AN INDUSTRIAL VISIT TO NALCO

(ALUMINIUM SMELTER PLANT)

REPORT ON INTERGRAL CASTING MACHINE CAST HOUSE-B (ICM) By Shamim Ahmed Khan regd no: 0811018155

Under the guidance of Chandrasekhar Mahapatra Maintanence Engineer(Mech.)

Company Mission
To achieve growth in business with a global competitive edge providing satisfaction to the customer,employe es, shareholders and the community at large

COMPANYS PROFILE
Company Vision
To be a reputed global Company in the Metals and Energy sectors

After discovery of 1000 million tones of Bauxite reserves in the Eastern Ghats, the Government of India on March 28, 1978, authorized Aluminium Pachiney of France to prepare a feasibility report on the industrial exploration of Bauxite for the establishment of an integrated Aluminium complex. The result of this study led to the Koraput District in Orissa. NALCO was incorporated in 1981 as a public sector unit.

INGOT CASTING MACHINE

An ingot is a material, usually metal, that is cast into a shape suitable for further processing. Ingots require a second procedure of shaping, such as cold/hot working, cutting or milling to produce a useful final product.

FLOW CHART OF THE ENTIRE PROCESS TO PREPARE AN INGOT

45-T Furnace -> Spout -> Launder -> Casting Wheel -> Casting Crew -> Robotic Skimmer-> Casting Crew -> Primary Cooling -> Receiving Device -> Cooling Conveyor

-> Secondary Cooling -> Ingot Transfer Device -> Layering

Conveyor -> Centering Device -> Turning Device -> Stacker -> Stack Table -> Stack Conveyor -> Weighing Station -> Ink-Marking Station -> Strapping Section -> Stack Manipulator

45- T type furnace

There were two 45-T type furnaces used in the ICM unit. Capacity of melting 4tph of Aluminum

LAUNDER (U-Block type)

Helps to remove the dross from the molten aluminium Temperature tolerance of not more than 1100 degree centigrade.

CASTING WHEEL

A rotating cast iron star-wheel is directly driven by the passing moulds, ensuring synchronised pouring. By pouring through two outlets (one each side of the wheel) into the same mould the rate of metal flow in each outlet is halved.

This minimises turbulence and dross, allowing top quality ingot to be produced at higher production rates.

INGOT RECEIVING DEVICE

The molten Aluminium is transferred to the Ingot Moulds smoothly.

ROBOTIC SKIMMER

It was fully autonomous skimmer,it starts as soon as the conveyor belt runs. Used to remove the Oxide layer from the surface of the Ingot. The oxide layer is formed as soon as the molten metal is exposed to atmosphere.

DIRECT COOLING

Then the Ingot is subjected to direct spray of water for further cooling.
Direct cooling is done,only when the Ingot attains a solid state. It is done inside the water bath for 10 seconds.

INGOT TRANSFER DEVICE

Here the Ingot is separated from the casting mould. If it some cases the Ingot doesnt gets separated, then there is one operator employed who hammers the mould to separate it forcefully

CENTERING & TURNING DEVICE

Then the INGOT is centered and then turned 180 degree for stacking purpose.

STACKER

From the stacker,it is then transferred to stack table. Where a 9 layer of stacked INGOT is placed. Then from the stack table it is passed through the stack conveyor to the weighing station.

WEIGHING STATION

Here the 9-layered Ingot stacked is weighed and then it is transferred to the Ink-marking station

Ink-Marking System

Here the weight of the stacked Ingot is printed on the Ingot

Strapping station
Here the 9-layered Ingot is strapped from all sides.

STACK MANIPULATOR
Then it is kept in stacks at different places with the help of stack manipulator.

Then they are ready for the Market.