Project on

Plant layout

of

Electrotherm India Ltd.

Prepared by:-

Alpesh Gheewala – GLS 1116

Govind Israni – GLS 1117

Nikunj Makwana – GLS 1124

Harshank Patel GLS – GLS 1133

Parth Patel – GLS 1136

Karan Raheja – GLS 1141

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PREFACE

“Experience is the best teacher”. This saying has played a guiding role in

including visit as a part of the curriculum of the M.B.A. program of

Gujarat Technological University. Only theoretical knowledge is not

important but complete education, practical experience must accompany

theoretical knowledge to add meaning to education.

Today we find proper organization structure in each and every field.

As business grows its organization structure keeps on changing. It is now

become important to consider organization structure for the company to

survive in the market and also to make comparison between two

companies.

The main purpose of the factory visit done was to study how the

production process is carried at Electrotherm India Ltd. i.e. the process

from raw material to final output. The movement of inputs is thoroughly

explained in the layout. This process timing at each level of production is

also studied.

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ACKNOWLEDGEMENT 

 

It really feels very good to prepare the report on the industry. Our thanks to Mr. Ruparel, the director of our institute  who gave us chance to prepare a report on the industry and also to the Gujarat Technological University for including  such type of the projects in our curriculum.

We are very thankful to our subject teacher Prof. Gurmeet Singh, who is the in charge of this project and helped us in all the possible ways during the preparation of the report.

We are also helpful to all those who helped us directly or indirectly to prepare this project and survey in a systematic way.

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Index

Sr. No. Topic Page No.01 Company Profile 502 Product Profile 603 Plant Location 904 Plant Layout 1005 Process Flow 1106 Blast Furnace – Iron Making 1207 Raw Materials 1308 Output 1409 Working hours & Labour requirement 1510 Process Timing 16

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COMPANY PROFILE

Electrotherm India Ltd. (Electrotherm) has achieved market leadership in its core products because of the excellence and dedication towards continuous improvement. Today, Electrotherm has a clientele of over 1500 installations. Electrotherm has exported its products to Bangladesh, Ethiopia, Ghana, Greece, Kenya, Mauritius, Myanmar, Pakistan, Senegal, Sri Lanka, South Africa, Tanzania, Zimbabwe, The Middle East and many other East African countries.

Electrotherm is distinguished by the skill & knowledge of its leadership & experienced team. Prime importance is given to prompt after sales service. Electrotherm's operations are spread over 30 locations with 6 regional offices and representations at Bangladesh, China, Egypt, Malaysia, Pakistan, Russia, South Africa and Turkey.

Electrotherm's strong Sales & Service Network throughout India is manned by Metallurgical, Electrical and Electronics Engineers, who are committed to offer the best in terms of application engineering & in-time service to customers. Electrotherm's sales team is driven to offer the best customized solutions to each customer at his doorstep. Such a customer-focused attitude has made Electrotherm "A Solution Driven Company".

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PRODUCT PROFILE

Sponge Iron is a recognized alternative to steel scrap as a raw material for the manufacture of various steel products. The twin issues of rapid depletion of Coking Coal reserves and the scarcity of indigenous scrap, made the Government of India support production of sponge iron in the country. To boost the growth of the industry a major thrust was given by the Government of India by providing the manufacturers the following benefits: De-licensing, firm linkages, allocation of natural gas and financial support. This lead to an immense growth of the sponge iron industry in India, from a meagre capacity of 30,000 tonnes per annum in the year 1980-81 it grew to 7 million tonnes in 2001. Today, India ranks No.1 globally in the production of Sponge Iron.

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Modern construction relies heavily on steel reinforcement, which plays a significant role in influencing its structural behaviour. It is steel that has to bond with concrete and impart uniform strength. It is steel that has to stand tall despite attacks of corrosion. It is steel that has to withstand the ravages of time and ensure durability. It is steel that is the backbone of the buildings. A backbone responsible for the Inner Strength.

Yet, this reinforcement is taken for granted and the influence of metallurgical and production characteristics on the mechanical properties of structural steel is often ignored. Additionally, given the scenario of a liberalized import regime and the large scale conversion of scrap (rail, defense, automobile, imported etc) of unknown and unsuitable quality into steel rebars, possibly under uncontrolled conditions has led to the market being flooded by products whose quality and reliability are big question marks. Big enough not to be ignored.

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Learning from nature, observing through an engineer's eye and understanding the common man- that makes possible, the stimulation of these discoveries and creating engineering marvels to make lives easier.

One such marvel is the Ductile Iron Pipe. A marvel inspired by nature and driven by human ingenuity. A marvel that transports water across distant lands and through difficult terrains and links the demand and supply points seamlessly. In the Industrial research, field experience, tight quality control and contemporary production techniques has evolved the D.I pipes in to the efficient product it is today. We at Electrotherm (India) Ltd. are dedicated to the production and placement of the finest quality Ductile Iron pipe in the market to spread happiness and hope all around and ensure that no life on earth is deprived of this 'basic source of life'

PLANT LOCATION

Electrotherm Plant is located in Kutch at Shaymal khali. The selection of the location of plant depends on following factor.

1. Gujarat Government Announced Kutch as a Tax free zone after the 2000 earth quake to increases the employment and attracts the industrialist to build plant. Land is available at minimum rate and there is no land tax for 10 year.

2. Electrotherm plant is located near the railway station so the Raw material transportation cost is low

3. Electrotherm is located near Mudra port so carriage inward is less.

4. Labors in Kutch are available easily although there is scarcity of skill labor but training can be given to the worker

5. Water and electricity is available 24 hrs because of Narmada Dam. Cost of electricity per unit is less compare to other area.

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PLANT LAYOUT

10

PROCESS FLOW

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BLAST FURNACE - iron making

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Raw materials

Coke:

Fix C : 29.00%

Ash : 12.00%

P : 0.03%

S : 0.40%

Coal (South Africa) :

Fix C : 55.00%

Ash : 15.00%

VM : 30.00%

S : 0.80%

P : 0.04%

Moisture : 0.04%

Iron ore:

Total Fe : 63.5%

SiO2 : 2.25%

Al2O3 : 2.75%

P : 0.06%

S : 0.01%

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OUTPUT

Hot metal:

C : 4.00%

Mn : 0.50%

Si : 0.40%

P : 0.10%

S : 0.04%

Cast Iron (Foundry grade):

C : 4.00%

Mn : 0.50%

Si : 2.00%

P : 0.10%

S : 0.04%

Slag:

CaO : 38.73%

SiO2 : 32.98%

Al2O3 : 17.86%

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Working hours and Labour requirement

Steel production is a continuous process so the working hours is divided in to 3 shifts. First shift is from 7:00 Am to 3:00 pm. Second shift is from 3:00 pm to 11:00 pm and the last shift is from 11:00 pm to 7:00 am. There are approximate 30-40 people in every shift. In every shift there is a one shift incharge ,three computer operator,2 metallurgical engineer, 3 mechanical engineer, 3 electrical engineer, 4 instrumental engineer and rest are foramen , fitter and technician. After every shift it is compulsory to give report to the Director. Report include production in ton, wastage and chemistry of output and input material.

If there is a labour shortage or someone is absent without informing than the previous shift person with same qualification has to stay and work double. Sometime these double shifts create a lot of stress because of 16 hrs of work.

Working time is very tight if there is any miscommunication between the two shifts incharge it will create a loss in production and Cost Company very much or there are chances of accident because of miss information.

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Process timing

To produce 1 ton of iron it will approximately take 2.4 ton of raw material which contain mineral, coke and limestone. Raw material is to be heated at 1134 deg centigrade for its conversion to hot molten iron. The hot molten iron is at 1459 deg centigrade. This whole process take 6 hours after every 3 minute input material is charged in to furnace from top it takes 6 hours for its conversion to hot metal.

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