VOCATIONAL TRAINING

REPORT

PREPARED BY:PRADOSH URMALIYA

ROLL NO: 0201IP211063  JABALPUR ENGINEERING COLLEGE
JABALPUR ENGINEERING COLLEGE,
JABALPUR GOKALPUR, JABALPUR– 482011

AN INDUSTRIAL TRAINING REPORT ON

“UNDERSTANDING THE PROCESS OF REFRACTORY PRODUCTION”

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE

AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY IN INDUSTRIAL & PRODUCTION

ENGINEERING

SUBMITTED BY:
PRADOSH URMALIYA
0201IP211063
 ACKNOWLEDGEMENT
First of all, I would like to thank my God, for helping me from the
beginning to the end of my vocational training period.

I extend my supreme gratitude to Jabalpur Engineering College for

providing such kind of opportunity for students to broaden their
perception on how the real world in the field of engineering looks
like.

I would also like to express my special thanks to Mr. Subodh Dubey,

Plant Head of Calderys India Refractories Ltd., Katni Refractory
Works, for giving me a chance to spend my practice in his company.

I extend my grateful thanks to Mr. B.S. Gedam, Sr. Manager HR

Dept., for his moral support and valuable guidance during the
training period.

I would also like to express my sincere thanks to Mr. Kamlendu

Kumar Bhushan, Sr. Manager Maintenance Dept., for being my
mentor during the training time and helping me in my day-to-day
activities.

I extend my grateful thanks to all the employees in the site those

who helped me in moral and material needs as well as sharing me
their knowledge to improve my theoretical knowledge to the real
works.

Finally, I would like to express my special thanks to my family and

friends for helping me in all aspects.
 PREFACE
This Vocational Training Report is prepared after completion of
30 days of vocational Training at Calderys India Refractories
Ltd., Katni Refractory Works. Completion of Industrial Training is
compulsory for the award of the degree of Bachelor of
Technology from Jabalpur Engineering College. Vocational
Training program was held in the 2nd semester of the B.Tech
program curriculum. This report contains experiences and
knowledge which I have gained during my training period from
01/06/2022 - 30/06/2022.
CERTIFICATE OF TRAINING
 TABLE OF CONTENTS
1)INTRODUCTION TO CALDERYS
2)DAILY DIARY EXPERIENCES
3)SAFETY TRAINING
4)PRODUCTION UNIT
 CASTABLES PRODUCTION
 BINDER PRODUCTION
 REFRACTORY CRUSHING CIRCUIT
 SHRINKKOMP PRODUCTION
 READY SHAPE DEPARTMENT
 PRODUCER GAS PLANT
5)CONCLUSION
 INTRODUCTION TO CALDERYS
Calderys India Refractories Pvt. Ltd. is the subsidiary company of
IMERYS in the business group of High temperature solutions.
Katni Refractory Works (KRW) is one of the leading and biggest
plants among the Calderys group all over the world. The total
area is 22 hectares. The plant formerly known as ACC is located
in Katni, Madhya Pradesh in India. The plant gives special
emphasis on 5S and the IMERYS concept of I3, an abbreviation
for IMERYS Industrial Improvement which has been
implemented in July, 2016. The company management also
gives attention to Corporate Social Responsibilities, thus
improving the livelihood of the people living in the nearby
areas.

Equipment:

o Total capacity: 1,20,000 tons/annum

o Total number of lines: 11
o Monolithic lines: 5
o Grout lines: 2
o Rotary kilns: 3
o Ball mills: 5
o Blenders: 8
o Packing machines: 6
o Jaw crushers: 5
o Roller crusher: 4
o Vibrating screen: 4
 o Hammer crusher: 4

Products:

o Monolithics: Conventional, Low Cement, Insulating

castable
o Binders: 45%, 70% & 80% alumina, Synthetic aggregate
o Grouts: Non shrinkable grouting material Shrinkkomp,
Mortars
o RDS: Refractory bed support, Porosint, Semi insulating
bricks, PCPF

Major functional units:

o Safety Department
o Human Resource Department & Time Office
o Finance
o Commercial
o Sales
o PPC (Production, Planning & Control)
o Stores
o Production
o Maintenance
o Merchandise Department
o QPC (Quality Process & Control)
 DAILY DIARY EXPERIENCES
DAY 1:

Today was my first day at Calderys India Refractories Limited,

Katni Refractory Works; where I am doing my one-month
vocational training. Currently I am in 2nd semester of my B Tech
at Jabalpur Engineering College. So, as I entered the premises, I
submitted my particulars at the gate and I was provided with
the PPEs (Helmet, Safety Shoes, Safety Jacket, etc). Then a small
presentation containing safety measures to be taken inside the
plant was shown to me. Then I was directed to the conference
hall where we had a Safety Induction by Safety Head Mr. Sumit
Rai Sir. After that we were said to report to Mr. Kamlendu
Kumar Bhushan Sir (Sr. Manager Maintenance Dept.), at the
production and maintenance office. Then we gave our
Introduction to Kamlendu Sir, and he asked us about our topic
for industrial training. So, I answered that we want to learn the
complete process of manufacturing of final products from the
raw materials. For that he appointed Mr. Shiwam Singh
Raghuvanshi Sir as our trainer and mentor. Then we were said
to report at 8:30 from tomorrow morning. This was all about my
first day experience at Calderys.

DAY 2:

Today was my second day at Calderys Plant. I reached the office

on time, then we met Shiwam Sir. He told us that the first
process of manufacturing is ‘crushing of raw materials’, and in
this plant, there are 4 Refractory Crushing Circuits namely:
RCC1, RCC2, RCC3, HA2. Then he asked us to visit all the circuits
one by one and note down the details of various crushers and
also make their respective circuit diagrams by taking help from
the operators present over there. Accordingly, we visited RCC1,
where we met Mr. Ankit Kol (Operator). He explained us RCC1,
RCC2 and HA2 completely and also helped us to make the
circuit diagram. Then he asked us to visit all the circuits and
understand all the components. Hence, we completely explored
RCC1 and HA2 today.

DAY 3:

Today was my third day at Calderys Plant. I reached office on

time, and we met Ankit Sir. Today he explained us RCC3, and
helped us to make its circuit diagram. After that we explored
RCC2 and RCC3 completely. And by this we completed the first
process of manufacturing i.e., ‘Crushing’.

DAY 4:

Today was my fourth day at Calderys Plant. Today we reported

to Mr. Kedar Tripathi Sir. He explained us about the Raw-Mix
Circuit, and also provided us a complete tour of it. After that we
made its circuit diagram and read about each component
involved in this process. In this way today we completed Raw-
Mix Circuit completely.
DAY 5:

Today was my fifth day at Calderys Plant. Today I prepared the

report of my training till date, sitting in the office and also
collected some information required for it.

DAY 6:

Today was my sixth day at Calderys Plant. Today we were

provided with the manual of Calderys Plant and we were asked
to go through it and verify the information which we have
gathered till now. So, I read it and also improvised my report
accordingly. This was all about today.

DAY 7:

Today was my seventh day at Calderys Plant. Today we visited

Rotory Kiln 3, and explored it completely.

DAY 8:

Today was my eighth day at Calderys Plant. Today we visited

Rotory Kiln 3, and explored it completely.

DAY 9:

Today was my ninth day at Calderys Plant. Today we visited

Rotory Kiln 6, and explored it completely.
DAY 10:

Today was my tenth day at Calderys Plant. Today we visited Line

1 of Castable Production Unit, and explored it completely.

DAY 11:

Today was my eleventh day at Calderys Plant. Today we visited

Line 2 of Castable Production Unit, and explored it completely.

DAY 12:

Today was my twelfth day at Calderys Plant. Today we visited

Line 3A of Castable Production Unit, and explored it completely.

DAY 13:

Today was my thirteenth day at Calderys Plant. Today we visited

Line 3B of Castable Production Unit, and explored it completely.

DAY 14:

Today was my fourteenth day at Calderys Plant. Today we

visited Line 4 of Castable Production Unit, and explored it
completely.

DAY 15:
Today was my fifteenth day at Calderys Plant. Today we visited
Line 5 of Castable Production Unit, and explored it completely.
DAY 16:

Today was my sixteenth day at Calderys Plant. Today we visited

Shrinkkomp Production Unit, and explored it completely.

DAY 17:

Today was my seventeenth day at Calderys Plant. Today we

studied about Ready Shaped Department from the manual, and
noted down all the details.

DAY 18:

Today was my eighteenth day at Calderys Plant. Today we

visited Producer Gas Plant, and explored it completely.

DAY 19:

Today was my nineteenth day at Calderys Plant. Today I was

awarded with the vocational training certificate by Mr. B.S.
Gedam (Sr. Manager HR Dept.), and he wished me good luck for
my future.
 SAFETY TRAINING

Key Points of The Safety Training :

 TAKE 5:

 THINK through the task

Have a clear plan in mind

 LOOK for the exposure

How and where the work is done?

 ASSESS the risk

What could happen if things get out of control?

 TAKE precautions
Remove impediments to safety

 DO the job safely

Watch for changing conditions and exposure

 SERIOUS 7:

 ELECTRICAL SAFETY
Never approach high voltage without using arc flash protection.

 MACHINE GUARDING AND CONVEYOR SAFETY

Do not bypass, neutralize or damage any machine guards.
 LOCKED OUT, TAG OUT AND TRY OUT
Use authorized isolation systems.

 MOBILE EQUIPMENT
Maintain a safe distance from mobile equipment on soft floor.

 WORKING AT HEIGHTS
Never work above 2m without a protective railing or harness.

 GROUND CONTROL
Always inspect the mine face and ground stability before
beginning work.

 FORKLIFT SAFETY
Each site will formalize and enforce a site-specific management
plan.

 10 GOLDEN RULES OF CALDERYS:

 Conduct Take 5.
 Report All Accidents and Incidents Including First Aids, Near
Misses and Hazardous Situations.
 Never Perform a Task Without Authorization If Permit Is
Required.
 There Will Be No Human Intervention on Any Moving Parts.
 Never Override or Interfere with Any Safety Provisions or
Devices.
  Never Operate Mobile Machinery Without Proper Training
and Authorization and All Rules.
 Never Work at Heights Without Proper Fall Protection or
Fall Prevention Safety Equipment.
 Performing Electrical Safety Is Forbidden Unless Personnel
Is Competent and Authorized.
 Always Wear Appropriate PPEs.
 Use The Right Tool for The Right Task.

 PPEs:

PPE stands for Personal Protective Equipment; this equipment is

used for protecting ourselves from the damage. Some
important PPEs are:

Helmet

Safety shoes
Eye Wear

High visibility
Jacket

Dust Mask

Safety Gloves

Ear Plugs
 PRODUCTION UNIT

 CASTABLES PRODUCTION:
Castables are a mixture of binders and aggregates. The main
product of KRW is monolithic. There are 5 lines in total which
manufacture castables. All types of products including dense
conventional castable to low cement castable and ultra-low
cement castable are produced in this unit. Apart from this,
insulating castables are also manufactured.

Dense Castable:

Manufacturing of dense castables consists of refractory

crushing circuit and mixing of dense aggregates to the proper
binder depending on the desirable properties and demand of
the customer.

 Raw materials:

o Calcined Pyrophyllite - 42-44 % Alumina

o Calcined local bauxite - 76-80 %
o Calcined siliceous bauxite - 51-54% Alumina
o Calcined diaspore - 60-64 % Alumina
o Calcined fireclay - 42-43% Alumina
 o 60-70 % brick grog - 65-68 % Alumina
o High alumina aggregate (broken insulator) - 35-42%
Alumina
o Calcined GG grade bauxite - 82 % Alumina
o Calcined Low Iron Bauxite - 84 % Alumina
o BRO 62 grog- 60-64 % Alumina
o ICOBT bats (Insulating aggregate)

Insulating Castable:

In the insulyte line generally small duty crushers are used so

that the aggregates do not get broken. Fired clay grog, Icobt
bricks etc are the main raw materials in this case. The size
grading ranges from 0-1 mm and 1-6 mm. Dust particles are
avoided as it will increase the setting time and hence the
efficiency of the castables.

The main types of Castables produced are:

o Whytheat A
o Firecrete
o Accmon 45
o Accmon Drim
o Insulyte 11
Line 1: Dense Castables

Line 2: Insulating Castables

Line 3A: Medium Cement Castables

Line 3B: DVAI

Line 4: LCC

Line 5: Low Cement and High Grade

 BINDER PRODUCTION:
The principle binders produced in this unit are:

 Calundum: 45% alumina containing cement

 CalAl 70: 70% alumina containing cement

 Calundum:

This type of binder is mainly of low quality and is used for

producing conventional castables. The production
temperature is around 1200-1300° C. A producer gas plant is
present alongside which provides the fuel for combustion and
thus for manufacturing.

Raw materials:
 o naturally occurring bauxite
o limestone

Machines used:

o Conveyors
o Bucket elevators
o Jaw crusher
o Hammer crusher (Impact crusher)
o Ball mill
o Fluxo pump
o Nodulizer
o Dryer
o Rotary Kiln
o Cooler

Basic process flow:

Raw material testing

Size reduction
 Co-grinding

Nodulization

Drying

Firing

Cooling

Milling (fine powder form)

 Calal 70:

It is a higher and purer variety of binder and is mainly used in

the manufacturing of low cement and ultra-low cement
castables. The operation temperature is around 1600-1700° C.
The fuel in this process is pet coke.

Raw materials:

o Calcined Alumina
o Hydrated Lime

Machines used:

o Ball mill
o Weighing Hopper
o Intensive Mixer
o Surge Hopper
o Nodulizer
o Dryer
o Rotary Kiln
o Cooler
Basic process flow:

Raw material testing

Size reduction (Grinding)

Batching

Mixing

Nodulization

Drying

Firing

Cooling

Milling (fine powder form)

 Equipment used in production:

Rotary Kiln:

The rotary kiln consists of a tube made from steel plate, and
lined with firebrick. The tube slopes slightly (1-4°) and slowly
rotates on its axis. The raw material generally enters the kiln
in the form of nodules at a temperature of around 350-400°
C. The total time for completion is around 2-3 hours. The fired
clinker coming out through the firing side is at a temperature
of around 150°-200° C. The main zones of the kiln are the
drying zone, preheating zone, calcination zone and cooling
zones. After the clinkers are ejected, they enter into a rotary
cooler which lowers the temperature of the clinkers to
around 70°C. The clinkers are then stored in silos which are
later ground in ball mills. During firing, primary air is provided
along with the heavy furnace oil in case of the kiln producing
Calal 70 which helps in atomisation of the fuel. The stabilizing
air, swirl air & axial air helps in the combustion process. In
this case when the temperature of the furnace reaches
around 700-800° C, HFO is substituted by pet coke. The flue
gas generated is used for drying the nodules in the dryer.

RK-6:

o Length: 55m
o Diameter: 2.1(OD), 1.7(1D)
o Process: Semi dry counter current mechanism
o Length of cooler: 21m
o Cooler diameter: 1.7 m
o Firing temperature: >1650°c
o RPM of cooler: 3/min
o Exhaust fan rpm: 1550 (max)

RK-3:

o Length: 55m
o External Diameter: 2.1m
o RPM: 1.6 (max)
o Length of cooler: 20m
o Cooler diameter: 1.7 m
o Firing temperature: >1450°c
o RPM of cooler: 1.9-2.1
o Thickness of refractory lining and cooler: 0.4m
o Dryer speed (rpm): 400-900
o Exhaust fan rpm: 1450 (max)
 Control Parameters for Rotary Kiln:

o Fixed Parameters:

 Loose Bulk Density

 Burning Zone Temperature
 Combustion Efficiency
 Temperature Profile
 Draft Profile

o Variable Parameters:

 Fuel Feed Rate

 Root Blower RPM
 Rotary Kiln RPM
 Dryer RPM
 ID Fan RPM
 Damper Operations

o Auxiliary Parameters:

 Specific Gravity of Organic Binder

 Point Load
 Moisture Content

Ball Mill:

The KRW unit consists of 5 ball mills; out of which 2 are closed
circuit (Ball Mill 2 & 4) and the other three are open circuit.
The main functions of the mills are as follows:
 o Ball Mill 1: for grinding the raw materials for calundum.
o Ball Mill 2: for grinding the finished product of rotary kiln 3
i.e. calundum.
o Ball Mill 3: for grinding the aggregates for castables.
o Ball Mill 4: for grinding the finished product of rotary kiln 6
i.e. calal 70.
o Ball Mill 5: for grinding the raw materials for calal 70.

Ball mills are rotating steel cylinders where size reduction of the
mill feed is performed by motion of the grinding media.
Rotation of the mill cylinder raises the mill feed and grinding
media to an optimum high, necessary for grinding operation.
Grinding is performed by impact and friction between the
grinding balls which hit one against another, as well as between
the grinding media and the mill lining itself.

Two different processes occur inside the mill:

o Crushing: Breaking up of the incoming particles from

a size of about 30 mm to a size of minus 2.5 mm
diameter. This process takes place in the first
compartment of the mill.

o Refining: Powder the particles until they reach the

required fineness. This process takes place in the
second compartment of the mill.
Grinding can be done with two kinds of circuits:

o Open Circuit: An open circuit is the one in which the

material at the outlet of the mill has the required
size and it goes directly to the storage silos.

o Closed Circuit: A closed circuit is the system in which

the material at the outlet of the mill passes through
a separator, driving the material with the required
fineness to the storage silo and the coarse particles
back to the mill inlet.

Note:

o Only one third of the mill is filled with balls.

o The total weight of balls is around 12 T (ST+7T).
o Dynamic separator is present in a closed circuit unit with
a back filter. The principle of cyclonic separation is used
in this case.
o High chrome grinding media is used.
o The calundum weight feeder of ball mill 1 takes in 60%
bauxite and 40% limestone input.
o Capacity = 5 ton/hour (BM 1); 2.8 ton/hour (BM 2)
o Grinding aids are added in quantities from 0.006% to
0.08% of the clinker weight. Amine acetate, Ethylene
glycol, and Propylene glycol are some examples of
grinding aids.
 REFRACTORY CRUSHING CIRCUIT:

 Some information regarding the crushing circuit:

o Primary crusher is the Jaw Crusher.

o The secondary crusher is the hammer mill or hazmag
crusher.
o The input from the dumping pit is around 30-35 ton.
o Jaw crusher capacity is 25T/hour
o Hazmag crusher output is 20T/hour
o There are a total of around 12 hoppers with 120 T
capacity
o Mainly used for crushing and grinding of Bauxite,
Chamotte, Mullite, Silica and Refractory Reclaimed
materials to obtain different size fractions.
o Magnet is provided on the belt conveyor at the inlet and
outlet of all the crushers.
o Storage in hoppers is as follows:
o C1: Cal Diaspore
o C2:Cal Clay
o C3:Cal Bauxite
o C5:Cal Pyrophyllite
o C6:Cal Bauxite Clay
o F1: Pyrophyllite Clay
o F2: Calcined Clay
o F3: Local Bauxite
o F5: Brick Grog
o F6: Mix Dust
Flowchart of RCC 1 & 2:
Flowchart of RCC 3:
Flowchart of HA2:
Details of different crushers:

Sayaji Crusher:

 Make/Type: Sayaji Jaw Crusher

 Type of Crusher: Jaw Crusher
 Used As: Primary Crusher
 Input Size: 8” max
 Output Size: 3” max
 Capacity: 15 MT/hr
 Motor HP: 40
 Motor RPM: 1475
 V Belt No: C162
 Installation: 1983

Hazmag Crusher:

 Make/Type: Hazmag Impact Crusher

 Type of Crusher: Impact Crusher
 Used As: Secondary Crusher
 Input Size: 2” max
 Output Size: 0/1.5”
 Capacity: 15 MT/hr
 Motor HP: 60
 Motor RPM: 980
 V Belt No: D220
Table containing details of various crushers:

S.No: Name: Type: Used As:

PCR1,2&3
Primary
1. (Sayaji Jaw Jaw Crusher
Crusher
Crusher)

Hazmag1,2
Impact Secondary
2. (Hazmag
Crusher Crusher
Crusher)

Ambica Impact Secondary

3.
Crusher Crusher Crusher

VSG
Impact Tertiary
4. (Vertical Shaft
Crusher Crusher
Grinder)
 SHRINKKOMP PRODUCTION:
Shrinkkomp is Non-Shrink, Free-Flowing, High Compressive
Strength, Self-Levelling, Non - Metallic, Oil & Water Resistant,
Chloride-Free Premixed cementitious grout for foundation
grouting applications.

Advantages of Shrinkkomp:

o Concrete made by using Ordinary Portland Cement will

shrink on drying and therefore do not provide a firm grip
to anchoring devices & hence results in failure of the
machine parts as well as the concrete foundations.
o Shrinkkomp Grouts are based on the Expansive Hydraulic
Setting Binders which impart controlled expansion that
ensures the permanent bond between the Machine and
the foundation.
o These grouts are ideally suited for all types of Static and
Dynamic Loads. They develop very high compressive
strength and unlike metallic grouts do not generate any
gases leading to the failure of the bond with the surface
in contact.

Mills:
 o There are two lines manufacturing Shrinkkomp in this
plant namely line 6 (Shrinkkomp main hall) and line 7
(Kusum Mill) having a capacity of 2.25 T and 2.5 T
respectively per charge.
The various tests carried out at Shrinkkomp lab:

o CCS
o Flexural Strength (MOR)
o Flowability Test
o Setting Time
o Cement testing
o Fineness of Gypsum
o Expansion Test
o Sieve Analysis of River Sand

Applications:

o Foundations Grouting
o Dams
o Soil Stabilization
o Rocks (Strengthening of Underground Structure and
Seepage check)
o Repairs of structure (Micro concreting)

Variants and their application:

o Shrinkkomp 10: Plastic

 o Shrinkkomp 20: Free flow (for grouting of medium size
machine foundation)
o Shrinkkomp 30: Free flow (for grouting of heavy machine
foundation like Turbines, DG Sets etc., Heavy Vibrating
machine foundation; Dynamic load)
o Shrinkkomp 40: Free flow (For early Commissioning of
Projects within 3 days)
o Pumpable Grout: Water logged areas and Arresting
Seepages in underground structures.
o Insulcrete: Cementitious binding material for Pin
Grouting of Disc Insulators.
o Accmix: For bolting in roofs of underground mining
operations.
o Flash Binder: Fast setting cement which can be used for
the early strength concrete mix for non-structural
purposes.

Flowchart for Shrinkkomp Grout:

 READY SHAPE DEPARTMENT:

Products produced in this unit:

1. Refractory Bed Support (RBS)

2. Precast pre fired (PCPF)
3. Porosint Bricks
4. Refratherm Bricks

1. Refractory Bed Support (RBS):

Raw Materials:
o Calcined Alumina (99% purity)
o CBS binder

Size: RBS varies from 2mm to 75mm.

Application: Mainly used in petrochemical industries

for oil refining.

Equipment used:

 Nodulizer:
 Rotation per minute: 9 to 12 rpm
 Number of Nodulizer: 3
  Capacity: 300 kg per shift
 Inclination: 45°

 Bogie Dryer:
 Drying temperature: 150 °C
 Bogie Kiln/ Batch kiln
 Capacity: 4.5 tons/cycle
 Firing temperature: 1560 °C to 1580 °C
 Fuel: C-9 oil or LDO

 Rotary Kiln:
 Capacity: 7 to 8 tons/day
 Firing temperature: 1700 to 1800 °C
 Length: 18 m
 Inclination: 4°
 Rotations: 2 to 3 rpm
 Fuel: furnace oil

Flowchart of Refractory Bed Support (RBS):

2. Precast Pre Fired (PCPF) Blocks:

 Some information regarding PCPF production:

o Castables are used to manufacture these bricks.

o The advantage of these type of blocks is that they can
be made into all kinds of shapes and sizes as
demanded by the customer.
o These bricks are manufactured by outside sources
through job work. The mould and castable are supplied
to them and the product after manufacturing is sent
back to KRW for packing and dispatch.
 o These are widely used in the steel and refractory
industry.
o Application: Well blocks, Burner blocks, aluminium
transportation lining, etc.
o Generally wooden moulds are used for this purpose, in
which the requisite castable is poured to give the
definite shape, after which it is dried and fired (around
700°C).
o Raw material and water is maintained at a particular
low temperature in cold room (set at 50-7° C) so as to
mix them later at the desired temperature.
o There are a total 3 mixers of 300 kg, 500 kg & 1000 kg
capacity.
o Equipment used:
 Bucket Hoist
 Hopper
 Mixer
 Conveyor belt
 Dryer
Flowchart of Precast Pre Fired (PCPF) Blocks:
3. Porosint Bricks:

Some information regarding Porosint Bricks production:

o These are white-coloured insulation bricks used in

furnaces of heavy duty to provide thermal insulation
due to very high porosity content (65-70%).
o These are very useful owing to very low thermal
conductivity, low bulk density (<1 g/cc), high strength
and low iron content. Their very low thermal
conductivity helps the furnace to reserve ample
amounts of heat and hence ultimately the cost
conservation is enhanced.
o These bricks are manufactured according to their
application areas (hot face, lining, etc.).

Types of Porosint bricks manufactured are:

o Porosint-500
o Porosint-650
o Porosint-700
o Porosint-750

Applications: Steel as well as Non-Steel Industries.

 Raw Materials:

o Alumina based products (Calcined diaspore)

o Clay
o EPS (Expanded Polystyrene)
o Plaster of Paris

4. Refratherm Bricks:

Some information regarding Porosint Bricks production:

o The refratherm bricks are semi-insulating bricks and

hence possess intermediate properties between dense
refractory bricks and insulating bricks, having a bulk
density of about 1.8 g/cc.
o These bricks optimize strength with thermal
conductivity so that adequate strength is present along
with low heat loss from the structure.

Applications:

o Calcining zone of rotary kiln used in cement industry

o Backup lining in steel plants
o Pre-heaters
Raw Materials:

o Alumina based products

o Insulating grog
o Clay
o Saw dust
o Binder

Equipment used:

o Counter current Mixer (CCM):

 Capacity - 1000 kg (1 no.) & 750 kg (2 no.)

 Friction screw press (FSP)
 Load-400 MT

o Wellmont Dryer:

 Temperature - 300 °C
 Time-24 hrs
 Fuel - Furnace oil (viscosity = 0.92)
 PRODUCER GAS PLANT:
Some information regarding Producer Gas Plant:

o Producer Gas is used in RK3 as fuel.

o Raw Material:
 Bituminous Coal (1.5-3 inch)
 Water (Steam)

o Zones from bottom to top:

 Ash Zone
 Oxidation Zone
 Primary Reduction Zone
 Secondary Reduction Zone

o Soft Water Plant:

 The water is processed through the soft water plant
to make it usable in the boiler.
 The hard water contains minerals which can lead to
scaling on the inner sides of the boiler.
 Hence to prevent this, the water is passed through
the sand and resin filters and the resulting soft water
is then sent to the boiler.
 Flow chart of Soft Water Plant is as follows:
o Reactions occurring in the gas plant:
 2C + O2  2CO
 C + H2O  CO + H2
 C + 2H2O  CO2 + 2H2
 CO + H2O  CO2 + H2
Flowchart for Producer Gas Plant:
 CONCLUSION

In conclusion, this vocational training has been a very useful

experience for me. I can safely say that my understanding of the
job environment has increased greatly. However, I do think that
there are some aspects of the job that I could have done better
and that I need to work on. This opportunity also enabled me to
further expand my creativity while seizing the profession ethical
values as basis to venture into professional career in the future.
The two main things that I learned after my experience in this
firm are the importance of time management and being self-
motivated.