REPORT ON INDUSTRIAL VISIT
Industry: Bhoruka Steel and Services Limited (Refractory Division)
Venue: No. 34/1 Whitefield Road, Mahadevapura,
Bangalore – 560048, Karnataka, India.
Established : 1969.
Business : Manufacture and sales refractory bricks for various industries
Contact Person : Mr. Rajasekhar Ajay (Quality Head).
o Students: III rd Semester Mechanical – A -Date: 01-09-2014 o Students: III rd Semester Mechanical – B -Date: 08-09-2014.
o Students: III rd Semester Mechanical – C -Date: 09-09-2014.
Type of Industry:
Bhoruka Steel & Services Ltd was established in the year 1969, and presently engaged in Manufacturing of Refractory items and Stevedoring and other port related activities.
Refractory Division Manufactures high quality refractories and monolithics to meet the requirement of Critical & Core Industries like Iron & Steel, Cement, Sponge Iron, hermal power, Coke, oven and Glass etc.
Stevedoring Division is involved in loading and unloading of bulk consignments with specialty in handling Iron Ore, Steel Scrap, Cobble Stone, Granite & Coal, and offers complete Logistic Solutions from the Port to Plant and vice-versa of the End Users.
Storage - The first part of the industry is the godown which contains the raw materials used for the production of bricks
Storage Godown
Crushing
The crushing part which has the grinding unit in which the bricks are converted into size of 1.5 to 3mm.It consists of jaw crusher with fixed crushers to breakdown the bricks into small pieces, then the pieces are carried by the conveyer belt to the impact mill were it is again crushed into pieces by the vibrating column which contain sieves which separates grains of different particle size. The grains can be collected from the conical mill
Disintegrator
3 Jaw Crusher
4 Jaw Crusher- Conveyer Belt-Impact Mill
For making bricks there are 3 types of grains- coarse, medium and fine grains. Chinese bauxite a mixture added to the production of bricks is imported from china. Calcine bauxite is an Indian product from Gujarat which is also added to the mixture making bricks. Grog
which is waste (used bricks) is to produce low quality bricks. There are different grade of ingredients which are used for the production of good, low medium quality bricks.
Casting
They also have casting section in which they produce permanent moulds prepared by pressing of sand. hey produce permanent mould using cement to get the desired shape.
Special type of molding in which 3-4% of water is added. There is a vibrating column to ensure that the mould is prepared well
Permanent Casting
Vibrating Column
Mixing
The next part is the mixing segment. The machine we saw first was Muller Mixer which mixes coarse and medium grains for about 15 minutes by the addition of mixture. Then we add the fine powder and mix it for about another 15 minutes. There one more machine called CCM(Counter Current Mixer) which use molasses as a binder which is a byproduct from the sugar cane industry.
Muller Mixer and Continuous Casting Machine
Pressing
The next process is the pressing part were they weigh the amount of sand added according to the given product. The machine which is in use for pressing is FSP(Friction Screw Pressing) which gives a load of 150 ton to the sand which presses the sand to the given dimensions.
Graphite is added to the sand mixture as a non-sticking agent.
Drying
Then the next process is natural drying to remove moisture by keeping the finished bricks under room temperature for 3 days. Then artificial drying by keeping the bricks in a trolley and move into a heated zone to remove moisture at 300-400oC. The moisture is removed from the bricks in order to avoid catching of fire
Firing
Then the final stage in the industry is firing. It consist of 3 zones which are preheating zone (800-900oC) followed by burning zone (900-1450oC) finally the cooling zone (300-400oC). The bricks are continuously pushed through 3 zones. It takes 3 hours to complete the process. Daily 8 times it can be done in the process.
Friction Screw Pressing Machine
Drying of Bricks
Firing of Bricks
Quality Testing
The quality testing happens outside the industry. First the material is dried to remove the moisture. The it’s heated in a muffler furnace at 1000oC. Then the material is crushed and made into solution which is further tested in various testing machines the first one Spectrophotometer used to determine the presence of Fe2O3 and iO2. hen Flame Photometer uses to test the presence of Na2O and K2O. hen the strength of product is tested in CCS (Cold Crushing Strength).Then material is reheated in PLC (Permanent Linear Change) to see whether the product will withstand high temperatures. Then the product is used in glass industries and used to make furnace, ladles etc…
Finally packed for transportation.
Dryer and Muffler Furnace
Continuous Casting Machine and PLC MACHINE (Permanent Linear Change)
o Students : III rd Semester Mechanical – A Faculty: Prof. Ben Rajesh and Prof. Jennifer R Mode of Transport: College Bus
Date : 01-09-2014
Start Time at College : 12:00 PM Reached Company at : 02:00 PM
o Industrial Visit : 02:10 PM to 04:10 PM Started from Company : 04:30 PM
Reached College at : 06:00 PM.
Students : III rd Semester Mechanical – B
Faculty: Prof. Ben Rajesh and Prof. Priyadarshini Jayashree Date : 08-09-2014.
Mode of Transport: College Bus Start Time at College : 12:00 PM Reached Company at : 02:00 PM
o Industrial Visit : 02:10 PM to 04:10 PM Started from Company : 04:30 PM
Reached College at : 06:00 PM.
Students : III rd Semester Mechanical – C
Faculty: Prof. Ben Rajesh and Prof. Ram Kumar Date : 09-09-2014.
Mode of Transport: College Bus Start Time at College : 12:00 PM Reached Company at : 02:00 PM Industrial Visit : 02:10 PM to 04:10 PM Started from Company : 04:30 PM Reached College at : 06:00 PM.
