HINDALCO SUMMER TRAINING Report Main File

8/20/2019 HINDALCO SUMMER TRAINING Report Main File

1/62

A PROJECT REPORT ON

SUMMER TRAINING PROGRAMME

UNDER

“FABRICATION MECHANICAL

MAINTAINANCE”

DONE AT

HINDALCO INDUSTRIES LTD.

RENUKOOT, U.P.

SUBMITTED TO SUBMITTED BY

MR. ANUBHAV SINGH SUMIT KUMAR GUPTA

DEPT. FABRICATION MECH MAIN. B.TECH. 2ND YEAR NIT

ALLAHABAD


2/62

Contents

ACKNOWLEDGEMENT

INTRODUCTION OF HINDALCO INDUSTRIES LTD.

AluminiumCopperMinesVision, Mission & Values

ALUMINIUM PROPERTIES

APPLICATIONS OF ALUMINIUM

PRIMARY ALUMINIUM PRODUCTS

• Ingots• Wire Rods• Billets

PRODUCTION PROCESS

• Fabrication

MAIN PLANTS OF THE COMPANY

• ALUMINA LAN!• ALUMINIUM "M#L!#R • FABRICA!I$N LAN!

FABRICATION PLANT LAYOUT

ROLLING MILL

• %$! R$LLIN•

C$L' R$LLIN• R$C#"" FL$W C%AR! $F %$! R$LLIN MILL• R$C#"" FL$W C%AR! $F C$L' R$LIN MILL

EXTRUSION

• Classi(ication• !erminolog)• rinciple *ariables• Isot+ermal temperature• 'ie !)pes


3/62

• arts o( #trusion ress• ress $peration• ress "peci(ications• Billet !emp- Range (or Aluminium Allo)s• Application o( ma.or Aluminium Allo)s• Aging•

'e(ects

HYDRAULIC CYLINDERS

• %)draulic C)linders• !)pes• arts• %)draulic C)linder 'esigns

TO DETERMINE THE WORKING CONDITIONS OF FURNACE FOR PROPANE GAS

WHEN CONDITIONS FOR METHANE GAS IS GIVEN

A"#$U" FUL#"• !)pes o( aseous (uels• roperties o( aseous (uels• Calori(ic Values• Combustion• Waste +eat reco*er)

"$M# #/UIM#N!" IN A" FIR#' ALUMINIUM L$ %#A!IN FURNAC#• Recuperator • Centri(ugal Fan• $ri(ice late and parameters on 0+ic+ (lo0 t+roug+ ori(ice plate depends

'ata gi*en (or t+e met+ane gas 0or1ing as (uel in (urnace• !able 2 Volume (lo0 rate and pressure di((erence 'elta (or !+e Air $ri(ice Flange• !able 2 Volume (lo0 rate and pressure di((erence 'elta (or !+e as $ri(ice Flange

(or nat!a" #as $%et&ane'-• Volume (lo0 rate and pressure di((erence 'elta (or Air $ri(ice Flange and as

$ri(ice Flange (or 3one 4,5,6,7,8,9,:,; in t+e (urnace using met+ane as (uel Data P!e(a!e) *o! t&e %et&ane #as +o!,-n# as *e" -n *!nae

• !able 2 Volume (lo0 rate and pressure di((erence 'elta (or !+e Air $ri(ice Flange• !able 2 Volume (lo0 rate and pressure di((erence 'elta (or !+e as $ri(ice Flange

(or PROPANE GAS-• Volume (lo0 rate and pressure di((erence 'elta (or Air $ri(ice Flange and as

$ri(ice Flange (or 3one 4,5,6,7,8,9,:,; in t+e (urnace using ropane as (uel

BIBLIOGRAPHY

ACKNOWLEDGEMENT


4/62

I am t+an1(ul to %IN'ALC$ IN'U"!RI#" L!'- , 0+ic+ pro*ided me t+e opportunit) to (ul(ill t+esummer training as a curriculum o( B-!ec+- 5nd


5/62

AN INDUSTRY LEADER IN ALUMINIUM AND COPPER :

An industr) leader in aluminium and copper, %indalco Industries Limited, t+e metals (lags+ip compan) o( t+eAdit)a Birla roup is t+e 0orlds largest aluminium rolling compan) and one o( t+e biggest producers o primar) aluminium in Asia- Its copper smelter is amongst t+e largest single location custom smelter globall)-

#stablis+ed in 4D8;, 0e commissioned our aluminium (acilit) at Renu1oot in eastern Uttar rades+, India in4D95- Later, acuisitions and mergers 0it+ Indal, Birla Copper and t+e Ni(t) and Mt- ordon copper mines inAustralia, strengt+ened our position in *alueadded alumina, aluminium and copper products-

!+e acuisition o( No*elis Inc- in 5EE: positioned us among t+e top (i*e aluminium ma.ors 0orld0ide and t+elargest *erticall) integrated aluminium compan) in India- !oda), 0e are a metals po0er+ouse present in t0o o(t+e (astest gro0ing metal segments aluminium and copper, 0it+ global (ootprints in 46 countries and 0it+ aconsolidated turno*er o( U"' 47-; billion >Rs- ;E,4D6 crore?-

ALUMINIUM:

%indalcos ma.or products include standard and specialit) grade aluminas and +)drates, aluminium ingots, billets, 0ire rods, (lat rolled products, etrusions and (oil-

!+e integrated (acilit) at Renu1oot +ouses an alumina re(iner) and an aluminium smelter, along 0it+ (acilities(or t+e production o( semi(abricated products, namel), redra0 rods, (lat rolled products and etrusions- !+e plant is bac1ed b) a cogeneration po0er unit and a :75 MW capti*e po0er plant at Renusagar to ensure t+econtinuous suppl) o( po0er (or smelter and ot+er operations-

A strong presence across t+e *alue c+ain and s)nergies bet0een operations +as gi*en us a dominant s+are in t+e*alueadded products mar1et- As a step to0ards epanding t+e mar1et (or *alueadded products and ser*ices

0e +a*e launc+ed *arious brands in recent )ears G #*erlast roo(ing s+eets, Fres+0rapp 1itc+en (oil andFres+pa11 semirigid containers-

FI 2 ALUMINIUM "%##!"

COPPER


6/62

Birla Copper, %indalcoHs copper unit, is located at 'a+e. in u.arat, India- !+e unit +as t+e uniue distinction o being t+e largest singlelocation copper smelter in t+e 0orld- !+e smelter uses stateo(t+eart tec+nolog) and+as a capacit) o( 8EE,EEE tpa- Birla Copper also produces precious metals, (ertilisers and sulp+uric and p+osp+oric acid- !+e unit +as capti*e po0er plants (or continuous po0er generation and a capti*e .ett) to(acilitate logistics and transportation-

Birla Copper up+olds its longstanding reputation (or ualit) copper cat+odes and continuous cast copper rod b) assuring its management processes meet t+e +ig+est standards- It +as acuired certi(ications suc+ as I"$DEE425EEE >/ualit) Management ")stems?, I"$47EE425EE7 >#n*ironmental Management ")stem? and$%"A"4;EE425EE: >$ccupational %ealt+ and "a(et) Management ")stems?-

MINES

%indalco acuired t0o Australian copper mines, Ni(t) and Mt- ordon, in 5EE6- !+e Birla Ni(t) copper mineconsists o( an underground mine, +eap leac+ pads and a sol*ent etraction and electro0inning >"#W?

processing plant, 0+ic+ produces copper cat+ode-!+e Mt- ordon copper operation consists o( an underground mine and a copper concentrate plant- Untilrecentl), t+e operation produced copper cat+ode t+roug+ t+e (erric leac+ process-

Bot+ Ni(t) and Mt- ordon +a*e a longterm li(e o( mine o((ta1e agreement 0it+ %indalco (or suppl) o(copper concentrate to t+e copper smelter at 'a+e.-

!+e largest integrated primar) producer o( aluminium in Asia, %indalco also ran1s as one o( t+e most cost

e((icient producers globall)- Wit+ a panIndia presence t+at encompasses t+e entire gamut o( operations, (rom bauite mining, alumina re(ining, aluminium smelting to do0nstream rolling, etrusions and rec)cling%indalco en.o)s a leaders+ip position in aluminium and do0nstream *alueadded products in India-

$ur India aluminium operations in india are integrated and consist o( bauite mining, alumina re(ining,smelting and con*erting primar) metal into *alueadded products- We +a*e dedicated sources (or critical ra0materials suc+ as bauite, po0er and to a limited etent, coal- We also +a*e committed suppl) sources (orauiliar) c+emicals-

$ur (inis+ed products include alumina, primar) aluminium in t+e (orm o( ingots, billets and 0ire rods, *alue

added products suc+ as rolled products, etrusions, (oils and allo) 0+eels and specialit) alumina productsAlumina is used (or our o0n capti*e needs, t+e ecess o( 0+ic+ is sold to t+ird parties- Aluminium is used in arange o( industries including 0atertreatment c+emicals, re(ractories, ceramics, cr)olite, glass, (illers and plastics, con*e)or belts and cables, among ot+ers-

%indalco manu(actures intermediate products reuired (or our o0n production suc+ as po0er and carbon anode$ur Indian aluminium operations are located in 4E states and one union territor) in India, 0it+ t+ree re(ineriesand t0o smelters t+at are capable o( producing o*er 9EE 1tpa o( aluminium-


7/62

VISION ; MISSION AND VALUES

V-s-on

!o be a premium metals ma.or, global in siJe and reac+, ecelling in e*er)t+ing 0e do, and creating *alue (or itssta1e+olders-

M-ss-on

!o relentlessl) pursue t+e creation o( superior s+are+older *alue, b) eceeding customer epectation pro(itabl)unleas+ing emplo)ee potential, 0+ile being a responsible corporate citiJen, ad+ering to our *alues-

Va"es

at+ to ecellence-

Integrit) %onest) in e*er) action- Commitment $n t+e (oundation o( integrit), doing 0+ate*er it ta1es to deli*er, as promised- assion Missionar) Jeal arising out o( an emotional engagement 0it+ 0or1- "eamlessness !+in1ing and 0or1ing toget+er across (unctional silos, +ierarc+) le*els, businesses and

geograp+ies- "peed Responding to sta1e+olders 0it+ a sense o( urgenc)-

ALUMINIUM PROPERTIES

!+e ma.or ad*antages o( using aluminium are tied directl) to its remar1able properties- "ome o( t+ese properties are outlined in t+e (ollo0ing sections-

St!en#t& to +e-#&t !at-o : Aluminium +as a densit) around one t+ird o( t+at steel and is usedad*antegeousl) in man) applications 0+ere +ig+ strengt+ and lo0 0eig+t are reuired- !+is included*e+icles 0+ere lo0 mass results in greater load capacit) and reduction (uel consumption-

Co!!os-on !es-stane : W+en t+e sur(ace o( aluminium metal is eposed to air, a protecti*e oidecoating (orms almost instantaneousl)- !+is oide la)er is corrosion, resistant and can be (urt+eren+anced 0it+ sur(ace treatments suc+ as anodiJing-

E"et!-a" an) t&e!%a" on)t-1-t


8/62

Re


9/62

In ato%at-on -n)st!


10/62

Was+ing mac+ines 'is+0as+ers Ice tra)& grid "to*e top pots "team .ac1eted 1ettles as (ired 1ettles A-C- Filter grill Water (ilter Furniture %angers

PRIMARY ALUMINIUM PRODUCTS

In#ots:

%indalco produces +ig+purit) ingots t+roug+ smelting- Allo) ingots o( *arious grades are also produced andmainl) used (or t+e production o( castings in t+e auto industr) and in electrical applications- Bot+ t+ese

products are remelted and (urt+er processed into a large number o( products (or *arious do0nstreamapplications-

%indalco metal is accepted under t+e +ig+grade aluminium contract on t+e London Metal #c+ange >LM#? asa registered brand-

W-!e !o)s2

%indalco manu(actures 0ire rods in a continuous casting and rolling process- #lectrical conductor >#C? 0irerods are used (or t+e production o( cables and AC"R and AAC conductors- Allo) 0ire rods are used to produceAAAC conductors-

B-""ets:

%indalcos aluminium billets are produced b) a stateo(t+eart Wagsta(( casting process using Airsliptec+nolog)- !+ese are topualit) billets 0it+ a smoot+ (inis+- !+e) are used mainl) to produce etrusions and(orgings-

ALUMINIUM PRODUCTION PROCESS:

!+e 8 steps in t+e aluminium c)cle


11/62

ReAlumina? turns into Aluminium t+roug+ an electrol)tic reaction-

Fa0!-at-on2 First Aluminium is allo)ed according to reuirement- Metal is added to gi*e speci(ic designc+aracteristics- It is done t+roug+ di((erent t)pes o( (abrication process 0+ic+ includes t+e2

4? Casting5? Rolling

6? Forging7? 'ra0ing8? #truding

Main !an" #$ "%& '#(an)

Hindalco, at Renukoot, house a fully integrated plant, comprising of 3 main Plants i.e. the

Alumina, Smelter & Fabrication Plant. ach plant employs !arying "echnology. #ith


12/62

integrated facilities, outputs from !arious plants are used by others, along $ith !arying

ra$ materials.

A!*(ina P!an"

Hindalco%s Alumina Plant employs the con!entional ayer's process $as commissioned

$ith an initial capacity of (),))) *"PA $hich has no$ increased to ++),))) *"PA. "he

ompany has been inducting ne$ technology from time to time and the most recentinitiati!e in this regard is the adoption of Alusuisse Precipitation "echnology for energy

e-ciency and capacity enhancement. "he maor ra$ materials for the Alumina Plant are

au/ite, Steam and austic Soda. au/ite is procured from the ompany%s *ines in

0harkhand and hhatisgarh, as $ell as through market purchases and re1uirement of

steam is met thru ogeneration plant at Renukoot.

A!*(ini*( S(&!"&+

"he ompany%s Smelter commenced operations in 2+4 $ith 2 Potline ha!ing a capacity

of 4),))) *"PA. "he smelter no$ has 22 Potlines $ith 4)35 Pots installed $ith annualcapacity of production of 3,(4,))) *". "he Smelter employs the Hall Heroult lectrolysis

Process for the e/traction of Aluminium from Alumina. asic ra$ materials for the

smelter are Alumina, Po$er, Anodes and Aluminium Fluoride. Alumina is produced by the

ompany%s Alumina Re6nery at Renukoot, Po$er is made a!ailable from the ompany%s

apti!e Po$er Plant at Renusagar and ogeneration plant at Renukoot and Anodes are

produced at the arbon Plant located in the Renukoot . Aluminium Fluoride is sourced

from the ompany's 07, amongst other sources.

Fa+i'a"i#n P!an"

"he Fabrication Plant at Renukoot comprises of ( *ain Sections8

R&(&!" S%#

Ca-" H#*-&

R#!!in Mi!!-

E/"+*-i#n 0 C#n$#+(

"he Remelt Shop houses Proper9i *ills for the production of #ire rods and Feedstock to

onform *achine.

ast House is comprised of a state of the art Pig :ngot casting, Rolling :ngot ;slab< casting

and /trusion illet casting facilities. Product of Pig :ngot asting is directly sold to

customer and product of slab casting and billet casting are the feedstock to Rolling *ills

and /trusion presses respecti!ely. "he ompany has a Hot Rolling *ill and 4 old Rolling *ills. "he Rolling *ill facilities also

include a ontinuous Strip aster, $hich contributes substantially to nergy e-ciency

since it eliminates numerous intermediate operations. "he ompany's /trusion presses and one onform *achine are $ell supported by a $ell=

e1uipped >ie Shop


13/62

P!o)ts

A"%-n-%:

%indalco is Asias largest integrated primar) producer o( aluminium and among t+e most coste((icient

producers globall)- $ur aluminium units across India encompass t+e entire gamut o( operations, (rom bauite mining, alumina re(ining, aluminium smelting to do0nstream rolling, etrusions and rec)cling

P!o)t Uses

A"%-n-% In#ots Remelted and used in t+e (orm o( Castings, Consumer 'urables, o0ders& C+emicals, Redra0 Rods etc-

A"%-n-% B-""ets "upplied to "econdar) #truders (or t+e production o( #truded ro(iles

A"%-n-% W-!e!o)s 'ra0n to smaller 'iameter (or applications largel) in Conductors&Cables-

A"%-n-% S&eet !ransport, #lectrical & #lectronics, Consumer 'urables,Arc+itecturalP!o)ts Applications

A"%-n-% E=t!s-ons Ma.or consumption in Arc+itectural applications- $t+ers include !ransportComputer %ard0are, !etile Mac+iner), "trategic Applications

A"%-n-% Fo-"s ac1ing o( Food and +armaceuticals

BASIC INFORMATION OF ALUMINIUM :

ATOMIC NO. 46

ATOMIC MASS 59-D;48 AMU

MELTING POINT 99E-6:EC

BOILING POINT 579:-EEC

CRYSTAL STRUCTURE CUBIC

DENSITY AT 2>4 K 5-:E5 gcm6

COLOUR "ILV#R

SPECIFIC HEAT E-D 11gEC


14/62

FABRICATION PLANT LAYOUT


15/62

ROLLING MILL

In metal0or1ing, rolling is a metal (orming process in 0+ic+ metal stoc1 is passed t+roug+ one or more pairs o(rolls to reduce t+e t+ic1ness and to ma1e t+e t+ic1ness uni(orm- !+e concept is similar to t+e rolling o( doug+Rolling is classi(ied according to t+e temperature o( t+e metal rolled- I( t+e temperature o( t+e metal is abo*e itsrecr)stalliJation temperature, t+en t+e process is 1no0n as +ot rolling- I( t+e temperature o( t+e metal is belo0its recr)stalliJation temperature, t+e process is 1no0n as cold rolling- In terms o( usage, +ot rolling processesmore tonnage t+an an) ot+er manu(acturing process, and cold rolling processes t+e most tonnage out o( all cold0or1ing processes

!+ere are man) t)pes o( rolling processes, including ring rolling , roll bending , roll forming , profile rolling , andcontrolled rolling -

HOT ROLLING

%ot rolling is a metal0or1ing process t+at occurs abo*e t+e recr)stalliJation temperature o( t+e material- A(tert+e grains de(orm during processing, t+e) recr)stalliJe, 0+ic+ maintains an euiaed microstructure and pre*ents t+e metal (rom 0or1 +ardening- !+e starting material is usuall) large pieces o( metal, li1e semi(inis+ed casting products, suc+ as slabs, blooms, and billets- I( t+ese products came (rom a continuous castingoperation t+e products are usuall) (ed directl) into t+e rolling mills at t+e proper temperature- In smalleroperations t+e material starts at room temperature and must be +eated- !+is is done in a gas or oil(ired soa1ing pit (or larger 0or1pieces and (or smaller 0or1pieces induction +eating is used- As t+e material is 0or1ed t+etemperature must be monitored to ma1e sure it remains abo*e t+e recr)stalliJation temperature- !o maintain asa(et) (actor a finishing temperature is de(ined abo*e t+e recr)stalliJation temperature t+is is usuall) 8E to4EE C >DE to 4;E F? abo*e t+e recr)stalliJation temperature- I( t+e temperature does drop belo0 t+is

temperature t+e material must be re+eated be(ore more +ot rolling-

%ot rolled metals generall) +a*e little directionalit) in t+eir mec+anical properties and de(ormation inducedresidual stresses- %o0e*er, in certain instances nonmetallic inclusions 0ill impart some directionalit) and0or1pieces less t+an 5E mm >E-:D in? t+ic1 o(ten +a*e some directional properties- Also, nonuni(orm cooling0ill induce a lot o( residual stresses, 0+ic+ usuall) occurs in s+apes t+at +a*e a nonuni(orm crosssection, suc+as Ibeams- W+ile t+e (inis+ed product is o( good ualit), t+e sur(ace is co*ered in mill scale, 0+ic+ is an oidet+at (orms at +ig+ temperatures- It is usuall) remo*ed *ia pic1ling or t+e smoot+ clean sur(ace process, 0+ic+re*eals a smoot+ sur(ace- 'imensional tolerances are usuall) 5 to 8K o( t+e o*erall dimension

Co") !o""-n#

Cold rolling occurs 0it+ t+e metal belo0 its recr)stalliJation temperature >usuall) at room temperature?, 0+ic+increases t+e strengt+ *ia strain +ardening up to 5EK- It also impro*es t+e sur(ace (inis+ and +olds tig+tertolerances- Commonl) coldrolled products include s+eets, strips, bars, and rods t+ese products are usuall)smaller t+an t+e same products t+at are +ot rolled- Because o( t+e smaller siJe o( t+e 0or1pieces and t+eir

https://en.wikipedia.org/wiki/Metalworkinghttps://en.wikipedia.org/wiki/Metal_forminghttps://en.wikipedia.org/wiki/Metal_forminghttps://en.wikipedia.org/wiki/Metalhttps://en.wikipedia.org/wiki/Metalhttps://en.wikipedia.org/wiki/Rolling_pinhttps://en.wikipedia.org/wiki/Recrystallization_(metallurgy)https://en.wikipedia.org/wiki/Recrystallization_(metallurgy)https://en.wikipedia.org/wiki/Cold_workinghttps://en.wikipedia.org/wiki/Cold_workinghttps://en.wikipedia.org/wiki/Metalworkinghttps://en.wikipedia.org/wiki/Equiaxedhttps://en.wikipedia.org/wiki/Microstructurehttps://en.wikipedia.org/wiki/Semi-finished_casting_productshttps://en.wikipedia.org/wiki/Semi-finished_casting_productshttps://en.wikipedia.org/wiki/Continuous_castinghttps://en.wikipedia.org/w/index.php?title=Soaking_pit&action=edit&redlink=1https://en.wikipedia.org/w/index.php?title=Soaking_pit&action=edit&redlink=1https://en.wikipedia.org/wiki/Induction_heatinghttps://en.wikipedia.org/wiki/Induction_heatinghttps://en.wikipedia.org/wiki/Safety_factorhttps://en.wikipedia.org/wiki/Residual_stresshttps://en.wikipedia.org/wiki/Non-metallic_inclusionshttps://en.wikipedia.org/wiki/I-beamhttps://en.wikipedia.org/wiki/Mill_scalehttps://en.wikipedia.org/wiki/Oxidehttps://en.wikipedia.org/wiki/Pickling_(metal)https://en.wikipedia.org/wiki/Smooth_clean_surfacehttps://en.wikipedia.org/wiki/Strength_of_materialshttps://en.wikipedia.org/wiki/Strength_of_materialshttps://en.wikipedia.org/wiki/Strength_of_materialshttps://en.wikipedia.org/wiki/Strain_hardeninghttps://en.wikipedia.org/wiki/Surface_finishhttps://en.wikipedia.org/wiki/Engineering_tolerancehttps://en.wikipedia.org/wiki/Metal_forminghttps://en.wikipedia.org/wiki/Metalhttps://en.wikipedia.org/wiki/Rolling_pinhttps://en.wikipedia.org/wiki/Recrystallization_(metallurgy)https://en.wikipedia.org/wiki/Cold_workinghttps://en.wikipedia.org/wiki/Cold_workinghttps://en.wikipedia.org/wiki/Metalworkinghttps://en.wikipedia.org/wiki/Equiaxedhttps://en.wikipedia.org/wiki/Microstructurehttps://en.wikipedia.org/wiki/Semi-finished_casting_productshttps://en.wikipedia.org/wiki/Semi-finished_casting_productshttps://en.wikipedia.org/wiki/Continuous_castinghttps://en.wikipedia.org/w/index.php?title=Soaking_pit&action=edit&redlink=1https://en.wikipedia.org/w/index.php?title=Soaking_pit&action=edit&redlink=1https://en.wikipedia.org/wiki/Induction_heatinghttps://en.wikipedia.org/wiki/Safety_factorhttps://en.wikipedia.org/wiki/Residual_stresshttps://en.wikipedia.org/wiki/Non-metallic_inclusionshttps://en.wikipedia.org/wiki/I-beamhttps://en.wikipedia.org/wiki/Mill_scalehttps://en.wikipedia.org/wiki/Oxidehttps://en.wikipedia.org/wiki/Pickling_(metal)https://en.wikipedia.org/wiki/Smooth_clean_surfacehttps://en.wikipedia.org/wiki/Strength_of_materialshttps://en.wikipedia.org/wiki/Strain_hardeninghttps://en.wikipedia.org/wiki/Surface_finishhttps://en.wikipedia.org/wiki/Engineering_tolerancehttps://en.wikipedia.org/wiki/Metalworking


16/62

greater strengt+, as compared to +ot rolled stoc1, (our+ig+ or cluster mills are used- Cold rolling cannot reducet+e t+ic1ness o( a 0or1piece as muc+ as +ot rolling in a single pass-

Coldrolled s+eets and strips come in *arious conditions2 full-hard , half-hard , quarter-hard , and skin-rolledFull+ard rolling reduces t+e t+ic1ness b) 8EK, 0+ile t+e ot+ers in*ol*e less o( a reduction- "1inrolling, also1no0n as a skin-pass, in*ol*es t+e least amount o( reduction2 E-84K- It is used to produce a smoot+ sur(ace, a

uni(orm t+ic1ness.

SH*A": ?F A R?@@:B *:@@

PR?SSS8

Roll bending

Roll bending produces a c)lindrical s+aped product (rom plate-

Ro"" *o!%-n#

Roll (orming, roll bending or plate rolling is a continuous bending operation in 0+ic+ a long strip o( metal is passed t+roug+ consecuti*e sets o( rolls, or stands, eac+ per(orming onl) an incremental part o( t+e bend, untit+e desired crosssection pro(ile is obtained- Roll (orming is ideal (or producing parts 0it+ long lengt+s or inlarge uantities- !+ere are 6 main processes2 7 rollers, 6 rollers and 5 rollers, eac+ o( 0+ic+ +as as di((erent

ad*antages according to t+e desired speci(ications o( t+e output plate-

Flat rolling

Flat rolling is t+e most basic (orm o( rolling 0it+ t+e starting and ending material +a*ing a rectangular crosssection- !+e material is (ed in bet0een t0o rollers, called working rolls, t+at rotate in opposite directions- !+egap bet0een t+e t0o rolls is less t+an t+e t+ic1ness o( t+e starting material, 0+ic+ causes it to de(orm- !+edecrease in material t+ic1ness causes t+e material to elongate- !+e (riction at t+e inter(ace bet0een t+e materialand t+e rolls causes t+e material to be pus+ed t+roug+- !+e amount o( de(ormation possible in a single pass islimited b) t+e (riction bet0een t+e rolls i( t+e c+ange in t+ic1ness is too great t+e rolls .ust slip o*er t+e

https://en.wikipedia.org/wiki/Deformation_(engineering)https://en.wikipedia.org/wiki/Frictionhttps://en.wikipedia.org/wiki/Deformation_(engineering)https://en.wikipedia.org/wiki/Friction


17/62

material and do not dra0 it in-O4P !+e (inal product is eit+er s+eet or plate, 0it+ t+e (ormer being less t+an 9 mm>E-57 in? t+ic1 and t+e latter greater t+an +o0e*er, +ea*) plates tend to be (ormed using a press, 0+ic+ istermed forming , rat+er t+an rolling-

$(ten t+e rolls are +eated to assist in t+e 0or1abilit) o( t+e metal- Lubrication is o(ten used to 1eep t+e0or1piece (rom stic1ing to t+e rolls- !o (inetune t+e process, t+e speed o( t+e rolls and t+e temperature o( t+e

rollers are ad.usted-

Fo-" !o""-n#

Foil rolling is a specialiJed t)pe o( (lat rolling, speci(icall) used to produce (oil, 0+ic+ is s+eet metal 0it+ at+ic1ness less t+an 5EE Qm >E-EE:D in?- !+e rolling is done in a cluster mill because t+e small t+ic1ness reuiresa small diameter rolls- !o reduce t+e need (or small rolls pack rolling is used, 0+ic+ rolls multiple s+eetstoget+er to increase t+e e((ecti*e starting t+ic1ness- As t+e (oil s+eets come t+roug+ t+e rollers, t+e) are trimmedand slitted 0it+ circular or raJorli1e 1ni*es- !rimming re(ers to t+e edges o( t+e (oil, 0+ile slitting in*ol*escutting it into se*eral s+eets- Aluminum (oil is t+e most commonl) produced product *ia pac1 rolling- !+is ise*ident (rom t+e t0o di((erent sur(ace (inis+es t+e s+in) side is on t+e roll side and t+e dull side is against t+e

ot+er s+eet o( (oil-

R-n# !o""-n#

Ring rolling is a specialiJed t)pe o( +ot rolling t+at -n!eases t+e diameter o( a ring- !+e starting material is at+ic10alled ring- !+is 0or1piece is placed bet0een t0o rolls an idler roll , 0+ile anot+er roll, called t+e drivenroll , presses t+e ring (rom t+e outside- As t+e rolling occurs t+e 0all t+ic1ness decreases as t+e diameterincreases- !+e rolls ma) be s+aped to (orm *arious crosssectional s+apes- !+e resulting grain structure iscircum(erential, 0+ic+ gi*es better mec+anical properties- 'iameters can be as large as ; m >59 (t? and (ace+eig+ts as tall as 5 m >:D in?- Common applications include roc1ets, turbines, airplanes, pipes, and pressure

*essels-

A rolling mill , also 1no0n as a reduction mill or mill , +as a common construction independent o( t+e speci(ict)pe o( rolling being per(ormed-

Wo!, !o""s

• Ba,( !o""s are intended to pro*ide rigid support reuired b) t+e 0or1ing rolls to pre*ent bendingunder t+e rolling load

• Ro""-n# 0a"ane s


18/62

Ro"" oo"-n# an) "0!-at-on slong or coiled? and +eagons-

CONFIGURATIONS:

Mills are designed in di((erent t)pes o( con(igurations, 0it+ t+e most basic being a two-high non-reversing0+ic+ means t+ere are t0o rolls t+at onl) turn in one direction- !+e two-high reversing mill +as rolls t+at canrotate in bot+ directions, but t+e disad*antage is t+at t+e rolls must be stopped, re*ersed, and t+en broug+t bac1up to rolling speed bet0een eac+ pass- !o resol*e t+is, t+e three-high mill 0as in*ented, 0+ic+ uses t+ree rollst+at rotate in one direction t+e metal is (ed t+roug+ t0o o( t+e rolls and t+en returned t+roug+ t+e ot+er pair-!+e disad*antage to t+is s)stem is t+e 0or1piece must be li(ted and lo0ered using an ele*ator- All o( t+ese millsare usuall) used (or primar) rolling and t+e roll diameters range (rom 9E to 47E cm >57 to 88 in?-

!o minimiJe t+e roll diameter a four-high or cluster mill is used- A small roll diameter is ad*antageous becauseless roll is in contact 0it+ t+e material, 0+ic+ results in a lo0er (orce and po0er reuirement- !+e problem 0it+a small roll is a reduction o( sti((ness, 0+ic+ is o*ercome using backup rolls- !+ese bac1up rolls are larger andcontact t+e bac1 side o( t+e smaller rolls- A (our+ig+ mill +as (our rolls, t0o small and t0o large- A cluster mill+as more t+an 7 rolls, usuall) in t+ree tiers- !+ese t)pes o( mills are commonl) used to +ot roll 0ide plates,

most cold rolling applications, and to roll (oils-

https://en.wikipedia.org/wiki/Z-millhttps://en.wikipedia.org/wiki/Z-mill


19/62

7arious rolling con6gurations. Cey8

A. 4=high

B. 3=high

C. (=high

D. +=high

E. 24=high cluster

F. 4)=high Send9imir *ill cluster

D&$&'"-

In +ot rolling, i( t+e temperature o( t+e 0or1piece is not uni(orm t+e (lo0 o( t+e material 0ill occur more in t+e0armer parts and less in t+e cooler- I( t+e temperature di((erence is great enoug+ crac1ing and tearing can occur

Flatness and Shape

In a (lat metal 0or1piece, t+e (latness is a descripti*e attribute c+aracteriJing t+e etent o( t+e geometricde*iation (rom a re(erence plane- !+e de*iation (rom complete (latness is t+e direct result o( t+e 0or1piecerelaation a(ter +ot or cold rolling, due to t+e internal stress pattern caused b) t+e nonuni(orm trans*ersacompressi*e action o( t+e rolls and t+e une*en geometrical properties o( t+e entr) material- !+e trans*erse

distribution o( di((erential strainelongationinduced stress 0it+ respect to t+e materials a*erage applied stress iscommonl) re(erenced to as s+ape- 'ue to t+e strict relations+ip bet0een s+ape and (latness, t+ese terms can beused in an interc+angeable manner- In t+e case o( metal strips and s+eets, t+e (latness re(lects t+e di((erentia(iber elongation across t+e 0idt+ o( t+e 0or1piece- !+is propert) must be sub.ect to an accurate (eedbac1basedcontrol in order to guarantee t+e mac+inabilit) o( t+e metal s+eets in t+e (inal trans(ormation processes- "ometec+nological details about t+e (eedbac1 control o( (latness are gi*en in-O54P

https://en.wikipedia.org/wiki/Z-millhttps://en.wikipedia.org/wiki/Rolling_(metalworking)#cite_note-21https://en.wikipedia.org/wiki/Z-millhttps://en.wikipedia.org/wiki/Rolling_(metalworking)#cite_note-21


20/62

Profle

ro(ile is made up o( t+e measurements o( cro0n and 0edge- Cro0n is t+e t+ic1ness in t+e center as comparedto t+e a*erage t+ic1ness at t+e edges o( t+e 0or1piece- Wedge is a measure o( t+e t+ic1ness at one edge asopposed to t+e ot+er edge- Bot+ ma) be epressed as absolute measurements or as relati*e measurements- Forinstance, one could +a*e 5 mil o( cro0n >t+e center o( t+e 0or1piece is 5 mil t+ic1er t+an t+e edges?, or onecould +a*e 5K cro0n >t+e center o( t+e 0or1piece is 5K t+ic1er t+an t+e edges?-

It is t)picall) desirable to +a*e some cro0n in t+e 0or1piece as t+is 0ill cause t+e 0or1piece to tend to pull tot+e center o( t+e mill, and t+us 0ill run 0it+ +ig+er stabilit)-

F!a"n&--1

Roll deDection

Maintaining a uni(orm gap bet0een t+e rolls is di((icult because t+e rolls de(lect under t+e load reuired tode(orm t+e 0or1piece- !+e de(lection causes t+e 0or1piece to be t+inner on t+e edges and t+ic1er in t+e middle!+is can be o*ercome b) using a cro0ned roller >parabolic cro0n?, +o0e*er t+e cro0ned roller 0ill onl)compensate (or one set o( conditions, speci(icall) t+e material, temperature, and amount o( de(ormation-O44P

$t+er met+ods o( compensating (or roll de(ormation include continual *ar)ing cro0n >CVC?, pair cross rollingand 0or1 roll bending- CVC 0as de*eloped b) "M""iemag A and in*ol*es grinding a t+ird order pol)nomial cur*e into t+e 0or1 rolls and t+en s+i(ting t+e 0or1 rolls laterall), euall), and opposite to eac+ot+er- !+e e((ect is t+at t+e rolls 0ill +a*e a gap bet0een t+em t+at is parabolic in s+ape, and 0ill *ar) 0it+lateral s+i(t, t+us allo0ing (or control o( t+e cro0n o( t+e rolls d)namicall)- air cross rolling in*ol*es usingeit+er (lat or parabolicall) cro0ned rolls, but s+i(ting t+e ends at an angle so t+at t+e gap bet0een t+e edges o(t+e rolls 0ill increase or decrease, t+us allo0ing (or d)namic cro0n control- Wor1 roll bending in*ol*es using+)draulic c)linders at t+e ends o( t+e rolls to counteract roll de(lection-

!+e di((erent classi(ications (or (latness de(ects are2

https://en.wikipedia.org/wiki/Rolling_(metalworking)#cite_note-degarmo388-11https://en.wikipedia.org/wiki/Rolling_(metalworking)#cite_note-degarmo388-11


21/62

• ")mmetrical edge 0a*e t+e edges on bot+ sides o( t+e 0or1piece are 0a*) due to t+e material at t+eedges being longer t+an t+e material in t+e center-

• As)mmetrical edge 0a*e one edge is 0a*) due to t+e material at one side being longer t+an t+e ot+erside-

• Center buc1le !+e center o( t+e strip is 0a*) due to t+e strip in t+e center being longer t+an t+e stripat t+e edges-

• /uarter buc1le !+is is a rare de(ect 0+ere t+e (ibers are elongated in t+e uarter regions >t+e portion o(t+e strip bet0een t+e center and t+e edge?- !+is is normall) attributed to using ecessi*e roll bending(orce since t+e bending (orce ma) not compensate (or t+e roll de(lection across t+e entire lengt+ o( t+eroll-

It is important to note t+at one could +a*e a (latness de(ect e*en 0it+ t+e 0or1piece +a*ing t+e same t+ic1nessacross t+e 0idt+- Also, one could +a*e (airl) +ig+ cro0n or 0edge, but still produce material t+at is (lat- In order

to produce (lat material, t+e material must be reduced b) t+e same percentage across t+e 0idt+- !+is isimportant because mass (lo0 o( t+e material must be preser*ed, and t+e more a material is reduced, t+e more itis elongated- I( a material is elongated in t+e same manner across t+e 0idt+, t+en t+e (latness coming into t+emill 0ill be preser*ed at t+e eit o( t+e mill-

D!a*t

!+e di((erence bet0een t+e t+ic1ness o( initial and rolled metal piece is called 'ra(t- !+us i( tE is initiat+ic1ness and t( is (inal t+ic1ness, t+en t+e dra(t SdH is gi*en b)

!+e maimum dra(t t+at can be ac+ie*ed *ia rollers o( radius R 0it+ coe((icient o( static (riction ( bet0een t+eroller and t+e metal sur(ace is gi*en b)

!+is is t+e case 0+en t+e (rictional (orce on t+e metal (rom inlet contact matc+es t+e negati*e (orce (rom t+e

eit contact-

S!*ae )e*ets

!+ere are si t)pes o( sur(ace de(ects2

• La( 2 !+is t)pe o( de(ect occurs 0+en a corner or (in is (olded o*er and rolled but not 0elded into t+emetal- !+e) appear as seams across t+e sur(ace o( t+e metal-

M-""?s&ea!-n# !+ese de(ects occur as a (eat+erli1e lap- Ro""e)?-n sa"e !+is occurs 0+en mill scale is rolled into metal-

https://en.wikipedia.org/wiki/Mill_scalehttps://en.wikipedia.org/wiki/Mill_scale


22/62

Sa0s :!+ese are long patc+es o( loose metal t+at +a*e been rolled into t+e sur(ace o( t+e metal- Sea%s !+e) are open, bro1en lines t+at run along t+e lengt+ o( t+e metal and caused b) t+e presence o(

scale as 0ell as due to pass roug+ness o( Roug+ing mill- S"-1e!s rominent sur(ace ruptures-

PROCESS FLOW CHART OF HOT ROLLING MILL

E) **

SHAR

3E **

SHAR

"R

P:H

R?@@

"R

"A@

#?RC

R?@@S@AS

FR?*

S?AC:B

"R

P:HR?@@

HR P@A"S

F?R PGSA#

HR ?:@S

F?R ?@>

*:@@

:"

?:@R

"R

?:@R


23/62

DESCRIPTION OF THE E@UIPMENT

BLISS HOT MILL

MA=# M$'#RNI3#' 2 BLI"" 'AV


24/62


25/62

EXTRUSION PRESS

WHAT IS EXTRUSION

In general, etrusion is t+e process o( gi*ing t+e desired s+ape to a bloc1 o( metal- It is a plastic de(ormation process in 0+ic+ a bloc1 o( metal >billet? is (orced to (lo0 b) compression t+roug+ t+e die opening o( smallercrosssectional area t+an t+at o( original billet- !+e etruded product ta1es t+e same s+ape and siJe, as t+at o(die-

Fig 2 'e(inition and principle o( etrusion

#trusion is an indirectcompression process- Indirectcompressi*e (orces are de*eloped b) t+e reaction o( t+e0or1piece >billet? 0it+ t+e container and die t+ese (orces reac+ +ig+ *alues- !+e reaction o( t+e billet 0it+ t+econtainer and die results in +ig+ compressi*e stresses t+at are e((ecti*e in reducing t+e crac1ing o( t+e billetmaterial during primar) brea1do0n (rom t+e billet- #trusion is t+e best met+od (or brea1ing do0n t+e caststructure o( t+e billet because t+e billet is sub.ected to compressi*e (orces onl)- #trusion can be cold or +ot


26/62

depending on t+e allo) and t+e met+od used- In +ot etrusion, t+e billet is pre+eated to (acilitate plasticde(ormation-

CLASSIFICATION OF EXTRUSION:

6' De(en)-n# on te%(e!at!e: >a? %ot etrusion >b? Cold etrusion In +otetrusion, t+e billet is pre+eated to (acilitate plastic de(ormation-

2' De(en)-n# on *"o+: >a? 'irect etrusion >b? Indirect etrusion

DIRECT EXTRUSION :

!+e most important and common met+od used in aluminum etrusion is t+e direct process- Figure s+o0s t+e

principle o( direct etrusion 0+ere t+e billet is placed in t+e container and pus+ed t+roug+ t+e die b) t+e ram pressure- 'irect etrusion (inds application in t+e manu(acture o( solid rods, bars, +ollo0 tubes, and +ollo0 andsolid sections according to t+e design and s+ape o( t+e die- In direct etrusion, t+e direction o( metal (lo0 0ill be in t+e same direction as ram tra*el- 'uring t+is process, t+e billet slides relati*e to t+e 0alls o( t+e container!+e resulting (rictional (orce increases t+e ram pressure considerabl)- 'uring direct etrusion, t+e load or pressuredisplacement cur*e most commonl) +as t+e (orm s+o0n in Fig- !raditionall), t+e process +as beendescribed as +a*ing t+ree distinct regions2

4? !+e billet is upset, and pressure rises rapidl) to its pea1 *alue-5? !+e pressure decreases, and 0+at is termed stead) state etrusion proceeds-

6? !+e pressure reac+es its minimum *alue (ollo0ed b) a s+arp rise as t+e discard iscompacted-In %IN'ALC$ 'irect%ot etrusion is emplo)ed-


27/62

Variation o( load or pressure 0it+ ram tra*el (or bot+ direct and indirect etrusion process

INDRIECT EXTRUSION :

In indirect etrusion, t+e die at t+e (ront end o( t+e +ollo0 stem mo*es relati*e to t+e container, but t+ere is no

relati*e displacement bet0een t+e billet and t+e container as s+o0n in Fig-9- !+ere(ore, t+is process isc+aracteriJed b) t+e absence o( (riction bet0een t+e billet sur(ace and t+e container, and t+ere is nodisplacement o( t+e billet center relati*e to t+e perip+eral regions- !+e *ariation o( load or pressure 0it+ t+e ramtra*el during bot+ direct and indirect etrusion processes is s+o0n in Fig- abo*e-

Fig 2 Indirect #trusion rocess

TERMINOLGY IN EXTRUSION:

6' E=t!s-on Rat-o: It is de(ined as t+e ratio o( area container to t+e (inial area o( etruded product-

#trusion ratio Ac Ae

W+ere,

Ac Area o( container Ae Area o( etrusion

2' D-e Fato!: It is t+e ratio o( die perimeter to 1g per meter o( die or etruded product-

'ie (actor die perimeter >1gmeter?


28/62


29/62

Allo) (lo0 stress

Fig2 #((ect o( principle *ariables on etrusion

ISOTHERMAL TEMPERATURE

!+e eit temperature can *ar) during etrusion 0it+ a constant ram speed due to mec+anics andt+ermod)namics o( de(ormation processes- A temperature increase to0ard t+e beginning and t+e end oetrusion is obser*ed (or a gi*en billet and container under di((erent etrusion conditions, suc+ as ram speeddie parameters, and allo) c+aracteristics- !+is c+ange o( temperature during etrusion is in (ull agreement 0it+man) t+eoretical calculations- #trusion 0it+ a constant eit temperature is re(erred to as isot+ermal etrusionand +as practical interests (or ac+ie*ing a uni(orm product ualit) and +ig+er producti*it)-

!+e practicalandeconomical*alueo(isot+ermaletrusionist+at,eceptat t+e *er) beginning, it allo0s t+e use ot+e optimum etrusion speed o*er t+e complete etrusion c)cle- $n t+e ot+er +and, i( t+e eit temperature*aries during etrusion b) an un1no0n amount, t+e press speed is usuall) ad.usted in accordance 0it+ t+emaimum pre*ailing temperature-

In t+e case o( a continuall) increasing eit temperature o( aluminum allo) etrusion, isot+ermal etrusion can be carried out in t+e (ollo0ing 0a)s2

• Reducing t+e eit speed during t+e etrusion according to t+e measured eit temperature- !+is reuires

continuous temperature measurement-• Reducing t+e etrusion speed according to a preselected speed program- $n a modern press, t+e ram

displacement can be di*ided into steps o( *ar)ing lengt+s, eac+ 0it+ a programmed speed-• Non uni(orm +eating o( t+e billet to gi*e a lo0er temperature at t+e bac1 o( t+e billet- !+is is 1no0n as

taper +eating and can be ac+ie*ed b) induction +eating 0it+ suitable coil connections or b) usingadditional burners, 0+ic+ trans(er more +eat to t+e (ront o( t+e billet t+an to t+e rear, in gas (urnaces-Anot+er met+od is to +eat t+e billet uni(orml), and t+en uenc+ t+e bac1 end 0it+ a 0ater spra) as t+e billet is trans(erred (rom t+e (urnace to t+e container-

!+e most common industrial met+ods o( isot+ermal etrusion o( aluminum allo)s are t+e (ollo0ing2


30/62

• !aper +eating or taper uenc+ing billet prior to (eeding into t+e container• 'irect measurement o( t+e etrusion temperature using noncontact s)stem and a (eedbac1 bet0een

measured temperature and t+e etrusion ram speed

P!-n-("e an) Bene*-ts o* Isot&e!%a" E=t!s-on:

!+e principle o( isot+ermal etrusion as s+o0n in Fig- 45 is to get constant etrusion temperature (or a set o(

input *ariables, including billet lengt+, initial billet temperature, etrusion ratio, and ram speed- !+e bene(its o(isot+ermal process in direct etrusion are uite signi(icant2

• Impro*ed dimensional stabilit)• Uni(orm sur(ace ualit)• Impro*ed or consistent mec+anical properties 0it+ uni(orm microstructure• Faster etrusion speed to increase producti*it)• Better air *enting t+roug+ t+e container, reduced brea1t+roug+ pressure, and so on

Te%(e!!emper is t+e combination o( aluminum +ardness and strengt+ produced b) mec+anical andor t+ermaltreatments- !+e measures used to test mec+anical properties o( aluminum are tensile, )ield, and elongation-Tens-"e is an indication o( t+e maimum pulling load t+at a material can stand 0it+out (ailure, usuall) measuredin pounds per suare inc+ o( crosssectional area- Y-e") is t+e stress at 0+ic+ a material (irst e+ibits a speci(ic permanent set- E"on#at-on is t+e maimum percentage o( stretc+ a material 0ill stand be(ore brea1ing- Ade(ined range o( allo) and temper properties must be met in order to satis() certi(icate o( compliancereuirements-

Ro,+e"" Ha!)ness is an indentation +ardness test based on t+e penetration dept+ o( a speci(ied penetrator intoa specimen under certain (ied conditions-

We0ste! is a relati*e indicator o( +ardness but does not guarantee certi(icate o( compliance reuirements-

BILLET PROCESS EFFICIENCIES


31/62

DIE TYPES

ETRUSION DIES

SOLID OR FLAT FACES DIES

SOLID DIE


32/62

HOLLO3 DIE

HOLLO3 DIE

BEARING SURFACES

CONTROL MATERIAL FLO3


33/62

DIE STACK

BILLET PROCESS EFFICIENCIES

ETRUSION PRESS SCHEMATIC DIAGRAM 1


34/62

Pa!ts o* t&e P!ess


35/62

Understanding +o0 an etrusion press 0or1s reuires identi()ing t+e press parts and eplaining t+eir use- Anetrusion press is made up o( a (ront platen and bac1 platen +eld toget+er b) (our tie rods- !+e parts o( t+e presst+at actuall) ma1e t+e etrusion are as (ollo0s2

Ma-n C


36/62

Ba,F!ont P!ess P"aten !+e etrusion press consists o( t+ese t0o sections-

T-e Ro)s Connects t+e bac1 and (ront press platen-

Can-ste! used to +elp guide t+e aluminum etrusions (rom t+e die- It +as t+e same number o( +oles as

t+e die itsel( and can be used on all presses- Ne0nan is mo*ing a0a) (rom using t+em because t+e) arecostl) and +ard to +andle-

P"aten P!ess!e R-n# A +ardened tool steel ring inserted into t+e platen to support t+e die stac1

ressure applied b) t+e main c)linder to t+e ring causes stress and 0ear resulting in a need (or periodicreplacement-

Ste(s -n t&e a"%-n% e=t!s-on (!oess

4- Billets must be +eated to approimatel) ;EED58 F-

5- A(ter a billet reac+es t+e desired temperature, it is trans(erred to t+e loader 0+ere a t+in (ilm o( smut olubricant is added to t+e billet and to t+e ram- !+e smut acts as a parting agent >lubricant? 0+ic+ 1eepst+e t0o parts (rom stic1ing toget+er-

6- !+e billet is trans(erred to t+e cradle-

7- !+e ram applies pressure to t+e dumm) bloc1 0+ic+, in turn, pus+es t+e billet until it is inside t+econtainer-

8- Under pressure t+e billet is crus+ed against t+e die, becoming s+orter and 0ider until it +as (ull contac0it+ t+e container 0alls- W+ile t+e aluminum is pus+ed t+roug+ t+e die, liuid nitrogen (lo0s aroundsome sections o( t+e die to cool it- !+is increases t+e li(e o( t+e die and creates an inert atmosp+ere0+ic+ 1eeps oides (rom (orming on t+e s+ape being etruded- In some cases nitrogen gas is used in place o( liuid nitrogen- Nitrogen gas does not cool t+e die but does create an inert atmosp+ere-

9- As a result o( t+e pressure added to t+e billet, t+e so(t but solid metal begins to sueeJe t+roug+ t+e dieopening-

:- As an etrusion eits t+e press, t+e temperature is ta1en 0it+ a !rue !emperature !ec+nolog) >6!instrument mounted on t+e press platen- !+e 6! records eit temperature o( t+e aluminum etrusion- !+emain purpose o( 1no0ing t+e temperature is to maintain maimum press speeds- !+e target eittemperature (or an etrusion is dependent upon t+e allo)- For eample, t+e target eit temperature (or t+eallo)s 9E96, 9796, 9E96A, and 94E4 is D6E F >minimum?- !+e target eit temperature (or t+e allo)s9EE8A, and 9E94 is D8E F >minimum?-

;- #trusions are pus+ed out o( t+e die to t+e leadout table and t+e puller, 0+ic+ guides metal do0n t+erunout table during etrusion- W+ile being pulled, t+e etrusion is cooled b) a series o( (ans along t+e


37/62


38/62


39/62

?:@ IS 8 SR7? SS"* 7B 2))

F::SH I" 8 ).E *"R N 23 *"R #:"H AI"? S"ACR

TERMINOLOGIES IN OPERATION1

89 S&'i:' P+&--*+&1 "his is the pressure inside the container. :t is de6ned as unit

pressure i.e. force per unit container area. As the container bore increases, the speci6c

pressure inside the container decreases, and as a result, e/trusion capability decreases.

29 U;S&""in1 #hene!er a hot billet going to e/trude, 6rst it takes the shape same as

that of container by the ram pressure.

9 D&a? C)'!& Ti(&1 :t is de6ned as non=producti!e time, in $hich e/trusion of meta

does not take place.

@9 B*+ C)'!&1 "he burp cycle is used $ith bridge, porthole and sometimes=Dat dies. :t

does not aOect the basic cycle e/cept to interrupt it for a short period. "he purpose of

burp cycle is to release trapped air at the die face. ?ther$ise, e/trusion defects like

blisters etc may take place.

9 D+) ')'!&1 "he press cycle $ithout the billet is kno$n as dry cycle. "his is done for

testing of press.

79 En? S!# S"+#=&1 At the end of e/trusion, $e slo$ do$n the speed of ram and

hence e/trusion. "he main reason is that, during e/trusion, $hen billet length becomesshorter, the pressure increases on die. So, there may be chances of breaking of die or

cracking of e/truded product. "his phenomenon generally happens $ith harder alloy. So,

$e decide and feed the length of billet in P@, from $hich $e need to slo$ do$n the

e/trusion speed.

Bi!!&" T&(&+a"*+& Ran&1

A! A!!#) G+#* Bi!!&" T&(&+a"*+&

Ran& C9

D&"ai!-

2 (E)=(E) PIR A@I*::I*

4 (E)=(J) ?PPR

3 (()=(J) *n

( (()=(J) Si

E (+)=E)) *g

+ (()=E)) *n & *g

J (+)=() ==


40/62

APPLICATION OF MAOR ALLOYS:

• 6XXX #lectrical Conductors, Cables etc-• 2XXX %ig+ "tressed Components, Aircra(ts etc-• XXX Welding Wire-• XXX "tructure #posed to marine atmosp+ere, Wire ropes etc-• 7XXX "tructural and general #ngg- Items, #lectrical Bus Car etc-• 5XXX Ver) %ig+ strengt+ structure used in de(ence-

Ain1

"o get the re1uired mechanical properties of the material, aging is done. :t is the process

of heating and soaking the material to the re1uired length of time. #hene!er a customer

needs the material designated $ith "+ and "+=4, $hich means they re1uire the materia

$ith good hardness and hardness $ith bending property respecti!ely, so the material

must undergone through aging.

"he follo$ing designation is adopted for some material in our plant8

R2= aging at 42JQ for 22 hours, counduti!ity=E+.E

R4= aging at 422Q for 2) hours, counduti!ity=EE

ETRUSION PROCESS SCRAP 1

utt Scrap 8 3 to E

nd Scrap 8 2) to 2E

MAJOR ETRUSION DEFECTS 1

?O >imension

Scratches, >ent etc.

lister

>ie @ining

end and Cink

?range Peel o=ring or Piping

hatter

Failure of the *echanical properties

H)?+a*!i' C)!in?&+1


41/62

A Hydraulic cylinder ;also called a linear hydraulic motor< is a mechanical actuator that is

used to gi!e a unidirectional force through a unidirectional stroke.

Hydraulic cylinders get their po$er from pressuri9ed hydraulic Duid, $hich is typically oil.

"he hydraulic cylinder consists of a cylinder barrel, in $hich a piston connected to a

piston rod mo!es back and forth. "he barrel is closed on each end by the cylinder bottom

; also called the cap end < and by the cylinder head $here the piston rod comes out of

the cylinder. "he piston has sliding rings and seals. "he piston di!ides the inside of the

cylinder in t$o chambers, the bottom chamber ;cap end< and the piston rod side

chamber ; rod end


42/62

A hydraulic cylinder consists of the follo$ing parts=

C)!in?&+ a++&!1 "he cylinder barrel is mostly a seamless thick $alled forged pipe

that must be machined internally. "he cylinder barrel is ground andGor honed

internally.

C)!in?&+ a-& #+ 'a1 :n most hydraulic cylinders, the barrel and the bottom

portion are $elded together. "his can damage the inside of the barrel if done

poorly. "herefore, some cylinder designs ha!e a scre$ed or Danged connection

from the cylinder end cap to the barrel. ;See "ie rod cylinder, belo$< :n this type

the barrel can be disassembled and repaired.

C)!in?&+ %&a?1 "he cylinder head is sometimes connected to the barrel $ith a

sort of a simple lock ;for simple cylinders


43/62

bearing to support the $eight of the piston rod and guides it as it passes back and

forth through the rod gland. :n some cases, especially in small hydraulic cylinders,

the rod gland and the rod $ear ring are made from a single integral machined part.

O"%&+ a+"-189 ylinder base connection29 Sealsblast (urnace gas?

Gases %a)e *!o% (et!o"e%

• Liue(ied etroleum gas >L?• Re(iner) gases• ases (rom oil gasi(ication X ases (rom some (ermentation process

P!o(e!t-es o* #aseos *e"s

"ince most gas combustion appliances cannot utiliJe t+e +eat content o( t+e 0ater *apour, gross calori(ic *alueis o( little interest- Fuel s+ould be compared based on t+e net calori(ic *alue- !+is is especiall) true (or naturalgas, since increased +)drogen content results in +ig+ 0ater (ormation during combustion-


44/62


45/62

ha!e to tra!el through the heat e/changer and up the stack faster to allo$ the

introduction of additional fuel air mi/ture.

"his nitrogen also can combine $ith o/ygen ;particularly at high Dame temperatures< to

produce o/ides of nitrogen ;?/


46/62

Waste Heat Reo1e!<

Waste +eat reco*er) s)stems etract energ) (rom (urnace e+aust gases and rec)cle it bac1 into t+e process-"igni(icant e((icienc) impro*ements can be ac+ie*ed b) using t+e reco*ered +eat to pre+eat t+e combustion airor c+arge material, generate steam, +eat 0ater, or suppl) +eat to ot+er processes- Recuperators are generall)used to reco*er +eat (rom clean (lue gases >as in aluminum re+eating or +eat treating (urnaces?, 0+ereasregenerators 0it+ ceramic +eat trans(er media are used 0it+ (lue gases containing contaminants >as in aluminummelters?-

4? P!e&eat o%0st-on a-! Waste +eat reco*er) de*ices >0+et+er regenerati*e burners or recuperators placed in t+e (lue gas outlet or e+aust stac1 can etract a large portion o( t+e t+ermal energ) in (luegases and trans(er it to t+e incoming combustion air- rocesses operating abo*e 4,7EEY F are generall)good candidates (or combustion air pre+eating, alt+oug+ it ma) also be used coste((ecti*el) in processes 0it+ temperatures as lo0 as 4,EEEY F-

5? P!e&eat t&e &a!#e"oa). !rans(erring +eat (rom +ig+temperature e+aust gases to t+e relati*el) cooincoming load can reduce t+e energ) reuired in t+e (urnace and lo0er t+e energ) t+at escapes in t+e

e+aust gases- %eat (rom (urnace (lue gases can be used to dr) t+e c+arge and pre+eat t+e load (ormelting (urnaces or to pre+eat t+e load (or +eating and +eat treating (urnaces-

6? Casa)e +aste &eat. !+e +eat (rom e+aust gases can be used as a source o( +eat (or lo0er temperature process +eating euipment- For eample, 0aste +eat boilers can use t+e t+ermal energ) (rom (lue gasesto generate +ot 0ater or steam- Waste +eat (rom +eattreating (urnaces can also be used in aging or paintdr)ing o*ens- !o maimiJe bene(its o( t+e +eat reco*er), t+e do0nstream +eating euipment must be inoperation 0+ile t+e (urnace is operating

SOME E@UIPMENTS USED IN FURNACE :

F"e #as &eat !eo1e!< 3 o%0st-on a-! (!e&eat-n# 0< s-n# *"e #as &eat -n a !e(e!ato!

!+e most commonl) used combustion air pre+eating arrangement is commonl) 1no0n as a recuperator s)stem(or aluminum +eating (urnaces- In t+is case (lue gases or combustion products (rom a (urnace are directed to anair pre+eater- In almost all cases 0+ere a recuperator is used, t+e (lue gas temperature (rom an aluminummelting (urnace is too +ig+ (or t+e materials used in t+e air pre+eater de*ise and it is necessar) to temper t+e(lue gases and bring t+em do0n to a temperature o( about ;:4C >49EEF? or lo0er prior to t+eir introduction tot+e air pre+eater de*ice- At t+is time t+e economics >capital cost *s- sa*ings? o( (lue gas +eat reco*er) (orcombustion air pre+eating allo0 7EK to 9EK +eat reco*er)-

!+e industr) uses se*eral designs o( recuperators +o0e*er, t+e) can be broadl) di*ided into t0o categories2con*ecti*e recuperators and radiation recuperators-

Con1et-on !e(e!ato!s2 Con*ection recuperators use t+ermal con*ection as a primar) mode o( +eat trans(eron t+e (lue gas side as 0ell as t+e combustion air side- A t)pical con*ection recuperator design includes anumber o( tubes- Combustion air or (lue gases pass t+roug+ t+e tubes and ot+er gases >(lue gases or combustionair respecti*el)? (lo0 o*er t+e tubes- %eat is trans(erred (rom (lue gases to t+e tubes and t+en (rom tubesur(aces to combustion air- Flo0 o( (lue gases and air can be parallel >in t+e same direction? or counter (lo0>cold air enters t+e area 0+ere cooled (lue gases are disc+arged and +ot (lue gases enter t+e area 0+ere +ot air is


47/62

disc+arged to burners? or cross (lo0 >(lue gases or combustion air (lo0s in t+e cross 0ise direction T DE T tot+e combustion air or (lue gases respecti*el)?-

Ra)-at-on !e(e!ato! 2 !+e radiation recuperator design is based on t+e use o( t+ermal radiation (rom +ig+temperature (lue gases containing C$5 and %5$ to pre+eat combustion air- In t+is case (lue gases pass t+roug+a metallic stac1 t+at is surrounded b) t+e (lo0ing combustion air- %eat trans(er on t+e (lue gas side is b)t+ermal radiation 0+ile it is b) con*ection on t+e combustion air side- !+is design is most suitable (or (urnacest+at disc+arge (lue gases abo*e :9EC >47EEF? and use relati*el) large stac1s, usuall) larger t+an 4-5 m >7 (t?in diameter-


48/62

A t)pical con(iguration (or radiation recuperator is s+o0n in Fig- It s+ould be noted t+at *er) (e0 aluminummelting (urnaces in t+e U" use radiation t)pe recuperators-

FI 2 #AML# $F A RA'IA!I$N !usuall) $)gen (rom air? to produce +eat in a controlled 0a)-


49/62

TYPES OF BURNER :

P!e%-=

• Fan po0ered so t+at t+e (uelair ratio can be care(ull) controlled-

•

Run lean >Z5EK? 0it+ N$emissions [ 78 mg1W+

• !)picall) produce s+ort intense blue (lames

• "+ort reaction Jones and t+e +ig+est burning *elocities +ence t+e smallest residence times & +ig+e((iciencies

• !+e +eat ec+anger can >and s+ould? be located *er) close to cool t+e e+aust as uic1l) as possible toa*oid N$(ormation-

At%os(&e!-

• Most common t)pe o( domestic burner >tube arra)s, blade assemblies?, lo0 cost manu(acture 0it+ littlemaintenance-

• artiall) premiing >air entrained into gas stream be(ore burner? to lo0er (lame temperature-

• Run on a ric+air mi to (orm inner combustion Jone, pre*enting t+ermal N$0it+ lo0 $ concentration-

• !end to gi*e relati*el) large (lame *olumes gi*ing longer residence times (or N$production to occur-

CENTRIFUGAL FAN:

A ent!-*#a" *an is a mec+anical de*ice (or mo*ing air or ot+er gases- !+e terms blo0er and suirrel cage(an >because it loo1s li1e a +amster 0+eel? are (reuentl) used as s)non)ms- !+ese (ans increase t+e speed oair stream 0it+ t+e rotating impellers-

!+e) use t+e 1inetic energ) o( t+e impellers or t+e rotating blade to increase t+e pressure o( t+e airgas stream

0+ic+ in turn mo*es t+em against t+e resistance caused b) ducts, dampers and ot+er components- Centri(ugal(ans accelerate air radiall), c+anging t+e direction >t)picall) b) DE? o( t+e air(lo0- !+e) are sturd), uietreliable, and capable o( operating o*er a 0ide range o( conditions-

Centri(ugal (ans are constant displacement de*ices or constant *olume de*ices, meaning t+at, at a constant (anspeed, a centri(ugal (an 0ill pump a constant *olume o( air rat+er t+an a constant mass- !+is means t+at t+e air*elocit) in a s)stem is (ied e*en t+oug+ mass (lo0 rate t+roug+ t+e (an is not-

ORIFICE PLATE 1

https://en.wikipedia.org/wiki/Airhttps://en.wikipedia.org/wiki/Airhttps://en.wikipedia.org/wiki/Airhttps://en.wikipedia.org/wiki/Gashttps://en.wikipedia.org/wiki/Gashttps://en.wikipedia.org/wiki/Hamster_wheelhttps://en.wikipedia.org/wiki/Impellerhttps://en.wikipedia.org/wiki/Impellerhttps://en.wikipedia.org/wiki/Airhttps://en.wikipedia.org/wiki/Gashttps://en.wikipedia.org/wiki/Hamster_wheelhttps://en.wikipedia.org/wiki/Impellerhttps://en.wikipedia.org/wiki/Impeller


50/62

An ori(ice plate is a de*ice used (or measuring (lo0 rate, (or reducing pressure or (or restricting (lo0 >in t+elatter t0o cases it is o(ten called a restriction plate?- #it+er a *olumetric or mass (lo0 rate ma) be determineddepending on t+e calculation associated 0it+ t+e ori(ice plate- It uses t+e same principle as a Venturi noJJlenamel) Bernoullis principle 0+ic+ states t+at t+ere is a relations+ip bet0een t+e pressure o( t+e (luid and t+e*elocit) o( t+e (luid- W+en t+e *elocit) increases, t+e pressure decreases and *ice *ersa-

D&-'+i"i#n

Fig 8 ?ri6ce plate sho$ing vena contracta

An ori(ice plate is a t+in plate 0it+ a +ole in it, 0+ic+ is usuall) placed in a pipe- W+en a (luid >0+et+er liuidor gaseous? passes t+roug+ t+e ori(ice, its pressure builds up slig+tl) upstream o( t+e ori(iceO4P2;8T;9 but as t+e(luid is (orced to con*erge to pass t+roug+ t+e +ole, t+e *elocit) increases and t+e (luid pressure decreases- Alittle do0nstream o( t+e ori(ice t+e (lo0 reac+es its point o( maimum con*ergence, t+e vena contracta >seedra0ing to t+e rig+t? 0+ere t+e *elocit) reac+es its maimum and t+e pressure reac+es its minimum- Be)ondt+at, t+e (lo0 epands, t+e *elocit) (alls and t+e pressure increases- B) measuring t+e di((erence in (luid

pressure across tappings upstream and do0nstream o( t+e plate, t+e (lo0 rate can be obtained (rom Bernoulliseuation using coe((icients establis+ed (rom etensi*e researc+

P!ess!e ta((-n#s

!+ere are t+ree standard positions (or pressure tappings >also called taps?, commonl) named as (ollo0s2

• Corner taps placed immediatel) upstream and do0nstream o( t+e plate con*enient 0+en t+e plate is pro*ided 0it+ an ori(ice carrier incorporating tappings

• D and D/2 taps or radius taps placed one pipe diameter upstream and +al( a pipe diameter do0nstreamo( t+e plate t+ese can be installed b) 0elding bosses to t+e pipe

• Flange taps placed 58-7mm >4 inc+? upstream and do0nstream o( t+e plate, normall) 0it+in specialised pipe (langes-

:ncompressible Do$

https://en.wikipedia.org/wiki/Venturi_effecthttps://en.wikipedia.org/wiki/Bernoulli's_principlehttps://en.wikipedia.org/wiki/Orifice_plate#cite_note-Linford-1https://en.wikipedia.org/wiki/Orifice_plate#cite_note-Linford-1https://en.wikipedia.org/wiki/Venturi_effecthttps://en.wikipedia.org/wiki/Bernoulli's_principlehttps://en.wikipedia.org/wiki/Orifice_plate#cite_note-Linford-1


51/62

B) assuming stead)state, incompressible >constant (luid densit)?, in*iscid, laminar (lo0 in a +oriJontal pipe>no c+ange in ele*ation? 0it+ negligible (rictional losses, Bernoullis euation reduces to an euation relatingt+e conser*ation o( energ) bet0een t0o points on t+e same streamline2

$r

B) continuit) euation2

or V 1 ! / "1 and V 2 ! / "2 2

"ol*ing (or ! 2

!+e abo*e epression (or / gi*es t+e t+eoretical *olume (lo0 rate- Introducing t+e beta (actor as

0ell as t+e disc+arge coe((icient 2

And (inall) introducing t+e meter coe((icient C 0+ic+ is de(ined as

to obtain t+e (inal euation (or t+e *olumetric (lo0 o( t+e (luid t+roug+ t+e ori(ice2

https://en.wikipedia.org/wiki/Incompressible_flowhttps://en.wikipedia.org/wiki/Inviscid_flowhttps://en.wikipedia.org/wiki/Laminar_flowhttps://en.wikipedia.org/wiki/Bernoulli's_principlehttps://en.wikipedia.org/wiki/Discharge_coefficienthttps://en.wikipedia.org/wiki/Incompressible_flowhttps://en.wikipedia.org/wiki/Inviscid_flowhttps://en.wikipedia.org/wiki/Laminar_flowhttps://en.wikipedia.org/wiki/Bernoulli's_principlehttps://en.wikipedia.org/wiki/Discharge_coefficient


52/62

Multipl)ing b) t+e densit) o( t+e (luid to obtain t+e euation (or t+e mass (lo0 rate at an) section in t+e pipe2

$here8

U !olumetric Do$ rate ;at any cross=section


53/62

!+e parameter is o(ten re(erred to as t+e velocit# of approach factor and multipl)ing t+e coe((icient

o( disc+arge b) t+at parameter >as 0as done abo*e? produces t+e (lo0 coe((icient C - Met+ods also eist (or

determining t+e (lo0 coe((icient as a (unction o( t+e beta (unction and t+e location o( t+e do0nstream

pressure sensing tap- For roug+ approimations, t+e (lo0 coe((icient ma) be assumed to be bet0een E-9E and

E-:8- For a (irst approimation, a (lo0 coe((icient o( E-95 can be used as t+is approimates to (ull) de*eloped

(lo0-

Pa!a%ete!s on +&-& 1o"%e *"o+ !ate t&!o#& o!-*-e ("ate )e(en)s : ?

From t+e euation o( (lo0 t+roug+ ori(ice plate 0e see t+at t+e *olume (lo0 rate depends in*ersel) on t+e

densit) o( t+e (luid-

/m \ >4 T 5? p p

/p \ >4 T 5? pm

"o (or same pressure di((erence t+e *olume (lo0 rate 0ill be in*ersel) proportional to densit) o( t+e gases-

"ince relati*e densit) o( met+ane gas E-9

And relati*e densit) o( propane gas 4-85

"o /p \ pm p p /m

So @( 8.7294 X @%'ata (or t+e Met+ane >Natural as? are pro*ided as (ollo0s 2


54/62


55/62


56/62

Ta0"e : Vo"%e *"o+ !ate an) (!ess!e )-**e!ene De"ta P *o! T&e Gas O!-*-e F"an#e *o!

nat!a" #as $%et&ane'.


57/62

So using e1uation 4 .26< 4(

!+e table (or met+ane gas 0ill be con*erted into propane gas as (ollo0s2-

TABLE : F"o+ !ate o* (!o(ane o!!es(on)-n# to t&e (!ess!e )-**e!ene De"ta P *o! Gas

O!-*-e F"an#e *o! PROPANE GAS

FLANGIA TARATA

GAS PROPANE

DN 2 ? ᴓ 6

)-a *!a%%a D64 %%

FLANGIA TARATA

GAS PROPANE

DN 8 ? ᴓ 2

D-a *!a%%a D22 %%

De"ta P

%% H2O

PORTATE

PROPANE

N%4 &

PERDITE

RESIDUE

%% H2O

De"ta P

%% H2O

PORTATE

PROPANE

N%4 &

PERDITE

RESIDUE

%% H2O

E

4E

5E

6E

7E

8E

9E

:E

;E

DE4EE

44E

45E

46E

47E

E

6-E;

7-68

8-65

9-48

9-;:

:-86

;-47

;-:E

D-56D-:6

4E-5E

4E-99

44-4E

44-84

E

:

48

55

5D

69

77

84

8;

99:6

;E

;;

D8

4E5

E

4E

5E

6E

7E

8E

9E

:E

;E

DE4EE

44E

45E

46E

47E

E

D-E:

45-;5

48-:E

4;-46

5E-5:

55-5E

56-DD

58-97

5:-5E5;-9:

6E-E:

64-7E

65-9D

66-D5

E

;

49

47

66

74

7D

8:

98

:6;4

DE

D;

4E9

447


58/62

48E

49E

4:E

4;E

4DE5EE

54E

55E

56E

57E

58E

59E

5:E

5;E

5DE

6EE

64E

65E

66E

67E

44-9:

45-6E

45-9D

46-E8

46-7446-:9

47-ED

47-76

47-:8

48-E:

48-6;

48-9D

48-D;

49-5;

49-8:

49-;8

4:-45

4:-7E

4:-9:

4:-D7

4ED

44:

457

464

46D479

486

494

49;

4:8

4;5

4DE

4D:

5E7

545

54D

559

566

574

57;

48E

49E

4:E

4;E

4DE5EE

54E

55E

56E

57E

58E

59E

5:E

5;E

5DE

6EE

64E

65E

66E

67E

68-44

69-59

6:-6:

6;-79

6D-857E-87

74-87

75-85

76-7:

77-74

78-66

79-56

7:-44

7:-D:

7;-8:

7D-98

7D-98

84-5D

85-E;

85-;9

455

46E

46;

47:

488496

4:4

4:D

4;:

4D8

5E6

545

55E

55;

569

577

585

59E

59D

5::

An) Ta0"e *o! Vo"%e *"o+ !ate an) (!ess!e )-**e!ene De"ta P *o! T&e A-! O!-*-e F"an#e

+-"" 0e sa%e.


59/62

T&e )eta-"s *o! t&e Met&ane #as *o! one 9; 5; 7; ; -n *!nae *o! %a-nta-n-n# !eJ-!e) &eat-n# 1a"e -s:

"o For t+ese Jones *olume (lo0 rate (or met+ane gas is 84-5 Nm6+

And *olume (lo0 rate (or air is 87;-D Nm6+

"o (rom t+e table gi*en (or M#!%AN# A" >dia(ramma ᴓ 55mm ?and AIR >dia(ramma ᴓ D5mm?

We get corresponding pressure di((erence as '#L!A ARIA>AIR? 2 D-D mbar

And '#L!A NA!URAL A" 2 45-5 mbar -

We 1no0

Lo0er %eating Value o( met+ane ;698 1calNm6 ;698 7-4;9 1Nm6

Lo0er %eating Value o( propane D68:8 1Nm6

Volume Flo0 Rate (or met+ane 84-5 Nm6+

Volume Flo0 Rate (or propane ^

"ince 0e are reuired to 1eep t+e %eating po0er o( t+e (urnace same as earlier- "o

>Lo0er %eating Value? ] >Volume Flo0 Rate? o( Met+ane

>Lo0er +eating *alue? ]>Volume (lo0 rate? o( propane

So; Vo"%e F"o+ !ate o* (!o(ane 6>.67 N%4&

"ince Air 2 Fuel Ratio (or propane 58

So Vo"%e F"o+ !ate o* A-! 6>.67 2 N%4& 5> N%4&

T&e o!!es(on)-n# (!ess!e )-**e!ene a!oss Gas O!-*-e F"an#e an) A-! O!-*-e F"an#e *o! P!o(ane #as

an 0e *on) *!o% t&e Ta0"e *o! Gas $)-a*!a%%a ᴓ 22%% 'an) AIR $)-a*!a%%a ᴓ >2%%'


60/62

"o (or t+e Jones ;,:,9,8,7 in t+e (urnace2

!+e pressure di((erence across as ori(ice (lange (or propane gas is to be maintained at 7:-4E mm o( %5$

$r .72 %0a!

And !+e pressure di((erence across Air ori(ice (lange is to be maintained at 76-5: mm o( %5$

$r .2 %0a!.

T&e )eta-"s *o! t&e Met&ane #as *o! one 4;2;6 -n *!nae *o! %a-nta-n-n# !eJ-!e) &eat-n# 1a"e -s:

>dia(ramma ᴓ 55mm ?and AIR >dia(ramma ᴓ D5mm?

Volume (lo0 rate (or met+ane gas 4:-: Nm6+

Volume (lo0 rate (or air 4;D-6 Nm6+

'elta across as ori(ice (lange (or met+ane 46-5 mbar

'elta across Air $ri(ice Flange 45-D mbar

'ia(ramma (or as $ri(ice (lange ᴓ 55mm

'ia(ramma (or Air $ri(ice (lange ᴓ D5mm


61/62

We 1no0

Lo0er %eating Value o( met+ane ;698 1calNm6 ;698 7-4;9 1Nm6

Lo0er %eating Value o( propane D68:8 1Nm6

Volume Flo0 Rate (or met+ane 4:-: Nm6+

Volume Flo0 Rate (or propane ^

"ince 0e are reuired to 1eep t+e %eating po0er o( t+e (urnace in t+ese Jones same as earlier- "o

>Lo0er %eating Value? ] >Volume Flo0 Rate? o( Met+ane

>Lo0er +eating *alue? ]>Volume (lo0 rate? o( propane

So; Vo"%e F"o+ !ate o* (!o(ane 7.72 N%4&

"ince Air 2 Fuel Ratio (or propane 58

So Vo"%e F"o+ !ate o* A-! 7.72 2 N%4& 67 N%4&

T&e o!!es(on)-n# (!ess!e )-**e!ene a!oss Gas O!-*-e F"an#e an) A-! O!-*-e F"an#e *o! P!o(ane #as

an 0e *on) *!o% t&e Ta0"e *o! Gas $)-a*!a%%a ᴓ 64%% 'an) AIR $)-a*!a%%a ᴓ %%'

"o (or t+e Jones 4,5,6 in t+e (urnace2

!+e pressure di((erence across as ori(ice (lange (or propane gas is to be maintained at 77-6E mm o( %5$

$r .4 %0a!

And !+e pressure di((erence across Air ori(ice (lange is to be maintained at 7:-9E mm o( %5$

$r .77 %0a!.

An) P!o(ane Gas Connet-on Va"1e 667 N%4&

BIBLIOGRAPHY A te=t0oo, on ALUMINIUM EXTRUSION TECHNOLOGY 0< P SAHA

+++.a)-t


62/62

HINDALCO SUMMER TRAINING Report Main File

Documents

Transcript of HINDALCO SUMMER TRAINING Report Main File