LOGISTICS MANAGEMENT AND ENHANCEMENT OF CONVEYOR BELT SYSTEM

Done AtFERTILIZERS AND CHEMICALS TRAVANCORE LTD

(FACT) COCHIN

EXTERNAL GUIDE

N MOHANSENIOR TECHINICAL ENGINEERFACT COCHIN

DONE BY

ARUN ANTONY1021106CHRIST UNIVERSITY

COMPANY PROFILE

• FACT India’s first large scale unit was set up in 1943

• Large scale fertilizer manufacturer in India.• Fertilizers and Chemicals Travancore Ltd have

their own Raw Material Handling systems at Q10 berth and Ammonia berth of Wellington Island, Kochi.

• The belt conveyors are used for the bulk movement of imported raw materials .

RESEARCH METHODOLOGY

Problem Definition:-• The bulk movement of raw materials ships to

their storage areas and reclamation of these materials to their different plants at various sites is a tedious and expensive task.

• By the effective enhancement of the conveyor belt system and raw material handling method, we can improve the logistics process of the company.

OBJECTIVES:-1.To study about present logistics management process

in FACT2. To study about various problems affecting the

conveyor system.3. To enhance the capacity of conveyor belt system and

logistics process.DATA COLLECTION:- Primary Data:- Interviews and interaction with the faculties in the

company and personal experience. Literature review

Secondary Data:-• Data that already exist in the company• Reports and Journels

Tools used:- Charts and diagrams

Raw Materials Department in FACT (RMD)

• Procurement of raw materials like Sulphur, Rock phosphate, Ammonia, Phosphoric Acid.

• Shipping office at Wellington Island also comes under this section.

CHALLENGES TO RAW MATERIAL PROCUREMENT o 1. Scarcity of Raw materialso 2. Sky rocketing priceso 3. Shipping Problemso 4. Working Capital crunch

LOGISTICS MANAGEMENT IN FACT

CONVEYOR SYSTEM IN FACT• Loading and Unloading the raw materials.• Idlers, pulleys, drive, reducer, take up, skirt board,

scraper.• The conveyor belting used in FACT is cotton rubber

covered with carrying and return faces conforming to IS: 1891.

• The electric power required is AC at 480 volts, 3 phases, 50 Hz.

• CONVEYOR SYSTEM IN Q10 BERTH

• 22 conveyors of different lengths.• The width of the conveyor is 750mm, 1000mm, 1200mm.• The conveyors belong to S series are S1, S2, S3, S4, S5, S6, S7,

S8, S9, S10, S11 and S12.• The conveyors in the P series include P3A, P3B, P4, P6, P7A,

P8A ,P8B and P9A.

Sub-system 1• This sub system consists of the conveyors S1, S2, S3,

P3A and S12.The function of this sub-system is the intake of sulphur or rock phosphate to the barges from the ship.

Sub-system 2• The sub system 2 consists of the conveyors S1, S2, S3, P3B, P5A and

P5B.The function of this sub system is the intake of the sulphur from the ship to the sulphur godown.

Sub-system 3• This sub system consists of the conveyors S1, S2, S3, P3A and P4. The

function of this sub system is the intake of the rock phosphate from the ship to the silos.

Sub-system 4• This sub system consists of the conveyors P8A, P8B, S4, S5 and S6. The

function of this sub system is the reclamation of sulphur from the sulphur godown to the barges to take the material to the different plants.

Sub-system 5• This sub system consists of the conveyors P9A, P7, S8 and S9. The

function of this sub system is the reclamation of rock phosphate from the rock godown to the barges to take the material to the different plants.

Sub-system 6• This sub system consists of the conveyors P7A, S10 and S11. The

function of this sub system is the reclamation of rock phosphate from the silos to the barges to take the material to the different plants.

PROCEDURE FOR THE UNLOADING PROCESS

DRAFT READINGS

Unnloader & Grab

Hopper

S1 conve

yor belt

Godowns/silos

• DRAFT READINGS

• The ship authorities will say from which hatch and how much materials should be taken at a time in consideration with the draft readings.

• The grab has a capacity of 10-12 TON/hr.• The ship unloader itself is movable and PLC

system is adopted.• The arm of the grab has a length of about

28m.• Direct discharge to the barge.

Discharge rate capacity of the conveyor is 600 Ton/ hr

Per grab discharge rate is 10Ton for Sulphur and 12Ton for Rock phosphate

The entire length of conveyor belt is 1390.35m

The electric power required is 480V,50Hz AC

The ship unloader name is WMI SIEMENS MAN

Capacity of Ammonia storage tank is: - 10000Ton

Capacity of Phosphoric Acid tank: - 3500Ton * 3 no.

Capacity of Rock Phosphate godown: - 3500T and 10000T

Capacity of Sulphur godown: - 12000T and 15000T

THE TRANSPORTATION OF RAW MATERIALS FROM GODOWNS TO BARGES AND VARIOUS DIVISIONS

• Direct unloading to the barges with the help of a chute .

• 13 conveyors act as the reclamation conveyors.• The silos which are used for the storage of rock

phosphate are working fully under the theory of gravity .

• TRANSPORTATION

GODOWNS

PAY LOADER

RECLAMATION BELT HOPPER BARGE

The RAW MATERIALS DEPARTMENT in Cochin Division FACT

Q10 berth

Barge/lorry

Barge unloader

HOPPER

BELT

SYSTEM

TRIPPE

R SYSTEM

GODOWN

Electric overhead Travelling Crane Barge unloader and Tata Friction Crane.

The discharge capacity is about 200T/hr and per grab discharge is 9T (EOT) and 3T (TFC).

Separate hopper and conveyor systems are provided for the unloading of Sulphur and rock phosphate to their respective godowns.

The Phosphoric acid that comes in the barge is been connected to the pipeline on the berth and it been pumped directly to the storage tanks.

Sulphur- 15000TRock phosphate- 3500T

FINISHED GOODS TRANSPORTATIONPLANT

CONVYO

R BELT SYSTEM

BAGGING

PLANT

STITCHING

CHUTES

LOADING

POINTS

The bagging plant unit is situated inside the FACT The bagging plant includes a bagging unit, a stitching unit, a

loading unit and a railway system where the packaged bags are being shifter to trucks or wagons.

Bagging happens in 50kg packs each Material flow is continuous There are 8 railway lines inside the FACT and 2 shutting engines

owned by the FACT to help the movement of materials to and from the FACT.

There are totally 8 loading points are there and they are designed in such a way that more than 2 wagons are loaded at a particular time. One wagon takes about 1320 bags of fertilizers

Problems related to conveyor system

• Misalignment of motor with gearbox• Improper maintenance of belt to avoid swaying• Bearing failure• Wear and tear of idlers• Fluid coupling failure• Improper lubrication• Fire • Gear box repair

12

10

7

6

6

2

.5

.5Sales

misalignment improper maintenancebearing failure wear and tearfluid coupling improper lubricationfire gearbox repair

22%

28%

SUGGESTIONS• In order to find the optimal path for the conveyor system, Route

Optimization Technique should be established.• Availability of employees during the arrival of ship must be make sure so

as to make the unloading process smoothly. Otherwise the company has to pay demurrage for the extra time the ship spent in the berth.

• The system that exists now is a longer one in the Q10 berth which was previously used by the Q9 berth. So proper channeling should be done so as to increase the speed and this will also help in reducing power consumption.

• The implementation of new barge and ship unloader in the different units of the FACT should be done with more advanced ones which are now available in the market.

• The number of barges should be increased so that more amounts of materials can be transported on a day.

• Make sure that the direct unloading of materials will be happening whenever it is possible since this will help to optimize the power consumption and also maximize the rate of carrying of the materials.

• The efficient use of railway transport system should be done since it provides the safest and cheapest way of transportation.

• The present capacity of the godown is only 10000T. When excess raw materials arrive from the international market, they are stored outside to the godown. The problem it leads to is the wastage of raw material when it’s being retrieved. It also hampers the quality of the raw material but to a very lesser extent.

• Presently the conveyor system is supported upon steel and cast iron supports. Since the conveyor system is located at the sea shore the chances of corrosion of the support structures are very high and as a result huge amount of money has to be spending to keep the corrosion under check. An ideal method of eradicating corrosion is by converting the support system to concrete structure.

• Preventive maintenance should be taken care so as to improve the efficiency of the whole system

THANK YOU