Republic of the Philippines

Laguna State Polytechnic University

College of Engineering
S.Y. 2020-2021

DEL ROSARIO, CJ O. Engr. Precious Arlene Villaroza Melendrez

BSME-5F

SUMMARIZED TOPIC OF INDUSTRIAL PROCESS

Module 1: Feeders
• Feeders or sorters are the auxiliary equipment replacing the manual intervention of the
operator in loading the main machine with the products or components to be process.

Screw Feeder
➢ Designed to meter bulk materials and are typically located at the beginning of
a process. Capacity or feed rate can be accurately controlled with screw feeders.
➢ The inlet of a screw feeder is always flood loaded (100-percent). A screw feeder
is typically mounted directly to a:
o Hopper – Square or rectangular in shape with sloped bottom and
limited storage capacity
o Bin – Square or rectangular in shape with sloped bottom and large
storage capacity
o Silo – Cylindrical in shape with cone or mass-flow bottom and large
storage capacity

There are 3 types of screw feeders:

➢ Variable or Stepped Pitch
➢ Tapered Outside Diameter
➢ Mass Flow

Module 2: Conveyors

• Conveyor- a mechanized device used to move materials in relatively large quantities

between specific locations over a fixed path. (Dr. Red). This are the most most
commonly used Conveyors:
➢ Roller - A roller track for a storage rack or roller conveyor, comprising a wall
arrangement, and a longitudinally-extending array of freely rotatable roller
units.
 ➢ Chain - A conveyor on which material is transported along solid pans by the
scraping action of crossbars that are connected by chains.
➢ Portable - Portable conveyors are used primarily for applications involving
mobility and space is a high priority.
➢ Vibrating - Vibrating conveyor’s operation is typically based on the natural
frequency principle. At the natural frequency, the conveyor will vibrate
indefinitely with only a small energy input.
➢ Screw/Spiral - Spiral conveyors are used mainly for heating, cooling or
accumulation.
➢ Belt - Conveyor belts are used in a wide variety of material transport
applications such as manufacturing, food processing, and heavy industry.
➢ Overhead - Overhead Conveyor Systems are typically used to convey unit loads
in a variety of industrial applications.

Module 3: Cement Industry Processes

• Concrete is an extremely versatile material, being used in the production of anything from
nuclear radiation shields to playground structures and from bridges to yachts.

Manufacturing Process
➢ Plant Layout of Cement Plant
 ➢ Process Flow Chart

The Manufacturing Process

1. Limestone is taken from a quarry. It is the major ingredient needed for making
cement. Smaller quantities of sand and clay are also needed.
2. Boulder-size limestone rocks are transported from the quarry to the cement plant
and fed into a crusher who crushes the boulders into marble-size pieces.
3. The limestone pieces then go through a blender where they are added to the other
raw materials in the right proportion.
4. The raw materials are ground to a powder. This is sometimes done with rollers
that crush the materials against a rotating platform.
5. Everything then goes into a huge, extremely hot, rotating furnace to undergo
a process called “sintering”. Sintering means to cause to become a coherent
mass by heating without melting.
6. The clinker is cooled and ground into a fine gray powder. A small amount of
gypsum is also added during the final grinding.
Module 4: Steel Manufacturing Process
➢ History of Iron Making
As early as 6,000 years ago, early civilizations used iron ore found in meteorites to
construct primitive tools. The first iron furnaces appeared in about 1400 BC. These were
very simple rounded hearths in which iron ore and charcoal were heated to very high
temperatures.

➢ Modern Iron Making

Iron is manufactured in a blast furnace. First, iron ore is mixed with coke and heated to
form an iron-rich clinker called ‘sinter’. Sintering is an important part of the overall process
as it reduces waste and provides an efficient raw material for iron making. Coke is produced
from carefully selected grades of coal.

Sinter Plant

Coke, ore and sinter are fed, or ‘charged’, into the top of the blast furnace, together with
limestone. A hot air blast, from which the furnace gets its name, is injected through nozzles,
called ‘tuyeres’, in the base of the furnace.

Basic Oxygen Steel Making

➢ Coke, ore and sinter are fed, or ‘charged’, into the top of the blast furnace, together
with limestone. A hot air blast, from which the furnace gets its name, is injected
through nozzles, called ‘tuyeres’, in the base of the furnace.

Iron and Steel Making by Products

o There are three main types of marketed iron making or BF slags, categorised
by how they are cooled – air-cooled, granulated, and pelletized (or
expanded).
1. Air-cooled slag is hard and dense and is especially suitable for use
as construction aggregate.
2. Granulated slag forms sand-sized particles of glass and is primarily
used to make cementitious material.
 3. Pelletized or expanded slag has a vesicular texture (like volcanic
rock) and is most commonly used as a lightweight aggregate.

Casting Steel
➢ Before molten steel can be rolled or formed into finished products, it has to solidify
and be formed into standard, semi-finished casting products which are available in
basic shapes called billets, blooms or slabs.

Module 5: Methods, Processes and Equipment involved in Manufacturing Glass

• Characteristics of Glass.
Glass is identified for its fragility as well as firmness that make it distinctive of a solid. At
the same time, it can be qualified as a liquid, outstanding to its somewhat fluid nature. But,
scientifically, glass is what is called an amorphous solid, a state between two states of
matter.
• What is Glass made of?
The main raw materials in glass are sand, soda, limestone, clarifying agents, coloring and
glistening glass. Glass sand is about 3/4 of the entire glass composition.
• How is Glass Produced?
A float line is almost like a river of glass that exits the furnace before its cooling process.
It makes its way to nearly 300 meters, after which it is cut into large sheets; these sheets
typically measure 3.21x2.25 meters.
• Float Glass.
Float glass, commonly known as flat glass, is made by floating molten glass on a bed of
molten tin. The molten glass spreads onto the surface of the metal and produces a high
quality, consistently level sheet of glass that is later cut into required sizes.

Manufacturing of Process of Glass

➢ Glass is made from its raw materials in a carefully controlled two-step process, and
is then molded to form either sheet glass or bottles. A schematic diagram of this
process is given.

Batch Mixing
➢ Glass is made of different ingredients in inconsistent proportions depending on the
desired end product, but most glass (except for some specialist glass) consists of all
the "majors" mixed with small quantities of some of the minors.

Laboratory Inspection
➢ The laboratory is primarily involved in the determination of the mix of ingredients
for each batch of glass. A small sample is taken from each batch and dissolved in
hydrofluoric acid and then analyzed in an atomic absorption spectrophotometer to
determine which elements it contains and their proportions.
Module 6: Different Equipments Used in Glass Manufacturing

• Equipment Used in Glass Manufacturing Process

Emission Monitoring System

➢ Measuring technologies (e.g. NDIR, UV, electrochemical or paramagnetic
principle, filter correlation, scattering light)
➢ Single and multi-component analyzers, on customer request
➢ Certified system by government agency
➢ CEMS system can be integrated in plant control scada system
➢ Low maintenance costs
➢ Possible integration with process control.

Emission Monitoring System

➢ It is designed to keep the air/gas ratio steady
➢ Cooling and heating are grouped in one rack only
➢ Linear regulation valves are used to vary the flow according to valve opening
 ➢ Critical components for good forehearth management are pre-assembled and
installed in a dedicated unit, usually positioned in an area less exposed to the heat
coming from forehearths.

Emission Monitoring System

➢ It has no belt transmission or reduction on the drive to push the bottle came from
conveyors it has only linkage system for a very reliable mechanism. Accurate
wares handling with the possibility to adjust the angular and axial positioning of
the wares on the conveyor.
Glass Stacker
➢ Servo type glass stacker; it has rotation and arm movements controlled by two
identical brushless servo motors to guide the bottles while moving on the conveyor.
The stacker is installed on the rails with easy and quick withdrawal system.

Glass Weight Controllers

➢ Glass weight controllers has its unique weight control system trough the position
control of the plunger. This instrument controlled the weight of the glass by height
regulation of revolving tube.

Environmental Considerations
➢ The only substances discharged into the environment as a result of this process are
the CO2 and SO3 released during the batch melting process, and these gases are
simply released through a tall plant stack. However, the glass industry is also
working to support the environment by recycling its product. This lowers costs (as
cullet is cheaper and easier to melt than silica) and prevents wastage. Large industry
has been involved with recycling to a small extent, and began using the yellow
recycling bins throughout.