SUMMER TRAINING ON MATERIAL HANDLING EQUIPMENTS IN A STEEL PLANT & DESIGN OF A SPECIFIC BUCKET ELEVTOR

Submitted By: Ruman Deb - deb.ruman91@gmail.com Saurav Dutta duttasaurav31@gmail.com

Guided By: Mr. Somraj Chakravarty, Asst. Manager (Mechanical)

Dept Of Mechanical Engg. ,Sikkim Manipal Institute Of Technology

ACKNOWLEDGMENT

We are grateful to SAIL,(CET), RANCHI for giving us a scope to accomplish our summer training at the CET Headquarter Ranchi. We would also like to thank all those officers & employees of SAIL, CET, Ranchi, who have shared their valuable time with us in constantly guiding us through our entire training period and without whose co-operation our work would not have been accomplished. We are especially grateful to our instructor for helping us to revive our engineering knowledge through valuable information and practical work, with were the impetus to give practical shape. The preparation of this report has helped us to recapitulate all that we have learnt during our training period. Last but not the least we would like to thank all those who have been directly or indirectly associated with us throughout the entire training period and extending their helping hands towards us.

CERTIFICATE
This is to certify that Ruman Deb and Saurav Dutta student of VI th semester B.TECH (MECHANICAL ENGINEERING) has completed satisfactorily his training project on MATERIAL HANDLING EQUIPMENT(BUCKET ELEVATOR) under our guidance and supervision in the CENTRE OF ENGINEERING AND TECHNOLOGY(CET), SAIL, Ranchi.

Mr. A.R. Dasgupta DGM (Mechanical)

Mr. Somraj Chakravarty Assistant Manager (Mech)

CONTENTS

PAGE NOS

CHAPTER 1: STEEL OVERVIEW CHAPTER 2: STEEL AUTHORITY OF INDIA LIMITED (SAIL) CHAPTER 3: CENTRE OF ENGINEERING (CET) AND ITS ROLE CHAPTER 4: OVERVIEW OF MATERIAL HANDLING EQUIPMENT CHAPTER 5: BUCKET ELEVATOR CHAPTER 6: PROJECT PROBLEM CHAPTER 7: DESIGN CALCULATIONS CHAPTER 8: EXCEL DESIGN SHEET CHAPTER 9: CONCLUSION ANNEXURE 1: LIST OF IS CODES USED

(5) (6) (7) (8-9) (10-14) (15) (16-22) (23-24) (25) (26)

CHAPTER 1

Global Steel Scenario and Indian Steel Industry

Introduction :
Historical evidences show that iron and steel have been in use for almost 6000 years, but the modern form of iron and steel industry came into being only during the 19th century. The growth and development of iron and steel industry at global level was comparatively slow until the Second World War. But the industry grew very rapidly after the Second World War. World production of steel, which was only 28.3 million tonnes (MT) in 1900, rose to 695 MT by 1992. The oil crisis of the seventies adversely affected the global steel industry. Increasing use is being made of new technologies, new alliances, trade practices and other means like moving to off-shore locations etc. for long term survival and growth. World crude steel production stood at 1219.7 million tonne in 2009 ( Brazil, Russia, India, China) called the BRIC Countries and considered as the strongest areas as far as the business of steel is considered, accounted for over 58% of global consumption. It is also noteworthy that the crude steel production in Asia exceeded 795 million tonne registering 65% contribution to world steel production in 2009. Thus it can be observed that there is a definite shift towards the Eastern Part of the Globe both in terms of production and consumption of steel. Though there had been a sharp decrease in prices of steel in the last one and a half years because of the global economic meltdown, there has been signs of positive growth and it is also projected that the steel industry the world steel industry now seems firmly set on a path to recovery and the emerging economies will continue to show strong growth, driving world steel demand in the future. Increasing use is being made of new technologies, new alliances, trade practices and other means like moving to off-shore locations etc. for long term survival and growth. Thus it can be observed that there is a definite shift towards the Eastern Part of the Globe both in terms of production and consumption of steel. Though there had been a sharp decrease in prices of steel in the last one and a half years because of the global economic meltdown, there has been signs of positive growth and it is also projected that the steel industry the world steel industry now seems firmly set on a path to recovery and the emerging economies will continue to show strong growth, driving world steel demand in the future. The world economic recession had put thwarted the steel market upturn that began in 2002. The economic crisis led to the cancellation or review of many planned investments in capacity expansions in the steel industry. However, since many expansion projects continue to advance in some emerging economies, world steelmaking capacity is expected to maintain an upward trend into 2010 which will well exceed future demand levels. This imbalance between capacity and demand is likely to hasten retirement of inefficient, more environmentally polluting or high cost capacities in certain countries, further affecting industry employment. Steel makers in developed countries will maintain their pursuit of a shift from volume to value. The market, turbulent since the last few years, is more efficient and better prepared thanks to global restructuring and consolidation. The long-term prospect for the global steel market is strong. The speed of growth might have slowed down but the industry will continue to grow in different ways. Consolidation will reinforce Chinas position in the global market. Capacity expansion will continue in emerging markets with a steady growth in steel demand in all sectors. Steelmakers in developed countries will maintain their pursuit of a shift from volume to value..
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CHAPTER 2

SAIL: An Overview
Formation and Growth of Hindustan Steel Limited (1954-1973):
Government of India's decision to enter into the field of Iron and Steel production, led to formation of Hindustan Steel Limited (HSL) as a Limited Company, with President of India owning the shares on behalf of the people of India. The Hindustan Steel Limited was set up on January 19, 1954. To start with, it was designed to manage with one plant that was coming up at Rourkela. For Bhilai and Durgapur plants, the preliminary work was done by the Iron & Steel Ministry. From April 1957, the supervision and control of the Bhilai and Durgapur Plants were also transferred to Hindustan Steel Limited. The registered office, originally in New Delhi, was shifted to Calcutta in July 1956 and ultimately shifted to Ranchi in December 1959. Initially Bokaro Project was also under HSL. A new steel company Bokaro Steel Limited was incorporated in January 1964 to construct and operate the steel plant at Bokaro. Present Status Steel Authority of India Limited (SAIL) through its five integrated steel plants at Bhilai, Bokaro, Burnpur, Durgapur and Rourkela accounts for major steel production capacity of India. Its three special steel plants at Bhadravati, Durgapur and Salem produce a wide range of special steels, special alloy steels and stainless steel. MEL, Chandrapur, a subsidiary company, is one of the largest producers of bulk Ferro Alloys in the country. There is a proposal to merge it with SAIL. Other units of SAIL include Raw Materials Division, Central Coal Supply Organisation, Central Marketing Organisation, SAIL Consultancy Division, Research & Development Centre for Iron & Steel, SAIL Safety Organisation, Centre for Engineering and Technology, Management Training Institute, Environment Management Division, Growth Division, SAIL Refractory Unit (SRU) and SAIL Corporate Office. Plants & Units Bhilai Steel Plant (BSP) Rourkela Steel Plant (RSP) Durgapur Steel Plant (DSP) Bokaro Steel Plant (BSL) IISCO Steel Plant (ISP) Alloy Steels Plant (ASP) Salem Steel Plant (SSP) Visvesvaraya Iron & Steel Plant (VISP) Maharashtra Elektrosmelt Limited (MEL) Research & Development Centre for Iron & Steel (RDCIS): SAIL Safety Organisation (SSO) Centre for Engineering and Technology (CET) SAIL Refractory Unit (SRU)

CHAPTER 3

Centre for Engineering & Technology:

Centre for Engineering and Technology (CET), an ISO 9001 certified organisation, is the design, engineering and consultancy unit of SAIL. It has its Head Office at Ranchi, Sub Centres at Bhilai, Durgapur, Rourkela, Bokaro, Burnpur & Bhadravati, Unit Offices at Bangalore, New Delhi for formulation of Interplant Standards for Steel Industry. As a technical solution provider for all project needs, CET has been rendering complete range of services not only to the steel plants under SAIL but also to various clients other than SAIL both within and outside the country. CET is also the nodal agency for acquisition and lateral transfer of technologies within SAIL plants. The range of services includes conceptualisation, project evaluation & appraisal, project consultancy, design, engineering and project management in the areas of iron and steel making. Apart from this, CET has been providing its services in the related areas like mine planning and development, infrastructural development, industrial piping, material handling system, pollution control and environment management systems, water supply and sanitation, town planning, power projects, etc. CET is a reservoir of technical & managerial expertise of SAIL.

CHAPTER 4

MATERIAL HANDLING EQUIPMENT

Material handling equipment is all equipment that relates to the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. Material handling equipment is the mechanical equipment involved in the complete system. Material handling equipment is generally separated into four main categories: storage and handling equipment, engineered systems, industrial trucks, and bulk material handling. Material Handling Equipment s (M H E) are actually equipment s t hat facilitate t he handling of materials, which refer s t o t he movement and storage of materials in the facility. Importance of Material Handling : Material handling is import ant as it is the key to warehouse productivity. When materials in t he warehouse are being managed well , t her e will be an increase in efficiency and thus increase productivity. This is where M H E comes t o pl ace. On the other hand, without M H E, it will eventually lead t o poor material handling. Some of t he poor material handling effect s include confusion on product storage, too much walking, cluttered aisles, lack of standardisation, as well as high losses and damages.
Ways in Which Material Handling Equipment Can Improve Efficiency:

Material handling equipment is used to increase output, control costs, and maximize productivity. There are several ways to determine if the material handling equipment is achieving peak efficiency. These include capturing all relevant data related to the warehouses operation (such as SKUs), measuring how many times an item is touched from the time it is ordered until it leaves the building, making sure you are using the proper picking technology, and keeping system downtime to a minimum......
Types of Material Handling Equipment: Storage and handling equipment: Storage and handling equipment is a category within the material handling industry. The equipment that falls under this description is usually non-automated storage equipment. Products such as pallet racking, shelving, carts, etc. belong to storage and handling. Many of these products are often referred to as "catalogue" items because they generally have globally accepted standards and are often sold as stock materials out of Material handling catalogues. Engineered systems: Engineered systems are typically custom engineered material handling systems. Conveyors, Handling Robots, AS/RS, AGV and most other automated material handling systems fall into this category. Engineered systems are often a combination of products integrated to one system.
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Equipment and utensils used for processing or otherwise handling edible product or ingredients must be of such material and construction to facilitate thorough cleaning and to ensure that their use will not cause the adulteration of product during processing, handling, or storage. Equipment and utensils must be maintained in sanitary condition so as not to adulterate product.

Industrial trucks: Industrial trucks usually refer to operator driven motorized warehouse vehicles, powered manually, by gasoline, propane or electrically. Industrial trucks assist the material handling system with versatility; they can go where engineered systems cannot. Forklift trucks are the most common example of industrial trucks but certainly aren't the extent of the category. Tow tractors and stock chasers are additional examples of industrial trucks. Bulk material handling: Bulk material handling equipment is used to move and store bulk materials such as ore, liquids, and cereals. This equipment is often seen on farms, mines, shipyards and refineries. This category is also explained in Bulk material handling.

On-Rails Transfer Car: On-rails transfer cart is a kind of material handling equipment. It moves on the rails and can transfer heavy cargoes or equipment with the weight 1-300t between the workshops or warehouses in the factory. It is widely used in the line of metallurgy, coal, heavy manufacturing, automotive assembly, etc. Conveyors: Conveyors are another form of material handling. Conveyors can be used in a multitude of ways from warehouses to airport baggage handling systems. Some types of conveyors are unibolt, power and free, chain, towline and roller conveyors.

CHAPTER 5

Bucket elevator
A bucket elevator is a mechanism for hauling flowable bulk materials (most often granular materials) vertically or 90 degree.

It consists of:
Buckets to contain the material; A belt/chain to carry the buckets and transmit the pull; Means to drive the system;

BASIC COMPONENTS OF BUCKET ELEVATOR

Accessories for loading the buckets or picking up the material, for receiving the discharged material, for maintaining the belt tension and for enclosing and protecting the elevator. A bucket elevator can elevate a variety of bulk materials from light to heavy and from fine to large lumps. A centrifugal discharge elevator may be vertical or inclined. Vertical elevators depend entirely on the action of centrifugal force to get the material into the discharge chute and must be run at speeds relatively high. Inclined elevators with buckets spaced apart or set close together may have the discharge chute set partly under the head pulley. Since they don't depend entirely on the centrifugal force to put the material into the chute, the speed may be relatively lower. Nearly all centrifugal discharge elevators have spaced buckets with rounded bottoms. They pick up their load from a boot, a pit, or a pile of material at the foot pulley. The buckets can be also triangular in cross section and set close to on the belt with little or no clearance between them. This is a continuous bucket elevator. Its main use is to carry difficult materials at slow speed. Early bucket elevators used a flat chain with small, steel buckets attached every few inches. Current construction uses a rubber belt with plastic buckets. Pulleys several feet in diameter are used at the top and bottom. The top pulley is driven by an electric motor.

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The bucket elevator is the enabling technology that permitted the construction of grain elevators.

TYPES OF BUCKET ELEVATOR:

DEPENDING ON THE TYPE OF DISCHARGE:

Centrifugal:
It is the most common Great travelling speeds (1.2 and 1.4 m/s). Loading is carried out by dredging the material at the bottom of the elevator The separation distance between the buckets is 2 to 3 times the bucket height.

Gravity or continuous:
Lower travelling speeds (0.5 and 1.0 m/s). It is taken advantage of self weight.

Classification: Free gravity. It is necessary to change the free branch line or incline the bucket. Forced. The buckets are situated one after the other without separation between them. The discharge takes place due to gravity by means of the lower part of the preceding bucket that acts as a discharge

spout.

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Positive : Similar to the gravity elevator safe that buckets are fitted at the edges with two cords. Bucket speed i s low are appropriate for light, aired, sticky materials.

Functions of Bucket Elevators:

The main function of elevator is to continue pulsating flow of material through a vertical handling. Apart from centrifugal discharge type, there are others such as positive discharge type, continuous type and super capacity elevators. In case of large materials, a lumpy and abrasive material slow elevator may be used without scooping the material is lifted. The chains or belts as traction element are used and different bucket shapes, provide universal possibility of combinations. Apart from conventional bucket elevators there are overlapping buckets type elevator, shelf elevator, cradle elevator etc. The main function of the bucket elevator is to transport or elevate goods and materials from one place to another quickly and easily. The buckets are connected to a chain or belt which moves when the equipment starts to function. The contents of the bucket are moved from one location to another when the belt moves. The belt is either chain driven or friction driven. In the mining industries, these buckets are filled with ore which is moved vertically and then poured or dumped to a new location. Ore is a heavy material and therefore the bucket should be constructed with heavy materials such as metals. Metallic buckets are quite commonly used in most of the industries as it is durable and tensile, suitable for various purposes. One of the main functions of the bucket elevator is to elevate the goods in the bucket in a vertical direction. The products in the buckets are raised or lowered and the contents are dropped to another container. The entire process of raising and lowering is done with the help of mechanical and hydraulic power. Another function of the bucket elevator is transporting the bucket in a horizontal direction. The materials are moved or transported from one place to another with the help of these elevators.

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Advantages of Bucket Elevators:

Used in Number of Industries Large Conveying Capacity High Hoisting Height Smooth Transportation of Goods Less Maintenance Stable and Reliable Running Long Service Life Low Driving Power Wide Range of Lifting

Basic Advantages of Bucket Elevators:

The bucket elevators are used in most of the industries today for a variety of purposes. It has a huge transporting capacity with lower maintenance and better transportation facilities. These elevators are durable with low driving power. With the help of elevators, goods and materials can be transported smoothly and easily. Materials can be lifted to a great height with the help of these elevators. In addition to reliability, the bucket elevators have a wide range of lifting capabilities. Modern elevators use plastic buckets and rubber belts for better and efficient functioning.

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Disadvantages of bucket elevator:

One of the well known disadvantages of a bucket elevator is the back flow or spill. The accordingly lower capacity and increased power consumption are not always the worst consequences, provided that the boot does not become too full. With the considerable heights of modern bucket elevators, up to 225 ft and over, serious damaging of the conveyed material, an intensified noise level and increased wear can be far more inconvenient. The discharge of the buckets has been recognised as an extremely complicated phenomenon which strictly speaking cannot be analysed theoretically. This holds even more for free flowing materials. Nevertheless, an analytical approximation has been worked out for the relatively simple case of cylindrical buckets filled with cohesive bulk material, to start with. With the development approximative theory a spill free combination of the relevant parameters has been found.

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CHAPTER 6:

PROJECT PROBLEM:
Sail Refractory Unit (SRU) is a unit of Steel Authority Of India Limited (SAIL) engaged in manufacturing of various refractory materials for SAIL plants. SRU, Ranchi Road unit produces Magnesium-carbon bricks for lining of convertors and ladles. Raw materials at SRU, Ranchi Road is stored in 26 no. Bunkers which are filled through bucket elevators from ball mill. End user requirement for this bucket elevator are:

1) Material Grain Size ( 0-5mm) 2) Material Density (1.7 t/ ) 3) Moisture Content (0.2 % max) 4) Material Quality ( mildly abrasive) 5) Ball mill output (-5m) 6) Material Discharge Level (15m) 7) Bucket Elevator Capacity ( 5 tph )
Suitable Bucket Elevators satisfying the given conditions is to be designed.

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CHAPTER 7

DESIGN CALCULATION:
1) SCOPE: Depending on the type of low moisture content, we have choose Centrifugal type of bucket elevator. 2) Selection of Elevator: Depending upon the density of material of 1.17 t/ , we choose the material to be Quartz which may be pulverised or granular It may be belt/ chain type. Type of elevator used is I = Centrifugal Elevator.

CAPACITY CALCULATION: From IS: 7167-1974 T=

T= 5 tph C=? W=1.7 t/m^3 =1700 kg/m^3 Approximated bucket size= 510 V= 1.55 m/s S= 0.48m Now, C=
. . . ^( )

=0.36143 litres

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SELECTION OF CASING:Casing is selected as per IS: 7054-1973+ depending upon the take up at head shaft and take up at boot shaft. SELECTION OF CHAIN/BELT:Chains are selected as per the table 1 and according to the material used. CALCULATION OF MAXIMUM TENSION OF CHAINS : Method of calculating maximum tension should be as follows: Tm= Ta +Tb + Tw + Tt Where Tm=maximum chain tension in N, Ta= tension due to mass of chain in N Tb=tension due to mass of buckets in N Tw =tension due to mass of material in buckets in N and Tt=tension due to mass of pick of material in N. The individuals tensions may be estimated from the following formula: T a= Height of elevator (H) Mass of chain in kg/m For calculating mass of chain in kg/m we do as follows: AS PER IS: 10131 DIAMETER OF CHAIN IS TAKEN TO BE 12mm

Pitch is found out to be 45 mm. And the no of links, n=9 Length of chain, l= n p = (90.045) = 0.405 m
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From table we get the value of W W=1.1 kg Mass of chain in kg/m= =1.1/0.405 =2.71 kg/m Ta= (20 2.71) N = 54.2 N Tb=
( )

MASS OF BUCKET IS TAKEN AS PER IS: 6833-1973. SPECIALLY FORM 1 IS USUALLY CHOSEN.

M=11.5 kg S=0.480 Tb=

. .

=479.17 N Tw=

=479.17 N Tt= =
. . ( )

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=239.58 N Ho= height factor to allow for pick up force in m, = 10 m for centrifugal and positive discharge elevator, = 3m for continuous type.

Now, maximum tension in chain Tm=Ta+ Tb + Tw + Tt = (54.2+479.17+479.17+239.58) =1252.12 N.

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CALCULATION FOR BELT:

Selection of Chain/Belt: If we choose belt then; a) Belt Width- 40% of Bucket Length = 0.4* 510 =204 mm = 0.2m b) No of plies= 5 (light powdery or free flowing materials free From lumps) Bucket projection= 200 c) Fabric & Grade of cover= N-17 Cover thickness= 1.5mm d) Belt tension1) Tension due to mass of Belt= B = 1.24 20 = 24.8 N Where, B= belt mass in kg/m run 2) Tension due to mass of bucket= =
. .

=47.91 N Where b= bucket mass in kg 3) Tension due to mass of load in bucket= =

. .

=864.16 N 4) Tension due to mass of pick up load and over coarse pulley friction =

20

= Where Ho= 10 m W= mass of material in each bucket in kg

. .

= 432.08 N

Maximum tension= 1+2+3+4 =24.8+47.91+864.16+432.08 =1368.95 N Maximum tension= (1+k) (Ho+H)

. .

= (1+0.80)

(10+20)

= 1944.375 N

K= 0.97 for bare pulley drive with screw take up, = 0.80 for lagged pulley drive and screw take up, = 064 for bare pulley drive with gravity take up, = 05 for lagged pulley drive with gravity take up. No of plies=

=0.243 1

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POWER REQUIREMNTS OF AN ELEVATOR: Head shaft power in an elevator in KN = Where v= belt/chain speed in m/sec =1.55 m/sec (from table) Te= effective tension in KN. = (H+ Ho) where H, Ho, W and S ARE ALL TAKEN

FROM THE TABLE AS ABOVE W=V ( volume is chosen 12.2 lit from table and we know that 1m^3=1000lit) Te=
0.01221700(20+10) 0.48

=1296.25 KN Head power at shaft input=

. .

=200.9 KN.

Motor output in KW= =

. .

(Efficiency is given to be as 80%)

=236.375 KW.

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CHAPTER 8

DESIGN SHEET OF BUCKET ELEVATOR:

We have also developed a design calculation sheet of bucket elevator Calculation as per IS. Snapshots of the same are enclosed

DATA INPUT SHEET

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DESIGN SHEET

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CHAPTER 9

CONCLUSION

This training was a very good opportunity for being acquainted with the industrial environment .The organisations work culture and the latest trends in this field of work has been observed .This experience will help us in developing a practical approach while going through the curriculum in the future. The time constraint has restricted a in depth study. However, from an engineering point of view, this training has been very beneficial and helpful.

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ANNEXURE 1: LIST OF IS CODES USED

SL.NO
1) 2) 3) 4)

IS CODES
IS: 7167-1974 IS:6833-1973 IS: 10131-1992 IS: 1891-1994

TITLE
BUCKET ELEVATOR BUCKETS CHAINS CONVEYOR AND ELEVATOR TEXTILE BELTING

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