INDUSTRIAL TRAINING REPORT

COMPLETED AT
BHARAT COKING COAL LIMITED , PATHERDIH
(From 08-09-2021 to 06-10-2021)

SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DEGREE OF

DIPLOMA
IN
GOVERNMENT POLYECHNIC JAGANNATHPUR
BY
ASHISH RAJ
REG. NO. 19408120008
DEPARTMENT OF MECHANICAL ENGINEERING

Government Polytechnic, Jagannathpur

 DECLARATION

I “ASHISH RAJ” hereby declare that I have undertaken 4 weeks

of “Industrial Training” at “BHARAT COKING COAL
LIMITED”, “PATHERDIH” during a period from 20-09-2021
to 19-10-2021 in a partial fulfilment of requirements for the
award of Mechanical Engineering Diploma at GOVERNMENT
POLYTECHNIC JAGANNATHPUR, WEST SINGHBHUM.
The work which is being represented in the training report.

SIGN. OF STUDENT
 ABSTRACT

As an undergraduate, this training program was an excellent opportunity

for me to get to the ground level and experience the things that I would
have never gained through going straight into a job. Industrial training
was a very great opportunity in got to apply the theories that I learnt
with the real industrial for the real situations. This also gave me the
chances move with different types of peoples in the industry. Having
exposed to such situations I was able to obtain lot of experiences which
will be definitely helpful to success my future career as an Engineer.
Finally, I can say with a great pleasure that 4 week of Industrial training
was a helpful period of time for me excel my skills. The experiences I
gained through this training program will be a strong foundation to my
career as an engineer. I hope that the university would continue to
conduct such opportunities for us even more.
 ACKNOWLEDGEMENT
I would like to express my gratitude to all those who gave me the
opportunity to prepare this visit report. I would like to thank Assistant
Engineer Sir for his kind suggestion, inspiration &guidance during
preparation of this visit.
I express my deep sense of gratitude towards Head of Mechanical
Engineering Department of my college for providing me all faculties.
Last but not list, this acknowledgement would be incomplete without
rendering any impartial gratitude to all those who have help me directly
or indirectly in the preparing of this report.
Also our warm thanks to “Government Polytechnic Jagannathpur”
who provides us this opportunities to carryout, this prestigious project
and enhances our learning in various technical fields.

Thanks to all who helped me.

ASHISH RAJ
MECHANICAL DEPARTMENT
GOVERNMENT POLYECHNIC JAGANNATHPUR
S.NO BRIRF DESCRIPTION PAGE.
NO
01.
What Does Coal Washing Mean?

02. Need of Coal washing

03.
How does Coal washery work?

04
How does Coal washery work?

05 crushing

CONTENTS
06 Work Involved During Preventive
Maintenance Of Ring Granulator Type Coal
Crusher
07 Coal Washing
08
NAME OF IMAGES
IMG 1A REFERANCE IMG
IMG 1B REFERANCE IMG
IMG 2 WSHERY POINT DIAGRAM
IMG 3 CRUSHER
IMG 4 CRUSHER THEETHS

BHARAT COKEING COAL LIMITED

PATHERDIH,

History of BCCL

Bharat Coking Coal Limited (BCCL) is a subsidiary of Coal India

Limited with its headquarters in Dhanbad and Kolkata, India.[1] It was
incorporated in January, 1972 to operate coking coal mines (214 in
number) operating in the Jharia and Raniganj Coalfields and was taken
over by the Government of India on 16 October 1971.
BCCL contributes 50% of total prime coking coal requirement of steel
sector.[2] Company operates 36 coal mines, which include eleven
underground, sixteen open cast & nine mixed mines in year 2020.
Company runs eight coal washeries and four are under construction.
Mines are grouped into thirteen area for administratisation.

BCCL is the major producer of prime coking coal (raw and washed) in
India. Medium coking coal is produced in its mines in Mohuda and
Barakar areas. In addition to production of hard coke, BCCL operates
washeries, sand gathering plants, a network of aerial ropeways for
transport of sand, and a coal bed methane-based power plant in
Moonidih.

What Does Coal Washing Mean?

Coal washing is a process that is undertaken in a coal washery or coal
preparation plant (CPP) where coal is refined or cleaned of impurities.
Coal washing involves using water, mechanical techniques and relies on
gravity and the difference of density between coal and it's impurities
which are usually more densely packed due to the fact that they are
inorganic.
 IMG 1(A)

Need of Coal washing

Coal that comes from a mine is a complex mixture of materials with a
large variety of physical properties. In addition to the coal itself, pieces
of rock, sand and various materials are contained in the mixture. Thus,
before coal can be sold to consumers, it must be cleaned. Coal washing
involves using water and mechanical techniques and relies on gravity
and the difference of density between coal and its’ impurities, which are
usually more densely packed due to the fact that they are inorganic.
Washing coal increases its efficiency and quality, therefore increasing its
price. Coal washing can also help to reduce emissions from burning.
The washability characteristics of a coal reserve are provided by
obtaining liberation data on the raw coal sample. Liberation refers to the
amount of physical breakage required to separate material of different
material densities. Low density material is clean coal while high density
material is reject rock.

Why coal processing is important:

 Remove extraneous, non-combustible material

 Ash reduction
 Lower particulates
 Reduced ash handling at power station
 Sulfur reduction
 Carbon emission reduction
 Reduced transportation costs per unit of heat
 Guaranteed consistent heat value
 Improved plant efficiency
FIG . 1(B)

How does Coal washery work?

Coal washing is accomplished by one of two major processes, by density
separation or by froth flotation. Both processes depend on the fact that
the particles of which a coal sample are made have different densities.
When water, for example, is added to the sample, particles sink to
various depths depending on their densities. The various components of
the sample can thus be separated from each other.
In some cases, a liquid other than water may be used to achieve this
separation. In a heavy medium bath, for example, a mineral such as
magnetite or feldspar in finely divided form may be mixed with water,
forming a liquid medium whose density is significantly greater than that
of pure water.

A number of devices and systems have been developed for extracting the
various components of coal once they have been separated with a water
or heavy medium treatment. One of the oldest of these devices is the jig.
In a jig, the column of water is maintained in a constant up-and-down
movement by means of a flow of air. Clean coal particles are carried to
the top of the jig by this motion, while heavier refuse particles sink to
the bottom.

Coal washing is accomplished by one of two major processes, by density

separation or by froth flotation. Both processes depend on the fact that
the particles of which a coal sample are made have different densities.
When water, for example, is added to the sample, particles sink to
various depths depending on their densities. The various components of
the sample can thus be separated from each other.

In some cases, a liquid other than water may be used to achieve this
separation. In a heavy medium bath, for example, a mineral such as
magnetite or feldspar in finely divided form may be mixed with water,
forming a liquid medium whose density is significantly greater than that
of pure water.

A number of devices and systems have been developed for extracting the
various components of coal once they have been separated with a water
or heavy medium treatment. One of the oldest of these devices is the jig.
In a jig, the column of water is maintained in a constant up-and-down
movement by means of a flow of air. Clean coal particles are carried to
the top of the jig by this motion, while heavier refuse particles sink to
the bottom.
Another method of extraction, the cyclone, consists of a tank in which
the working fluid (water or a heavy medium) is kept in a constant
circular motion. The tank is constructed so that lighter clean coal
particles are thrown out of one side, while heavier refuse particles are
ejected through the bottom.

Shaking tables are another extraction method. As the table shakes back
and forth, particles are separated by size, producing clean coal at one
end and waste products at the other.

In cylindrical separators, a coal mixture is fed into a spinning column of

air that throws the heavier waste particles outward. They coat the inner
wall of the cylinder and fall to the bottom, where they are drawn off.
The clean coal particles remain in the center of the air column and are
drawn off at the top of the cylinder.

Froth flotation processes depend on the production of tiny air bubbles to

which coal particles adhere. The amount of absorption onto a bubble
depends not only on a particle's density, but also on certain surface
characteristics. Separation of clean coal from waste materials can be
achieved in froth flotation by varying factors, such as pH of the solution,
time of treatment, particle size and shape, rate of aeration , solution
density, and bubble size.

.
 FIG . 2

How does Coal washery work?

 Crushing
 Screening into different size factions
 Physical, chemical or mechanical processes to remove undesired
impurities
 Dewatering
 Thermal drying
 Blending
 Agglomeration
crushing
How does Coal washery work?

How does Coal washery work?Ring Granulator crush material

by a combination of impact and rolling compression.

The crushing action is performed when material is dropped

through the feed opening where it is struck,in mid air by the
multiple rings which are being driven round by the rotor discs
in direction towards the breaker plate. The rings are mounted
on suspension bars as shown in the diagram. When the rotor is
set in the motion centrifugal force brings the ring out against
material to be crushed.

As material is fed to the machine the rings are forced back

towards the rotor center until bar is encountered by the ring
internal surface and a forward driving force is exerted.The
material is broken and discharged through the cage bars or
screen plates thus easing the load and allowing the ring to
move out until it is held again by suspension bar before
encountering the incoming feed once again.
 IMG 3
Coal crushing can include a two stage process, dependent on
deposit size. Coal is crushed in a feeder breaker, a chain
conveyor that breaks the biggest lumps. Coal size is further
reduced through a sizer. Screening is used to separate different
sizes of crushed coal

IMG 4

Work Involved During Preventive

Maintenance Of Ring Granulator Type Coal
Crusher
During preventive maintenance of ring granulator type crusher following
equipments/parts are checked and detected problems are corrected.

1. Rotor Assembly

. Breaker Plate-Check for proper tightness & any wear & tear.

5. Screen Plate-Check proper tightness, any wear & tear.

6. Hydraulic System - Check for oil leakages, oil level, oil condition,
cleanness.

7. Casing Bolt - Check bolts tightness with washer.

8. Receiving chute sealing (Bellow) - Check during operation no dust

leakage from the discharge chute. Bellow all bolt should be proper tight.

9. Discharge Chute - Check inside condition of chute. Cleaning should

be done if required.

10. NDE and DE Bearing

• Bearing greasing in regular interval of time.

• Check bearing clearance, grease quality & labyrinth seal condition.

11. Coupling - Check condition of all coupling.

12. Gear Box - Check for oil leakages, oil level, oil condition and
cleanness.

13. Bolts - Check proper tightening of all bolts.

The granulator rotor assembly generally require minimum maintenance

with the exception of hammer and suspension bar replacement.
Frequency of hammer and suspension bar replacement will depend upon
the material crushed and the rate it is fed. Preventive maintenance of
rotor assembly include the following:
• Check wear on hammers and suspension bars.

• Check disc clamp nuts for tightness.If not tight, suspension arms will
loosen and cause wear on the rotor key,rotor shaft and suspension arm
bore. In addition vibration may occur.

• Check suspension bar holes in suspension arms for any elongation.

After a long period of service, this is likely to occur.

• Check The suspension bar ends for wear which may also occur during
the wearing period of set of hammers.

Check End disc proper tightness & should not be any wear & tear.

1 Check any erosion on blade arm and hard facing condition.

2. Kick off plates - Check proper tightness, any wear & tear.

3. Liners-Check proper tightness, any wear & tear.

Coal Washing
. A coal preparation plant is a facility that washes coal of soil and rock,
crushes it into graded size chunks and stockpiles grades, preparing it for
transport to market. Coal washing represents the most important step of
coal preparation.
Coal washing is accomplished by one of two major processes, by density
separation or by froth flotation. Both processes depend on the fact that
the particles of which a coal sample are made have different densities.
When water is added to the sample, particles sink to various depths
depending on their densities. The various components of the sample can
be separated from each other. A number of devices and systems have
been developed for extracting the various components of coal once they
have been separated with a water treatment. One of these devices is the
jig. In a jig, the column of water is maintained in a constant up-and-
down movement by means of a flow of air. Clean coal particles are
carried to the top of the jig by this motion, while heavier refuse particles
sink to the bottom.

IMPORTANCE OF COAL WASHING

Coal that comes from a mine is a complex mixture of materials with a

large variety of physical properties. In addition to the coal itself, pieces
of rock, sand and various materials are contained in the mixture. Thus,
before coal can be sold to consumers, it must be cleaned. Coal washing
involves using water and mechanical techniques and relies on gravity
and the difference of density between coal and its’ impurities, which are
usually more densely packed due to the fact that they are inorganic.
Washing coal increases its efficiency and quality, therefore increasing its
price. Coal washing can also help to reduce emissions from burning.
 CONCLUSION

During one month of training period, a lot of experiences,

knowledge and exposures that I have handy. All disclosures
were awaken myself in a boost of self-confidence to face life
more challenging now. Practical is a compliment to the
engineering or theory learned. This is clearly the concept of
engineering and charity, were they have learned without practice
will be lost and will not give anything- what effect. So if we do
without the knowledge of course there will be problem in terms
of grip and stance ever changing.
During my industrial training, there are many changes from the
point of learning environments and discussion among
colleagues. It can directly increase the dedication and rational
attitude towards myself.

However, there are still some weakness that can be improved I

the future. Therefore I conclude that the industrial training
program is provided many benefits to students seven if there are
minor flaws that are somewhat disfiguring condition, so that this
weakness can be rectified in the future.
I can conclude that this industry is through training I received a
lot of exposure in the computing world. I would like to thanks
also “Government Polytechnic Jagannathpur” for giving us to
find their own experience with having industrial training like
this
 • THANK YOU •

REFERANCE :-
Wikipedia.com
Rsmsolve.vom