizing air to the
primary alumina silo and for the feed & distribution system.
From the feed box, the primary alumina is being feed into the
reactors through distribution air slide where it gets reacts with the
pot gases.
 ALUMINA INJECTION & RECIRCULATION:
∗ Adsorption of fluorides takes place after the primary alumina has
been injected into the raw gas in the reactor. For more enrichment
alumina is recirculated from the screw conveyor to the same
injection point where the primary alumina has injected.
∗ By varying the speed of the screw conveyor we can control the
rate of recirculation. All screw conveyors (6 Nos) rotate with the
same speed and is being controlled by frequency converter.
69