SUMMER INTERNSHIP REPORT

With reference to

FACOR ALLOYS LIMITED, SHEERAMNAGAR

GARIVIDI,VIZIANAGARAM

A INTERNSHIP REPORT SUBMITTED TO RAJIV GANDHI KNOWLEDGE

TECHNOLOGIES RK VALLEY, IDUPULAPAYA

in fulfillment of the requirement for the award of the degree of

MECHANICAL ENGINEERING DEPARTMENT

SUBMITTED BY
DEVADA ASHOK KUMAR
R131586
Mechanical department

Under the esteemed Guidance

B.IMRAN SHAREEF
Assistant professor
Mechanical department
Rk Valley, Idupulapaya
Kadapa-516330.
2015-2019

iv
 DECLARATION

I D. ASHOK KUMAR student of RGUKT -RK VALLEY Idupulapaya , kadapa hereby

solemnly declare that the internship report with reference to FACOR ALLOYS LIMITED,
SHEERAMNAGAR” is a bonafide work done by me as part of the partial fulfillment of the
requirements for the award of degree of Mechanical engineering by the RAJIV GANDHI
UNIVERSITY KNOWLEDGE AND TECHNOLOGIES and this has not been submitted to
any other university or institution earlier. I take the responsibility for any mistake if at all
exists in this work.

Place: GARIVIDI

Date: 25-07-2018

D.ASHOK KUMAR
R131586

iv
 ACKNOWLEDGEMENT
In the presentation of this report , I recall with the sincere gratitude to each of those who have
been a source of immense help and inspiration during the whole process of my project

I express my gratitude to P.MEENASKHI DEVI Madam, Head of the Mechanical

Department, RGUKT RK-VALLEY for giving me permission to undertake the internship.

I sincerely express deep sense of gratitude to our honourable Faculty Member, Department of
Mechanical , B.IMRAN SHAREEF for guiding in internship work and giving valuable
suggestions throughout my internship.

I express my gratitude to Mr.RAMANA RAO GARU ,GENERAL Manager,Maintenance

FAL,GARIVIDI for his support and guidance during the course of the project.

I express my gratitude to Mr.Y.R.V.SURYANARAYANA HR Manager, FAL,GARIVIDI

for his support and guidance during the course of the internship.

I also express my special thanks to my friends who helped me in finishing my internship

work in an effective manner.

Date: 25-07-2018
PLACE: GARIVIDI
D.ASHOK KUMAR
R131586

iv
 ABSTRACT

High carbon ferrochrome is one of the most common ferroalloys produced and is
almost exclusively used in the production of stainless steel and high chromium steels.
Production takes place primarily in countries with substantial chromite ore supply. Relatively
cheap electricity and reductants also contribute to the viability of high carbon ferrochrome.
The most common production technology utilized is submerged arc smelting in AC furnaces,
although open arc smelting in DC furnaces is becoming increasingly common. Production
processes have become more energy and metallurgically efficient by utilizing advanced
processes such as preheating, agglomeration of ore, and CO gas utilization. Recently installed
plants display manageable risks in terms of environmental pollution and occupational
health.Raw materials for the production of steel include iron ore, limestone, coal, alloy metals
and oxygen. Processing is done in four major steps: mining, reduction, refining and
fabrication.
Ferro Chrome is an alloy of chromium and iron containing between
50% and 70% chromium. The ferrochrome is produced by electric arc melting of chromites
and chromium ore. Ferrochrome is produced by electric arc carbothermic reduction of
chromite. It is chromium that confers upon stainless steel its remarkable corrosion resistance.
Out of the total world chrome ore output about 95% is used to produce
ferrochrome for the metallurgical industry, with 2% used in chemical industry and the
balance 3% in the refractory and foundry industry. Later majority of which is used in Cast
Iron, Alloy Steels & Stainless Steel.

iv
 CONTENTS

CHAPTER-1

 Introduction 1

CHAPTER - 2

 Company Profile 4

2.1 Industry History

CHAPTER - 3

 BRIQUETTING PLANT 18

3.1 Raw material

3.2 Process

3.3 Feed rates

3.4 Rotary Drier

CHAPTER - 4

 FERRO CHROME PLANT 21

4.1 Sub station

4.2 Weigh house

4.3 Furnace

4.4 Submerged electric furnace

4.5 Mechanical equipment of furnace

4.6 slipping of electrodes

MECHANICAL MAINTANANCE OF FERRO CHROME PLANT 39

FINDINGS AND SUGGESTIONS 40

REFERENCES

iv
 CHAPTER 1
INTRODUCTION
Ferro chrome is an alloy comprised of iron and chromium used primarily
in the manufacturing of stainless steel. The ratio in which the two metals are combined may
vary, with the proportion of chromium ranging between 50% and 70%.

Ferro chrome Production:

Ferro chrome is manufactured by conducting carbothermic
reduction of iron magnesium chromium oxide under high temperatures. Iron-chromium alloy
is produced by the reduction of Chromium Ore by the application of coal and coke. This
reduction process requires heat which comes from the electric arc of the furnace. The arc is
able to create temperatures around 2800 °C. A great amount of electricity is consumed while
producing such intense heat which makes this a very costly process.

Fig 1. ferro chrome metal

Ferro chrome is collected from the furnace at regular intervals. Once a considerable amount
of the iron-chromium alloy is produced in the furnace, the slag and the molten metal is
extracted from the tap hole which passes through a trough and is collected on a ladle or chill.
The molten ferro chrome is then solidified in large castings and then processed further.
Ferro chrome can be of two types based on the amount of carbon it has; low carbon Ferro
chrome and high carbon Ferro chrome.

1
Most of the Ferro chrome in the world market comes now from places like South Africa,
Kazakhstan, India and Turkey. In these counties, the substance is produced in specialized
Ferro chrome plants.
Ferro chrome Chemical and Physical Properties:
The physical and chemical properties of Ferro chrome are listed below:
1- Atomic Mass: The atomic mass for this alloy is 52.0.
2- Density: The apparent density for this compound is 7.15 g/cm3.
3- Melting Point: The melting point for this substance is 1900 °C.
4- Boiling Point: The boiling point for this alloy is 2642 °C.
5- Appearance: Ferrochrome is available in a variety of forms, including small crystals,
lumps and granules as well as in powder form.
6- Color: The color varies from dark gray to light gray.
7- Odor: Odorless; can be dangerous when inhaled.
8- Solubility: The alloy is not soluble in water.
9- Combustibility: The dust particles of this chemical alloy are combustible.

Ferro chrome Uses:

Most of the ferro chrome produced worldwide is used in
manufacturing stainless steel. The chromium content present in stainless steel provides
resistance to corrosion as well as gives stainless steel its customary appearance. Around 18%
of chrome is used in per unit content of stainless steel .Ferro chrome is also used when more
chromium is needed to be added to carbon steel. High carbon ferro chrome is used in the
manufacturing of ball-bearing steels, tool steels as well as other alloy steels.

Apart from making stainless steel, low carbon ferro chrome is also used in
the manufacturing of acid-resistant steels. High nitrogen ferro chrome is created by adding
0.75% of nitrogen to the different grades of ferro chrome. This nitrogen-rich alloy is used for
manufacturing high-chromium cast steels having a coarse crystalline structure. The nitrogen
content produces refined grains and adds strength to the finished product. Foundry-grade
ferro chrome containing around 62-66% chromium and almost 5% carbon is used for
producing cast irons. Ferro chrome powder is used in the field of powder metallurgy. Ferro
chrome slag is a chemically stable substance. It is used in road construction and civil
engineering as well as in the production of refractory materials.

2
 Ferro chrome is used in the production of Ferro chrome lignosulfonate.
Ferro chrome lignosulfonate is used in various water-based systems to control flow of
materials at high levels of temperature as well as to reduce the ill effects of mud and clay
contamination. Ferro chrome lignosulfonate operates well in gypsum, fresh water, lime and
salt water fluids. Ferro chrome dust is used in the leather tanning industry.

3
 CHAPTER 2

Ferro alloys production in India is about six decades old. In India bulk ferro alloys production
through electric submerged arc furnace route made a beginning in late 1950s. After the
invention by Soderberg of self- baking type electrodes, during 1920s, this became the most
preferred way for making bulk ferro alloys of Silicon, Manganese & Chromium in the world.
of Rs.133, 915million.Alloys, can switch over their furnace for producing any Ferro Alloy,
depending on the market conditions.

ORGANIZATION PROFILE
2.1 Ferro Alloys Limited:
The ranges of Ferro Alloys find application in various steel plants, boundaries and other
making units. We have both, low and high density Ferro Alloys. These are basically used as
additives in steel manufacturing to offer strength according to different grades. We offer
these Ferro Alloys in various compositions depending on the specifications provided by the
clients.

We offer below chemicals in Ferro Alloys category:

 Ferro Manganese
 Ferro Silicon
 Ferro chrome

High Carbon Ferro Alloys:

Commissioned under the scheme of small scale sector, we are amongst all others
commissioned under the scheme to export our products such as high Carbon Ferro Chrome
and other high grade Ferro Alloys to countries like Japan, South Korea, China, Thailand,
Germany, Egypt, Malaysia, Dubai, Italy, Ukraine, Turkey, UK, USA, and Peru. In our two
decades of operation, we have been hosts of awards, which mark our credibility such as
Regional Export Award and (South region), which were presented to the company in the
year 1998-99, 1999-2000, 2003-04, 2004-05,2005-06, 2006-07, 2007-08 responsibility. We
have also been awarded with gold trophy twice as “Top Exporter”.

4
Ferro manganese:
Ferro Manganese, a Ferro Alloy with high content of manganese, is made by heating a
mixture of the Oxides mno2 and fe2o3, with carbon, usually as coal and coke, in either a
blast furnace or an electric arc furnace type system, called a submerged arc furnace. The
oxides undergo carbon thermal reduction in the furnaces, providing the Ferro Manganese is
used as a deoxidizer for steel.

Ferro silicon:
The biggest plan of high purity Ferro silicon of china, Qinghai Wutong group arranged a
meeting with its customers in Xining Providence today, about 80 people including local
government officials and customers from POSCO, Baosteel, and Tisco etc participated this
meeting. Mr. Karl liu from Ferro alloys was invited to attend made a short presentation.
Wutong group is one of the major Ferro silicon producers in china; its current capacity
about 35000mt is under constructing. Two 3MVA furnaces will be constructed and one of
them will be operated by the end of this year. Wutong high purity Ferro silicon capacity is
the largest one in china.
The total capacity of high purity Ferro silicon in china currently is about 40000mt, the
major consumers are from local steel mills, like TISCO consumes about 100000mt high
purity Ferro silicon last year. JFE and other Japanese steels are major buyers from abroad,
POSCO consumes about 40000mt per annum. Norway, Brazil also produces high purity
Ferro silicon about 100000mt capacity in total.
High purity Ferro silicon is mainly used to produce special stainless steel, tool steels and
also in the foundry industry. China total local demands are about 25000mt.
Wutong group is 15 years old and expanded very quickly during the past 5years. It has its
own patent technology to use wasted heat to produce electricity and has 3000 stuffs
including over 28 high educated engineers.
Ferro chrome:
Ferro chrome alloy which is formed by the process of melting chromate in electric arc
furnaces. Ferro chrome contains 50% to 70% of chrome and rest iron, and its extensively
used in the production of stainless steel.

Low chromium content facilities production of stainless steel and high chromium content
is used for engineering steel. Stainless steel acquires the property of corrosion resistance

5
 due to the presence of chrome content in it.
As essential component in the manufacture of stainless steel and special steel, we provide
Ferro chrome that is manufactured through the sustained smelting of coke, chrome ore, coal
and quartz at the submerged arc furnaces (SAF). At the temperature range of 1600-1700
degrees centigrade, there is a reduction in the carbon of the reluctant to chrome ore. After the
solidification process is done, the metal is obtained from the receptacle and then crushed to
required sizes.
The Ferro chrome plant utilizes a mix of hard lumpy chrome ore, chrome ore briquettes&
friable chrome ore as its input charge material. The chrome ore is sourced from Orissa
Mining Corporation, which is the largest spiller of chrome ore in India.

High Carbon (HC) Ferro Chrome:

Ferro chrome is an alloy of chromium and iron containing between 50% and 70%
chromium. The Ferro chrome is produced by electric arc melting of chromites, an iron
magnesium chromium oxide and the most important chrome ore. Most of the world’s Ferro
chrome is produced in South Africa, Kazakhstan, and India, which have large domestic
chromate sources. Increasing amounts coming from Russia and China. The production of
steel is the largest consumer of Ferro chrome, especially the production of stainless steel with
chromium content of 10% to 20% is the main application of Ferro chrome.
Over 80% of the world’s Ferro chrome is utilized in the production of stainless steel. In
2006, 28mt of stainless steel were produced. Stainless steel depends on chromium for its
appearance and its resistance to corrosion. The average chrome content in stainless steel is
approximately 18%. It is also used when it is desired to add chromium to carbon steel.

Low Carbon (LC) Ferro Chrome:

This alloy has lower content of carbon than chromium, which is present in a substantial
amount. The alloy is widely used in industries such as metallurgy, chemical, electronics and
electrical for a variety of applications. Available at industry leading prices low carbon Ferro
chrome offered by as per the high international standards.
Then in 1968, two more furnaces were added for Low Carbon & High Carbon
FerroChrome products and in 1981 a 16 MVA furnace was put up for production of Ferro
silicon or additional quantities of High Carbon Ferro Chrome.

6
 In the meanwhile, Facor was keenly developing indigenous technology,
through its research and development department, to utilize low grade chrome ores, from its
own mining leases to produce Charge Chrome. Based on its in-house technology adopted
and provided to an experts committee of Government of India , in the 7.5 MVA plant at
Shreeramnagar, it set up a 100% export oriented 50,000 tons per annum Charge Chrome plant
in 1983 at DP Nagar, Randia, in Bhadrak district on Orissa.
Having established this base Facor decided to add value to its own output
by getting into forward integration. A sophisticated steel plant was set up at Nagpur to
produce Carbon Steel, Manganese Steel, Alloys Steel and Stainless Steel.
In order to meet part of their power requirements Facor has
established two plants of capacity 3*10 MW and 2*10MW at Shreeramnagar and Randia
respectively in 1989-90. These diesel power plants are supplied by MAN B&W Germany and
are operating with heavy fuel oil.
This of course, is not the only high point of achievement of the R&D
department has for long enjoyed the recognition of the Department of Science and
Technology, Council of scientific and Industrial Research, Ministry of Steel for having
developed and established processes for:
 Beneficiation of Low Grade Chrome Ore.
 Agglomeration of ore fines and concentrates by way of briquetting and
sintering.
 Production of intermediate Carbon Ferro Chrome.
 Production of Manganese Ferro Silicon.
 Metal recovery plant of 20 T/Hr capacity established in 1994 to recover
metal entrapped in slag.
1948-1956:
Late Rai Bahadur Durgaprasadji Saraf forms a company called R.B. Shreeram & Co. Pvt. Ltd.
In the name of his father Seth Shreeramji with its Head quarter in Tumsar in the state of
Maharashtra.
R.B.S. & Co. becomes India’s first pioneer miners of Manganese Ore with its mining
activities in Andhra Pradesh in a village called Garividi which was renamed Shreeramnagar.
R.B.S. expands activities to mining of Iron Ore in Goa.

1956:

7
 13th March 1956, Facor is formed and India’s first modernized Ferro Manganese Plant had
been set up and commissioned in Shreeramnagar.
1968:
Facor expands and sets up a Ferro Chrome Plant. Facor expands in Orissa Simultaneously
and start mining Chrome Ore.
1978:
Facor promotes VISCO (Vidharba Iron & Steel Co.) in Nagpur to produce Specially Steel
products.
1981:
Facor sets up India’s first 16 MVA totally indigenous plant located in Shreeramnagar.
1983:
Charge Chrome Plant is set up in Orissa, which became Asia’s first and largest single
45MVA Furnace, the plant was inaugurated by the President of India Shri Zail Singh in a
new township called DP Nagar.
1984:
Polyplex Corporation Limited is incorporated by Sanjeev Saraf.
1987:
Facor diversifies into Chemicals and Indian Maize and Chemicals Ltd.
1989:
Facor instants 50 MW diesel power plant, the first of its kind on land with 510MW DG sets
supplied by MAN B&W, Germany.

1997:
Superior packaging’s a flexible packaging company is promoted by Ashish Saraf.
2000:
Steel RX online e-commerce portal is launched by Anurag Saraf.
2002:
Polyplex commissions a Metalliser in India with a capacity of 300 MTPA.
2003:
Polyplex commences operations in Thailand with a 39,000 MT PET film plant.
2003:
Punjab Hydro is set up by Rohit Saraf.

8
2004:
Aqua Power is set up by Vinit Saraf.
2004:
Facor is trifurcated to three Public Limited Companies
 Ferro Alloys Corporation Ltd.
 Facor Alloys Ltd.
 Facor Steel Ltd.
2005:
Boula Platinum Mining Pvt. Ltd. is incorporated for mining activities in Orissa.
HEAD OFFICE & CORPORATE OFFICE:
Tumsar, Bhandra District in Maharashtra.
REGESTERED OFFICES & WORKS:
 Charge Chrome Works, Randia, Bhadrak dist, Orissa.
 Chromite Mining Complex, Bhadrak, Orissa.
 Facor Alloys Ltd., Shreeramnagar, Vizianagaram dist, Andhra Pradesh.
 Facor Steels Ltd., Nagpur, Maharashtra.

2.8 FACTS OF FACOR ALLOYS LIMITED:

Name : FACOR Alloys Limited
Incorporation : 1955
Commencement of business : 1958
Registered Office : Shreeram Bhavan, Tumsar
Authorized capital : 2000 lacks
Paid up capital : 1180.51
Factory : FACOR Alloys Limited (FAL)
Chairman : R.K.Saraf
Jointing managing director : Yogesh saraf Asim saraf
Executive Director : Anurag saraf
Director (Technical) : C.N.Harman
Bankers : Bank of India
Central Bank of India
State Bank of India

9
 Syndicate Bank of India
State Bank of Bikaner and Jaipur

FACOR has created a respectable place for remote place called Garividi in the industrial
scenario after establishing its first Ferro Alloys plant in 1956. The FACOR township is
named after late Bahadurdeth Shreeramji, the father of the founder of this great organization
late Sri. Durgaprasadji saraf (father of present chairman, sri. Umashankar Agarwal and V.C
& MD, Sri. R. K. Saraf) as SHREERAMNAGAR.

FACOR was established as a public limited company by the families of SARAF’s and
MOR’s in the History of Ferro Alloys, this has become the first of its kind a major producer
of Ferro Manganese in the country.
FACOR is not only a leader in the field of Ferro Alloys, but also produces special steels
of high standards. Its diversified activities extended beyond mining and production of Ferro
Alloys, to making the special steel and embrace the production and manufacture of synthetic
yarn and maize products.
Low Ferro Chrome was imported to India until 1996 to meet the demand of steel industry.
Then, FACOR has set up a Ferro Chrome to substituted the imports of Ferro Chrome and
about 12000mt low/high carbon Ferro Chrome to substituted the imports of Ferro Chrome
and meet the domestic demand along with Ferro Manganese production and saved lot of
valuable foreign occupies the first position as producer and exporter of Ferro Alloys, in the
country. It is a pride for the organization for such credentials.
2.9 Credentials of facor:
 It is the country’s first ferro alloys plant
 It is the first plant to innovate and introduce chromium alloys and also the only
single unit to meet country’s requirements.
 It is the first unit to produce magnesium ferro silicon.
 It took the initiation to produce charge chrome with it’s own technical
know-how.
 The first in the country’s to export Ferro Maganese.
 It is the first among the various Ferro Alloys, producing unit to take up the
manufacture of low carbon Ferro Alloys.
 It is the first form to produce a total of one million tones of Ferro Alloys by the

10
 end of 1981.
FACOR develops Ferro Alloys as per customer specifications besides making sizeable
exports. FACOR was awarded certificate foe exports recognition by the engineering export
promotion council, Western Region, and Bombay in recognition of the outstanding
performance in the export of Ferro Manganese, Ferro Chrome, during 1981-82.
Favorable causes of location of FACOR:
FACOR (Facor alloys limited) at Shreeramnagar (Garividi) is situated at 85km north
of Visakhapatnam port. The main factors to establish a factory in Shreeramnagar are:
 Availability of labor at cheap rates.
 Availability of continues water supply.
 Availability of power station nearby.
 Availability of low grade Manganese Ore nearby.
 Cheap availability communication and transport facilities.

Availability of labor at cheap rates is one of the important factors and it is true in the case of
facor. Regarding supply of water there is a big Banta situated very nearer to the plant. It is big
tank of 200ft.depth and four, five acres of plinth area.
This unit was established along the Madras- Howrah railway track. Which generally
contribute to easy transportation and facor is located the side roadway linking Srikakulam-
Visakhapatnam port to export its products. The government of Andhra Pradesh supply
electricity at lower rates. The near villages are the main sources of raw materials like Sand,
Manganese Ore is available at nearest to Garividi, Koduru, Garbham, Duvvam and
Sadanandapuram.

RAW MATERIALS USES IN FACOR:

The basic raw materials required for production of Ferro Alloys are given below:
Ferro Manganese (High Carbon) : Manganese Ore, Coke, Lime stone
and electric power
Low Carbon Ferro Chrome : Chrome Ore, Coke, fluxing agents and
electric power
Ferro Silicon : Chrome Ore, Lime stone, Electric power
Silicon Chrome : Chrome Ore, Coke, Quartz, Electric Power
Silicon Manganese : Manganese Ore, Coke, Quartz, Electric Power

11
 The raw materials are obtained from Orissa, Maharashtra,
Bihar and West Bengal. Some times coke and chrome are also imported from
Jaipur, China, Turkey, and U.A.E etc. Annual consumption of the raw materials
for full production is around 3 lakh tones.
The raw materials are sized and blended in ore
preparation plant before using in the furnaces. Blended materials are
stocked in the yard sheds near the furnaces

FINISHED GOODS HANDLING, SIZING AND T RANSPORTATION:-

Finished goods are handled manually or mechanically according to specifications
of the orders and transported
quantities are exported
by means of road or rail within the
to Jaipur, Germany.
country.
sorne: quantities -- Some
are also
exported to Japan, Germany, Korea and U.S.A. etc., by ship through Visakhapatnam
port.
MANUFACTURING PROCESS:
The raw materials 'are smelted/heated to
1500-2000C and then alloys are tapped from electric arc furnaces in molten states, at
prescribed intervals along with the by products which are called slag. The melt is
separated into metal and slag and collected in receptacles. After cooling the metal and
slag are handled separately.
FINISHED PRODUCTS:-
The various types of Ferro alloys products are as follows:
 High carbon Ferro chrome.
 Low carbon Ferro chrome
 Silicon chrome
 Silicon Manganese
 Manganese Ferro silicon.
 Ferro Manganese.
 Medium carbon Ferro chrome.
 Among the products the HIGH CARBON FERRO CHROME is only producing
by FACOR at present.

QUALITY ASSURANCE SYSTEM:

12
 A straight quality control-for both raw
materials and products is being maintained as per the standards and being supported by
a full-fledged inspection and quality control department.
FACOR has accredited by Dutch council for certification and achieved 150-9002
certificate recently issued by IRQS a dept. of Indian Register for shipping, Bombay.
ISO:

1994: Efforts has been paid to accreditation with 150-9002 Implementation.

1995: The certificate was issued at 150-9002, 1987 version.

Subsequently the certificate is upgraded with respect to

50-9002 1994 version.Indian Register of quality, systems-Mumbai.The certificate has

been renewed in December 2000 it is valid up to December 2003.

COMPANY PROFILE:
FACOR Alloys Ltd has occupied a significant place into the industrial
scenario of the country. It has been established its first Ferro Alloys Corporation Limited
has been incorporated in the year 1955 by the house of saraf & Mors to become the first
major producers of Ferro Manganese in Pure country with registered office in shreeram
Bhavan.
In the history of FACOR Alloys Ltd (FAL), this has become the first of its kind and
major producers of Ferro Manganese in the Country. FACOR is not only a leader in the field
of FACOR Alloys the company also producer’s special steel of high standard. It diversified
activities extended beyond mining and producing of Ferro Alloys to make the Special Steel
and embrace, the production and manufacture of synthetic yarn maize products.
In sequence with a provision of intermediate storage in the day bins. Necessary
weighment and charge mixing are also done as per the requirement. The various types of
FACOR Alloys being procedure High Carbon Ferro Chrome, Low Carbon Ferro Chrome,
Silica Chrome, Silicon Manganese & Manganese Ferro Silicon, Ferromanganese, etc.,
Low Ferro Chrome was used to be imported by operated , until 1966 to meet the
demand of Steel industry then, FACOR has set up a Ferro Chrome plant with two furnaces’
having capacity about 12,00mt low/high Carbon Ferro Chrome and substituted the imports of

13
Ferro Chrome and meet the domestic demanded do along with Ferro Manganese production
and saved lot of valuable foreign exchange, which has very badly needed for the country.
Thus FACOR Alloys limited occupies the first position at producer and exporter of Ferro
Alloys in the Country.
The various departments in the FACOR are as follows.
Human factor play a vital role in actuating Management plans. It is the willingness
of human factor to continue its might and co-ordinate rationally at different levels that give
the entrepreneur a combination of successful performance and work culture. Hence it is
necessary to manage the functional staff efficiently and effectively
The continuous demand for the steel in our nation increased the need for producing
different Ferro Allots on large scale Realizing. This need for producing Ferro Alloys in the
Country, M/s Ferro Alloys Corporation Ltd., was floated in the year 1955 by the house of
Sarafs and Mohrs to become the first major producers of Ferro Manganese in the country.
The year 1956 marked the beginning of the FERRO ALLOYS CORPORATION LIMITED
at SHREERAMNAGAR in GARIVIDI village situated at 85km.North of Visakhapatnam
port and with the registered office at TUMSAR (Maharashtra). The Ferro Alloys are use as
deoxidizers and all alloy additives in the steel making process. FACOR has been producing
various Ferro Alloys in an effort to meet the demands of Steel Industry.
In the year 1957, Ferro Manganese Plant went into production equipped with three
sub-merged electric arc furnaces of 7.5 MVA Transformer-rating each for production of High
Carbon Ferro Manganese and Ferro Silicon. In Dec. 1969 a fourth sub-merged electric are
finance of 12.0 MVA transformer-rating for production of High Carbon Ferro Chrome and a
fifth open are Slag Furnace of 8.0 MVA transformer –rating for production of Low Carbon
Ferro Chrome were commissaries. To cope up with the increasing demand, the company has
set up a sixth sub-merged electric arc furnace of 16.0 MVA transformer rating for production
of High Carbon Ferro Chrome; in 1981, using its own Technical know-how and indigenous
machinery and equipment. Thus the gross transformer rating of all furnaces put together has
been increased to 58.5 MVA to meet the installed licensed production capacity of 72500
metric tons per annum.
The plants have facilities for Raw Material Handling, Metal & Slag casting, Crushing,
Sizing and other ancillaries apart from furnaces for smelting of Ferro alloys. The Raw
Materials required for the production of Ferro alloys are Manganese Ore, Chromites and
Quartzite ores with principal elements. Mn, Cr and Si respectively; Carbonaceous reducing
agents such as cokes, coals and fluxing agents such as Lime-stone, Dolomite and Magnetite

14
etc. These raw materials are procured from Andhra Pradesh, Orissa, Madhya Pradesh and
Bihar etc., and transported to the worksite by Transport.
The sizes of the Raw Materials are in the range of 30mm to 40mm and stacked in
yards, crushed to the required sizes and fed to the electric arc furnaces by trucks, belt
conveyors, skip-hoists, buckets, tipper cars etc in a sequence, with a provision of intermediate
storage in the day-bins. Necessary weighment and charge mixing are also done as per the
requirement. These alloys are tapped from the furnace in molten state, along with the
bye-products, called as slag’s which are cast in pans/beds, cooled & solidified and removed
by EOT Cranes and dumpers to finishing yards handled manually/mechanically to the
required size -25 mm to 150 mm and transported by Rail/Road Transport to the Alloy Steel
Industries I India and exported by Ship to foreign Countries. The production campaigns
have been changed with the market trends Countries. The production campaigns have been
changed with the market tenders FACOR as a part of pollution Control systems has
connected tow-stage Venturi Scrubber system/ Bag house units to the furnaces, which are
operated to maintain a clean environment in and around the Industry. Continuous
monitoring is ensuring to control the pollution levels within the limits prescribed by the
pollution Control Board.
Also required facilities for beneficiation and alliteration of Chrome Ores have been
set up. A pilot plant for sintering of manganese/chrome ore fines and mechanized briquetting
plant were also set up FACOR set up a Metal Recovery Plant to extract the valuable metals
from slag-metal mixes. A Stringent quality control for raw materials and products is
ensured as per the standards. Supported by a full-fledged Inspection and quality control
department.FACOR’S pioneering spirit and vision continued and the company’s research and
development efforts have brought many laurels to its credit. The name a few –FACOR
developed Ferro Silicon Magnesium for the first time in the Country which had a wide
acceptance in the foundry industry thus saving valuable foreign exchange for the country and
also the company has very successfully developed the know-how for the production of
CHARGE CHEROME by using chrome fines as the main raw materials hitherto left as a
waste and the L.C. Ferro Chrome slag was successfully developed as agro-soil conditioner
and traded in the name of “Bhushakti’.
As a pioneer, the company has always been eager to utilize the opportunities for
growth the diversification in the elated areas and for that reason FACOR has required a
mini-steel plant at Nagpur, Maharashtra to produce quality Steel. Consistent and continuous
efforts for diversification have also resulted in setting up a 100% Export Oriented Charge

15
Chrome plant at D.P. Nagar, Randia, Dist Balasore in Orissa state with a production
cadsvoyu pg 50,000 Tons per annum.
M/s FERRO ALLOYS CORPORATION LIMITED has been trifurcated into the
following three independent companies from 01.07.2004.
1. FACOR ALLOYS LIMITED, SHREERAMNAGAR (A.P)-FAL
2. FRRO ALLOYS CORPORATION LIMITED, D.PNAGAR
(ORISSA)-FACOR
3. FACOR STEELS LIMITED, NAGPUR (MAHARASHTRA) -FSL
CURRENT PROFILE OF FAL:
This company has been current engaged in production of
High Carbon Ferro Chrome (HCFECR.) as pre-market demand and is capable of producing
various Ferro alloys like High Carbon Ferro Manganese (HCFEMN), Silicon Manganese,
Silicon Chrome, Ferro Silicon etc as per market demand.
The production of Ferro alloys is carried out through five electric are furnaces f a total
transformer rating of 50.5 MVA, on a licensed capacity of 72, 500 MTPA. The plant &
office buildings are laid out in a land of 60 acres. The company has supporting facilities such
as 132/11LV, arm receiving sub-station for distribution of power Purchase Agreement for a
CAMD OF 35 MVA.
The work force consists of about 110 supervisors and 521 regular employees apart
from 926 contractor’s workmen. The movements of employees to the factory are governed
computerized attendance recording system, Monitored by Personal Department. An
emergency control center is maintained at security main gate monitored by Security
department to meet all emergencies. In 1994 a Quality. Assurance system has been
established and implemented in the company as per the requirements of ISO-9002-1987
standard, which has been upgraded as per ISLO 9002-1994 standard in 1996. This System
has been replaced by Quality Management system as per the requirements of ISO 9001-2000
Standard from DEC2011.

ACHIEVEMENTS OF FACOR:
 It is country's first Ferro Alloys Plant.

 It is the first plant to innovate and introduce Chromium Alloys and also the only
single unit to meet country's requirements.

 It is the first UN it to produce Magnesium Ferro Silicon.

16
  It took the initiation to produce. Charge chrome with its own technical
know-how.

 It is the first take up the erection and commissioning of the wholly indigenous
furnace without any foreign component or consultancy.

 The first in the country's to export Ferro Manganese.

 It is the first among the various Ferro Alloys, producing. Unit to take up the
manufacture of low Carbon Ferro Alloys.

 It is the first firm to produce a total of one million tones of Ferro Alloys by the
end of 1981.

FACOR develops Ferro Alloys as per customer specifications besides making sizeable
exports. FACOR was .awarded certificate for export recognition by the Engineering
Export Promotion Council, Weston Region, and Bombay in recognition of the
outstanding performance in the export of Ferro Manganese, Ferro Chrome, during the
1981-82.

17
 CHAPTER 3

BRIQUETTING PLANT

In the briquetting plant,one of the raw material for the ferrochrome is

produced. Briquetting is a process where the ores will be made into small rectangular shapes
by addition of compounds like lime,molasses etc ..,known as briquettes. Briquetting is done
to improve the efficiency of the furnaces.

3.1 Raw materials:

-Chrome ore: It is available at any place in 3 stages 1. lump ore

2. Medium ore
3. Fines .
Chrome ore in lump and medium ore can be directly taken into furnace,but
fines will go agglomeration(i..e means sizing the ore fines into required size by using
binders).

- Molasses: Molasses, or black treacle is a viscous product resulting from refining

sugarcane or sugar beets into sugar. Molasses varies by amount of sugar, method of
extraction, and age of plant.molasses used as binder.

-lime:Limestone is a sedimentary rock, composed mainly of skeletal fragments of marine

organisms such as coral, forams and molluscs. Its major materials are
the minerals calcite and aragonite, which are different crystal forms of calcium
carbonate (CaCO3).lime stone as flux agent.

3.2 Process:
Briquetting plant consists of four circuits:

Circuit 1: Ore handling and processing unit.

Circuit 2: drying and mixing unit.

18
 Circuit 3: Pressing unit.
Circuit 4: Handling unit.

Circuit 1:
Chrome ore from the storage planet loaded in the skip and poured in to hopper from
skip bucket which is pulled by slip ring induction motor of 250 KW.It is screened using a
rolling screener which is rotated squirrel cage induction motor of required certain
power.Screened ore is moved to drier using conveyor belt-1 which is rotated by squirrel cage
induction motor of rating 5 hp and screened ore moved to circuit 2.

Circuit 2:
Ore particles filled in the drier,drier is an equipment which dries ore particles by
increasing the temperature.oil is pumped from the oil tank using 1.5 hp squirrel age induction
motor to the drier.air is also pumped into drier using a induced draught fan.this air sprays oil
throughout the drier uniformly.oil is lit externally.the heat liberated from the oil combustion
used to dry up the ore.again the dried ore moved to the screeners using conveyor belt-2 and
transported to hopper and stored there for further use.lime which is agent is stored in hopper2.
molasses from molasses tank is used as reducing agent and binder.
When PLC controller gives command according to requirement for
suppose 1000 kg ore,200 kg lime,20 litres of molasses.preferred amount moved to the
conveyor belt-3.first ore particles is moved to the mixer then the lime is added to the mixer
and at last molasses is added.the mixer is rotated with constant speed 10 rpm.the motor used
for this mixer unit is squirrel cage induction motor.

Circuit 3:
the mixed ore is feeded to the pressing and it is taken from the mixer through
conveyor belt-4.this mixed ore particles is transported to the hopper.the bottom of the hopper
have moving blades which make the mixed ore particles as fine particles for better
pressing.this fine particles ore allowed through two oppositely rotating motors,one motor is
clockwise and another in anti- clockwise.
When mixed ore particles is allowed in between this air gap,the ore is pressed and
made into briquettes.some remaining ore(unfinished) is again transported to another unit
which again processes this mixed ore and forms briquettes.

19
 Fig 2: briquettes from briquetting plant
3.3 Feed Rates:

 Daily output : 330 tonnes

 Tonnage of feed : 14 tonnes/hr
 Chrome ore feed rate : 1 tonne
 lime feed rate : 30 kg/ 1tonne of ore
 Molasses feed rate : 60 kg/ 1 tonne of ore
 Hydraulic pressure :120 kg/hr
 Rotation of rollers : 15 rpm
 No. of cavities of roller : 120
 Hourly output of press : 14 tonnes /hr
 Capacity of molasses tank : 80 tonnes

3.4 Rotary drier:

Rotary drier is type of industrial dryer employed to reduce moisture content of
material it is handling by bringing it into direct contact with a heated gas.

 20 t/h length of outer drum : 7650 mm

 Diameter of outer drum : 1944 mm

20
 Length of inner drum : 6150 mm
 Diameter of inner drum : 1220 mm
 Calorific value of furnace oil : 10500 kg.cal/m2

Fig 3: Drier of briquetting plant.

21
 CHAPTER IV

FERRO CHROME PLANT

Ferro chrome alloy is produced by raw materials like
bauxite,coal,dolomite,quartz,limestone..etc and briquettes made of molasses,lime and chrome
ore.
The entire ferro chrome plant is divided into 4 main parts:

1- Substation
2- Weigh house
3- Furnace
4- Pump house

4.1 Substation:
In the substation 132 /11 KV using step down transformer converts input of 132
KV into 11 KV for the purpose of plant. The out put from 132 /11 KV substation I..e, 11
KV is given as input to the ferro chrome plant substation. In this substation, there are three
transformers 750 KVA for miscellaneous purpose i..e for motors,pump house,cranes
conveyors..etc. Another transformer of rating 2 MVA serves pollution control plant.the
secondary voltage of these transformers is 415 volts. These are of oil cooled type (ONAN)
transformer.

4.2 Weigh house:

Several raw material required for ferro chrome alloys are stored with the help of
conveyors in weigh house. Conveyors are controlled PLC control room and it is automatic
batching system. There are eight bins in weight house,for every two bins there are two
conveyors moving in opposite directions to fill the bins with raw materials in proportional
quantities. A rail type shuttle is moving forward and backward to fill bins according to
material which is moved by two drive wheels connected to motor.
For every two bins one weigh hopper is present,so four such
hoppers are present below the eight bins. The two raw materials in the two bins are therefore

22
mixed in every weigh hopper. Below weigh hopper four scale hoppers are present. The raw
material from the scale hoppers to the discharge conveyor and then to the bins of furnace.
Ten bins are filled with raw material through reversible conveyor of SCR AND SCL.
Required amount of raw material allowed through PLC control room. Weigh house is
connected to automatic batching raw material plant.

Fig: automatic batching system of ferro chrome plant

4.3 Furnace:
Furnaces in this planet are submerged electric arc furnaces. In most the submerged
electric arc furnaces produces the desired output directly. The submerged arc process is a
reduction smelting process. The reactants consists of metallic ores (ferrous oxides,silicon
oxides,manganese oxides,chrome oxides,etc) and a carbon source reducing agent usually in
the coke, charcoal ,high and low volatile coal or wood chips. Lime stone may also added as
flux material. Raw materials are crushed,sized and in some cases, dried and then conveyed to
mix house for weighing and blending (mix different elements together).

23
 In this plant,there are two furnaces of open top hood electric furnaces. The power
supply for these furnaces is served by two transformers of ratings 16 MVA AND 12 MVA
(11KV/110-200V) The secondary bus of transformer is connected to flexible jumpers and
then to electrodes. Electrodes are moved up and down with mechanical arrangement. For
effective burning of raw materials carbon paste is filled in the electrodes. During starting of
the burning process the three electrodes are shorted with a wire and given supply for arcing.

The type of electrodes used for furnaces are SODER BURG SELF BAKING
FREELY SUSPENDED SEMI GRAPHITE ELECTRODES. Coke is the main raw material
for manufacture of electrodes.coal tar pitch blend are used as binder for electrodes. The
current supply to the electrode through the furnace yoke and gap between the tip of electrode
and charge or bottom of hearth is called ionic gap. The electrical energy coming through the
electrodes forms an arc and converts as heat energy. From here reduction process starts ,as
baking of electrode begins.

4.4 Submerged electric arc furnace:

In most cases, the submerged electric arc furnace produces
the desired product directly. It may produce an intermediate product that is subsequently used
in additional processing methods. The submerged arc process is a process is a reduction
smelting operation. The reactants consist of metallic ores ( ferrous oxides,silicon
oxides,manganese oxides,chrome oxides, etc) and a carbon source reducing agent, usually in
the form of coke,charcoal,high and low volatility coal or wood chips. Lime stone may also
added as flux material. Raw materials are crushed, sized and in some cases, dried and then
conveyed to a mix house for weighing and blending (mix different elements together).
conveyors, buckets,skip hoists or cars transport the processed material to hoppers to above
the furnace. The mix is then gravity fed through a feed chute either continuously or
intermittently as needed. At high temperature in the reaction zone, the carbon source reacts
with metal oxide to form carbon monoxide and to reduce to base metal. A typical reaction of
ferro silicon in shown below:

Fe₂O₃ + 2 Cr₂O₃ + 9 C → 2 FeCr + 9 CO

The process by which metal is smelted in a refractory lined cup shaped steel shell by
submerged graphite electrodes. The purpose of refractory lining is to protect the steel shell of

24
the furnace and the purpose of cooling is to keep the lining in shape. The principal of
conventional submerged arc furnace is electric resistance heating. Electric energy is
converted into heat ad reduction energy by using resistance (R) of burden or the molten slag,
sometimes reinforced by electrical resistance of arc between slag and electrode. The basic
equation for the power input into the furnace is given by equation P= 3EI COS? = 3 I^2
R ,P-power E- face voltage between transformer and furnace hearth, I- electrode current ,R-
ohmic hearth resistance. The effect of low power factor can easily be compensated by
installation of capacitor banks to correct the power factor on grid.

4.5 Mechanical equipment needed for furnaces:

 Furnace shell - Tap holes

 Smoke stack - Chutes
 Smoke hood - Clamps
 Pressure rings - Flexible copper bolts
 Copper pipes - Cushions
 Flat section - Filter section
 Electrode cooling fans - Hoist chains

Furnace shell :
The shell is manufacturing from boilers steel plate of 1520 mm. Thickness
the shell should be strong to withstand all the stress imposed at elevated temperatures by the
raw materials and metals as well as the pressure exerted by the furnace lining the diameter of
the shell is 7050 mm. Process by which metal is smelted in a refractory lined cup shaped steel
shell by submerged graphite electrodes. Purpose of refractory lining is to protect the steel
shell of the furnace and the purpose of cooling is to keep the lining in shape. Transfer
crucibles are refractory lined vessels used to transport molten chrome. The refractory lining
material depends upon the application. Desired characteristics include resistance to erosion
and thermal shock,minimal heat loss of metal being transferred.
Tap holes:
The alloy and slag bare tapped from the top after which they are closed with paste
plugs. Tapping operation is done with tapping rod connected to oxygen cylinder. Tapping
hole is created with pushing of tapping rod moving forward and backward to remove carbon
paste plugs.

25
Smoke stacks:
There are two smoke stacks auxiliary and main stacks to each furnace to
permit evolved gases in the furnace to control pressure in furnace. In one stack evolved gases
are out through it and another is connected to pollution control.
Chutes and hoppers:
The charge material from monorail or conveyors is dripped in the
hopper in the bins and passes through chutes to the furnace. Ten chutes are connected to ten
bins then to furnace shell. Raw materials are filled in the furnace when required through
chutes.
Smoke hood:
Smoke hood is provided at the side of the smoke stack to remove excess gases
released in the furnace.
Clamps :
The current is sent from copper pipes to the electrodes through the clamps which
are pressed by pressure ring. Closed top furnace consists of 8 clamps of each electrode and
open top furnace consists of six clamps of each electrode.
Pressure rings :
The closed top furnace consists a pressure ring to two pressure ring to the
two segments and open top furnaces consists of a pressure ring of a pressure ring of six
segments to held the clamps.

Fig : pressure rings

26
Cooling system:
Function of furnace cooling system is to cool furnace shell and prevent from
the overheating and subsequent burn through.
Cooling system provides the various methods
exist for cooling of the furnace. Each pressure ring should be cooled independently air
cooling systems arranged to electrode cables and furnaces bottom rest of parts are cooled
with water there is an emergency water tank to meet emergency requirement.
Baking of electrodes:
After filling the casing with carbon paste block,corresponding doing
the composition of paste on furnace conditions and electrode slipping the raw paste liquidizes
at certain temperatures of electrode. while going down electrode hardens itself slowly with
increasing temperatures, by this process in the furnace the electrode withstand higher
temperatures and gains high mechanical strength.

Temperature zone:
20 ° C - When paste is in solid.
70° C- Softened and made into solid state
300°C-Solidification starts
700°C-Solidification ends with evolution of remaining volatile matter.
- for most substances the melting and freezing pints are the same temperature.
- poor baking of electrode obtains when fast and more slipping taken for electrode.

4.7 Slipping of electrodes:

It is necessary to maintain certain distance between electrodes and
charge to maintain /supply the amount of energy uniformly.

Process :
The electrode has two pads namely upper and lower pad,each has a cylinder for it
to recluse and catch the electrode with air pressure and water pressure also. A cylinder is
connected to catch the electrode with hydraulic pressure or air pressure. The electrode is
clamped between spring connected cylinder. When the time of slipping up: upper pad is
opened by expanded by cylinder connected spring, lower pad is closed. A cylinder connected
between both pads, cylinder is expanded by hydraulic pressure. Now at last cylinder will be

27
retract to own length. A slipping 10 cm is done for one slipping . For slipping down: the
upper pad will be closed, with lower pad slipping action will takes place.
An electrode slipping apparatus for electric furnaces comprises an electrode,hydraulic hoist
with electrode- slipping hydraulic mechanisms mounted thereon,locking ring,contact shoes
with clamp and hydraulic clamping mechanisms,locking ring control valve,side valve for
controlling electrode the slipping hydraulic fluid pressure control unit and programming unit.
And nearly 10-12 cms can be done in slipping for a shift inner
ribs are intended to increase the surface contact between the shell and paste to make electric
conductivity and mechanical strength of electrode more durable or reliable.

Electrode measurements and operations:

Each electrode in 1st ,2nd,3rd,4th furnace had an
electrode diameter of 1050 mm and 5th furnace has 800 mm diameter and 6th furnace has
1100 mm diameter. And each casing of electrode has thickness of 20-30 mm and height of
1.2m (120 cm). the electrode is connected to hoist chains and finally to the motors whose
switches are provided in the control room if the electrode crosses certain point of cooling
system is damaged. So the electrode should be operate within limits provided which are
known as upper limit and lower limit.

4.8 Electrode assembly:

The following are the main mechanical and electrical parts or
equipment which assembly the electrode.
1-furnace yoke 2- pressure rings
2-pressure bolts 4-copper pipes and brass fitting.
5- contact clamps 6-suspension rod for pressure rings
6- water cooling shield 7-suspension ring
7- copper bus bars 8-copper cables and copper shoes
9-terminal box 10-cooling water pipes
11-suspension frame and mantle 12-electrode cooling fan
13-water cooling pipes.

4.9 Number of systems in ferro alloys:

 Water cooling system

28
 Hydraulic system
 Pneumatic system
 Pollution control system
 Conveying system
 Transport system

WATER COOLING SYSTEM:

Function of furnace cooling system is to cool the furnace shell and
prevent from the overheating and subsequent burn through. Coo;ling system removes the
excess heat generated in the blast furnace which is otherwise loaded on the shell. Cooling
system thus prevent the increase of the shell and lining temperature. Various methods exist
for cooling of the shell for the furnace. Each pressure ring should be cooled independently air
cooling system is arranged to electrode cables and furnace bottom rest of parts are cooled
with water. There is an emergency water tank to meet the emergency requirement.

Flow diagram of cooling water supply.

BUNTA
↓
Water treatment softener
↓
Pump house
↓
Inlet manifold
↓
Copper pipes
↓
Various parts of furnace
↓
Outlet manifold
↓
Cooling pond
↓

29
 Used for re-circulation

Hydraulic system:
Generally hydraulic systems are used for ferro alloys to operate the
electrode and it is also used for the raw material discharge, hopper chute gates are opened,
closing purpose and also used in slipping of electrode.

Parts of hydraulic system:

Hydraulic cylinders
Hydraulic hose pipes
Hydraulic piston rod.
Pneumatic systems:
Generally pneumatic systems are used in ferrro alloys pollution systems
and raw material discharge gate operating purpose. In pollution systems dust removing oust
side of the bag house bags.

4.10 Production process:

Chrome ore:
Chrome ore is available at any place in 3 stages 1- lump size 2- medium
size 3- fine size . Chrome ore in lump and medium size can be directly taken into furnace.
But fines will go agglomeration I..e sizing the ore fines into required size by using binder.
Reductants :
The reductants commonly used for reducing chrome ore, but not for
producing heat or as fuel.
Example:
Imported coke ------- 85% of fixed carbon
Cil coke ------- 65% of fixed carbon
Anthracite coal ------ 90% of fixed carbon
Fluxes :
Flux is used to maintain the fluidity bath. According to requirement acid and
base fluxes like quartz, lime stone,dolomite and magnetite are used.
Input required to produce 1 tonne of “Hc Fe Cr”
Raw material : 2.5 m.t
Fixed carbon : 400 kgs

30
 Power consumption : 3650 kwh

Charge taken into furnace:

1- Briquettes (chrome ore)
2- Chrome ore lump
3- Coke
4- Coal
5- Quartz
6- Dolomite
7- Hc remelts

All the charge mixer went into the furnace and then the reduction process is
done in the furnace depends on the the temperature of furnace and physical and chemical
properties of elements.
Properties like Fe melts at certain point as:
Element Melting point Boiling point
Fe 1535°c 3000°c
Cr 1890°c 2199°c
Si 1414°c 2287°c
Above elements starts reduction at their melting and boiling points.
Principal reactions for reduction of chrome and are as follows:

Cr₂O₃ +3C → 2 Cr +3 Co
FeO +C → Fe + CO
SiO₂ + 2C → Si + 2CO
The reduction of iron from ferrous oxide takes place simultaneously with the reduction of Cr
from Cr2O3.

Reduction of slag:
Temperature in the hearth is determined by slag composition. The metal
temperature with an alloy as 4% carbon and 70 % Cr is nearly above 1550°c. the metal
should be over heated by roughly 1000 above it’s melting points In order that it can flow
easily from the furnace tapping. The melting point of slag is more than the metal.

31
 Experience shows that
chrome ore contains rough equal qualities o both MgO and Al2O3. If may be assumed that
the same proportion remains in the slag. The SiO2 content in the slag with smelting points of
1700°c is about 28-32%.

Analysis of reduction:
Coke :
Ash : 12-13%
Volatile: 2.5-3.0%
Fixed carbon : 84%-85%
Phosphorus: 0.024-0.026.
Coal:
Ash :25-28%
Volatile 2.5-3.0%
Fixed carbon :84-86%
Phosphorus : 0.024-0.026
Analysis of flux:
Quartz :
SiO2 :98.4 %
Dolomite:
CaO : 28-29%
MgO: 20%
SiO2: 3-5%

4.11 Water softening plant:

Water softening plant is the removal of calcium, magnesium and
certain other metal cations in hard water.process involving replacement of calcium ions in
water with sodium donated by a cation-exchange resin.soft water extends the lifetime of
plumbing by reducing or eliminating scale build-up in pipes and fittings.
Ion exchange devices reduce the
hardness by replacing magnesium and calcium (Mg +2 and Ca+2) with sodium or potassium
ions(Na + and K +). When all the available Na+ ions have been replaced with calcium or

32
magnesium ions, the resin must be recharged by replaced the Ca +2 and Mg +2 ions using a
solution of sodium chloride (NaCl) or sodium hydroxide.

4.12 Tapping and it’s process:

Every tapping will be done as per the power consumption(20 MVA
and above) and from cylinder oxygen gas travel through iron pipe. Tapping is done with gas
coming out from iron pipe by pushing forward and backward. Slag and metal will come out
through tap hole after completion of hole and collected into cast iron’s mould bowls. cast
iron’s bowls are dressed up with sand at center and lime stone coating around the bowl inner
surface to reduce surface contact between metal and mould bowl.

4.13 EOT CRANES:

EOT Cranes means electrical operating travel cranes. For travelling of cast iron’s
mould bowls. From the furnace, the metal is collected in the mould bowls and cooled down.
For purpose of lifting this heavy weight,electric over head travel cranes are used. Each EOT
consists of four drives. One for main hoist and other for auxiliary hoist, other two drives are
for long travel and across travel of EOT. There are 6 EOT cranes are in this planet. For long
travel four wheels are used, two are drive wheels and other are driven wheels. The drive
wheels are run by squirrel cage induction motor of certain ratings connected to gear box
required speed. The hoist system is run by slip ring induction motor because to carry heavy
weight, torque required is very high. The EOT cranes are operated by crane operator.

4.14 PUMP HOUSE:

Used to circulate the water for cooling purpose. Pump house water supply can
be divided into for supply
1- Cooling of furnace and furnace parts.
2- Cooling of metal
3- General purpose
4- Dust controlling

The feed water is obtained from two sources:

→ some amount of water is from pond in mines using low feed water pumps.

33
→ remaining water from ground using submergible pumps.
The water from pump house is pumped through high pressure
feed water pumps into plants. Here the water is pumped with high pressure to meet the
distance and head at the plants. In order to obtain the high pressure, may be slip ring
induction motor or squirrel cage induction motor.

4.15 Flow of pump house water:

Dust controlling
↑
Pump house → Pipes → furnace parts
↓
Cooling purpose

Cooling of furnace:
The hot water in the plant is collected in the pump house through low
pressure pumps. Similarly the hot water from furnace is also collected. Again hot water is
cooled by two processes one by passing through cooling plates and exposing to atmosphere.
Another by sprinkling in the pond and exposing in the high atmosphere through high pressure
water pumps.
As the water is continuously flows in the pipes they get corroded. In order to avoid this
corrosion some chemicals such as brine solution(salt water) …etc are mixed. In order to
achieve high pressure, we are using slip ring induction motor to obtain variable torque a
control circuit is can be provided.
For both high and low pressure pumps slip ring induction motor is used. By
varying resistance in steps,we can meet required torque. As the motors are run by with 440 V ,
3 phase a transformer of 11 KV/440 V, 750 KVA is used to supply power to the pump house.

Slip ring induction motor ratings:

Power P = 110 KW current I = 194 A

Speed S = 1480 rpm voltage V= 415 V
Connection = delta
Auxiliary motor ratings :

34
Power P=215 HP speed S = 1480 rpm
Current I = 250 A Voltage = 41 V
Connection = delta.
The pump house has an auxiliary alternator for emergency purpose.
When supply is not available, its meets emergency condition.

Alternator ratings:
Speed S = 1500 rpm current = 252.5 A
Voltage = 415 V phase sequence = UVW

Excitation : (battery)
Voltage = 210 V current = 72 A

4.16 Pollution control:

Each system consists of one take and three type of motors. Two ways of
controlling
1- Electrostatic participators used in power plants.
2- Back filtering process used in industry.
Here we use back filtering systems. The gases
from chimney are sucking through induced draught fan. For 16 MVA furnace, motor run by
squirrel cage induction motor of 450 HP, 550A, 415V, 800 RPM, delta connection. Fro 12
MVA furnace, motor run by squirrel cage induction motor of 288 KW , 483A, 415V,800
RPM,delta connection. For 7.5MVA furnaces ,motor run by squirrel cage induction motor of
300 HP ,380A,415 V, 0.8 power factor , 800 RPM, delta connection. Here all these motors
are operated at one fourth load at 600 RPM.

Working of pollution control:

Gases from chimney are passed through dampers and bags in
pollution bags. By using purging process, solid and gases are separated out. Solid particles
goes to bottom then through screw conveyors, solid particles filled into bags. Gases will go
into atmosphere through chimney. Solid particles collected into bags through squirrel cage
induction motor 0f 1.5 HP, 415 V,1440 RPM,0.8 power factor. Pollution control is controlled
by PLC controller of transformer rating of 2 MVA of 11 KV/440 V supply for pollution
control.

35
4.17 METAL RECOVERY PLANT:
FeCr metal alloy which are small consisting of slag are recovered
at MRP.In this plant two crushers are present,one crusher is used to crush the big bowl shape
metal and slag into small pieces. Another crusher is to crush the again small pieces into very
small pieces. In this plant first the metal slag composition is moved into hopper of crusher.
Crushed material is moved to vibrator through belt conveyor. Again the big pieces moved to
crusher for crushing. Small pieces moved for cleaning process. Thus metal is recovered from
the metal and slag composition.

4.18 BELT CONVEYORS:

A conveyor belt consists of two or more pulley’s with continuous loop of
material, the conveyor belt that rotates about them. The powered pulley is called drive pulley
while the un powered called idler o driven pulley. The belt consists of one or more layers of
material. Belt can be made out of rubber, it have two layers. An under layer of material to
provide linear strength and shape called a carcass and over layer called cover.Cover can be
made for unusual applications like silicon for heat or gum rubber when traction is essential.
The cover can be made from cotton,plastic web or mesh depends upon application. The
carcass can be made from rubber or plastic compounds specified by use of belt.
The different conveyors like
screw conveyor,vibrating conveyor,pneumatic conveyor,roller conveyor which uses a series
of powered roller to convey boxes or pallets, the moving floor system, which uses
reciprocating slats to more cargo …etc. Belts regularly spaced partitions known as elevator
belts.

Types of belt conveyors:

There are over 400 types of conveyors. We are only going to discuss
7 of common conveyors that can relate to all others.

They are as given below :

1- Permanent belt conveyor:

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 This type of conveyor is installed for the life time of the mine.
They are used in main line, slope, long over land installation,preparation plants and
stockpiles.
2- Portable belt conveyor:
These are characterized by relative ease of assembling and
disassembling to facilitate advances and recovery in development and retreat operations in
underground mining.
3- Shift-able belt conveyor:
Used in continues surface mining this type of conveyor is
mounted on skid or supporting structures aligned together and the whole cane be shifted
transversely to follow the advancing working face.
4- High angle conveyor:
These are special type of conveyor belt arrangement used for
negotiating steeper angle of inclination. An angle about 70 °-80°.
5- Cable belt conveyor :
Where the belt is carried on moving wire ropes and the tractive force
is applied through the rope to the belt is known as cable belt conveyor.
6- Pipe belt conveyor :
The belt is made to form a pipe while running the main length of the
conveyor.
7- Mobile transfer conveyor:
Mobile transfer conveyor are installed between buckets, wheel
or chain excavators and shift-able bench conveyor allowing multi-block and multi bench
operations.
8- grass hopper style conveyor:
Installed as a chain like one connected to the other are part of
waste dumping. This can be eliminate dump trucks from mines.

Essential belt properties:

The belt works as tractive element as well as load carrying element.
It may be used for different kind of material transportation at a higher speed (6-8 m/s). for
this purpose the belt needs to have the following essential properties:
→ flexiablity
→ transverse rigidity

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→ low mass per unit length
→ high strength
→ simplicity and inexpensive
→ longer life
→ should not stretch under normal working stresses I..e low relative elongation

In belt conveyor the driving power is transmitted to the belt by the driving pulley which is
rotated by an electric motor. The basic mechanism of transmission of power from the pulley
to belt is based on theory of friction drive.

4.19 Pollution control system in FACOR:

The scrubbers are provided in Fe-Cr plant for controlling
of atmospheric pollution. The gases provided in Fe-Cr furnaces are harmful and contains
large amount of C0 carbon monoxide is harmful to health so it is not released in the
atmosphere. The CO is allotted to burn at the top while the other gases is cleaned by
scrubber.
Scrubbers:
It consists of tally cylinder with conical top and bottom. The enters is this at
point near the bottom of the cylinder and leaves through a centrally located outlet at the top
water is fed from the top in the form in the form of one or more rows water sprays to cover
the entire cross section the cylindrical shell inside the cylindrical shell several layers of
wooden packing with perfection face fitted to break up the gas glow in the small jets and
thereby bring intimate contact of gas and water. The dust contained in the stick to the wooden
packing and is washed with water.
The slurry that is formed collects at the bottom and is
continuously removed from there. Nearly 80-90% of the dust contained in the in going gas is
removed by this method with about 3.5-4.5 liters of water consumption per cubic meter of
gas. The dust content of the out going is 0.5-1.5/m3. the velocity of the out going gas is 4
m/s.
Bag house :
It is also called bag-filter. The main function bag house is to filter the dust from
out going gases. It is tall cylindrical shell with slight inclination towards top. The gases from
furnaces enter the bag house from the bottom and the cleaned gases are released to
atmosphere from the top.

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 The temperature of the top gas is approximately 700 ° K.
Top gas analysis:

CO = 72.5% CO₂ = 18.1%

H₂ = 0.5% H₂O = 3.1%

N₂ = 5.2% Cr(CrO₂)= 25.3%

Fe = 7% P = 0.25%

S = 0.25% CaO = 18%

MgO = 1% SiO₂ = 14%

Al₂O₃ =13.5% Temp= 700°K

Mechanical Maintenance of Ferrro Chrome plant:
1. E.O.T Cranes:
A) Check the brake liners of the 1) main hoist 2) auxiliary hoist
B) Check the coupling bolts /bushes of the 1) main hoist 2) auxiliary hoist
3) long travel 4) cross travel
2. Belt Conveyors:
A) Check the condition of the belt/skirt belts chutes
According to weeks furnace conveyors and MRP conveyors.
3. Hydraulics :
A) Check slipping aggregate oil level
B) Clean the slipping aggregates area
C) Clean the hydraulic hoisting area.
4. Pumps:
A) Check the gland leaks and change the gland packings if necessary
B) Bearings lubrication
5. MRP Jigs:
A) Check the jig membranes

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 B) Check jig bearing/connect rod and eccentric shaft.

FINDINGS AND SUGGESTIONS:

Ferro chrome is a material for production of stainless steel.
Facor Provide high carbon ferro chrome to TATA TISCROME. Regular removing of dust in
plant , make facor clean and green. By changing the both plants to automatic controlling will
produce more metal. Facor should provide checking or inspecting time for maintenance
departments in order to know problems at early stage for every a month or week.

CONCLUSION:
For the production of steels, ferro alloys plays important role, some of ferro
alloys are ferro manganese, ferro silicon, ferro chrome ..etc. High carbon ferro chrome is
used for the production of steel in steel plants. FACOR Alloys provide high carbon ferro
chrome for the production of steel.

REFERENCES:

1- http://www.metalandalloyscorporation.com/ferro-alloys/ferrochrome/
2- http://www.chemistrylearner.com/ferrochrome.html
3- https://www.sciencedirect.com/science/article/pii/B978008097753900009
4- http://www.facoralloys.com/
5- http://www.wbrl.co.uk/high-carbon-ferro-chrome.html

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