B.Tech Mech Engg., University of Kerala CHAPTER 1 INTRODUCTION The industrial revolution led to the development of factories for large-scale production, with consequent changes in society. Originally the factories were steam-powered, but later transitioned to electricity once an electrical grid was developed. The mechanized assembly line was introduced to assemble parts in a repeatable fashion, with individual workers performing specific steps during the process. This led to significant increases in efficiency, lowering the cost of the end process. Later automation was increasingly used to replace human operators. This process has accelerated with the development of the computer and the robot. Industry in the sense of manufacturing became a key sector of production and labour in European and North American countries during the Industrial Revolution, which upset previous mercantile and feudal economies through many successive rapid advances in technology, such as the steel and coal production. It is aided by technological advances, and has continued to develop into new types and sectors to this day. Industrial countries then assumed a capitalist economic policy. Railroads and steam-powered ships began speedily establishing links with previously unreachable world markets, enabling private companies to develop to then-unheard of size and wealth. Following the Industrial Revolution, perhaps a third of the world's economic output is derived from manufacturing industries—more than agriculture's share. 1
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
B.Tech Mech Engg., University of Kerala
CHAPTER 1
INTRODUCTION
The industrial revolution led to the development of factories for large-scale
production, with consequent changes in society. Originally the factories were steam-powered,
but later transitioned to electricity once an electrical grid was developed. The mechanized
assembly line was introduced to assemble parts in a repeatable fashion, with individual
workers performing specific steps during the process. This led to significant increases in
efficiency, lowering the cost of the end process. Later automation was increasingly used to
replace human operators. This process has accelerated with the development of the computer
and the robot.
Industry in the sense of manufacturing became a key sector of production and labour
in European and North American countries during the Industrial Revolution, which upset
previous mercantile and feudal economies through many successive rapid advances in
technology, such as the steel and coal production. It is aided by technological advances, and
has continued to develop into new types and sectors to this day. Industrial countries then
assumed a capitalist economic policy. Railroads and steam-powered ships began speedily
establishing links with previously unreachable world markets, enabling private companies to
develop to then-unheard of size and wealth. Following the Industrial Revolution, perhaps a
third of the world's economic output is derived from manufacturing industries—more than
agriculture's share.
There are many other different kinds of industries, and often organized into different
classes or sectors by a variety of industrial classifications.
Industry classification systems used by the government commonly divide industry
into three sectors: agriculture, manufacturing, and services. The primary sector of industry is
agriculture, mining and raw material extraction. The secondary sector of industry is
manufacturing. The tertiary sector of industry is service production. Sometimes, one talks
about a quaternary sector of industry, consisting of intellectual services such as research and
development (R&D).
Industrial visit is a part of the engineering course, during which students visit
companies and get insight of on the internal working environment of the company. The
1
B.Tech Mech Engg., University of Kerala
industrial visit also provides an insight on how companies work and also useful information
related to the practical aspects of the course which cannot be visualized in lectures. The
students get the opportunity to see the mechanisms which are used in the present day
industries by these kinds of field visits
As a part of our curriculum we visited 3 industries and undergo an inplant training on
an industrial plant. The factories visited are
Hindustan Machine Tools Limited, Kalamassery unit
The Fertilisers And Chemicals Travancore Limited, Udyogamandal
Shell Turning Lathe-SB CNC 60 4A 5M CD sub spindle
Flat Bed Lathes-CNC-AUTOMANN 26
Axle Turning Lathe AXLE TURN 40
2.5. MAJOR ACHEIVEMENTS
8
B.Tech Mech Engg., University of Kerala
1. First in the country to manufacture CNC Slant Bed Turning Center through in-house development
2. First in the country to develop flexible turning cells
3. Design, development, manufacture and commissioning of fully automated flexible turning system to manufacture heavy armor penetrator for Strategic Sector
4. Heavy duty CNC Turning Machines with gantry load/unload systems
Machines exported to Europe, America and Middle East Countries
CHAPTER 3
9
B.Tech Mech Engg., University of Kerala
THE FERTILISERS AND CHEMICALS TRAVANCORE LIMITED
FACT, a Government of India enterprise, has business interests in manufacturing and
marketing of fertilizers and caprolactum, engineering consultancy and fabrication of
equipments.
Units of FACT include the two manufacturing division, Udyogamandal complex
(UC) and Cochin division (CD), the consultancy unit FACT Engineering & Design
Organization (FEDO), the fabrication division FACT Engineering Works (FEW), and the
marketing division.
The company has also interests in petrochemicals, hydrometallurgy, chemicals and
pharmaceuticals.
3.1. UDYOGAMANDAL DIVISION
FACT commenced operation at Udyogamandal with the commissioning of 50,000
tons per annum Ammonium Sulphate Plant in 1947.
In the decades that followed multi stage expansion programs were undertaken
bringing in the latest technologies of the day which were quickly mastered and successfully
implemented. Today the division is a mostly mix of 35 year old small capacity plants and 2
year old state of the art technology plants.
The latest addition to this unit is 900 tons per day ammonia complex set up with an
investment of RS 642 corers. FACT Udyogamandal division is 14001 certified.
Udyogamandal Division
10
B.Tech Mech Engg., University of Kerala
3.2. COCHIN DIVISION
FACT Cochin Division has set up in the 1970's at Ambalamedu 30 km from
Udyogamandal and adjacent to the Cochin Refineries. Phase-I of the division saw the setting
up of an integrated Ammonia urea complex utilizing Indian Engineering skills. A large scale
complex fertilizer plant of 485,000 TPA was set up as phase-II of Cochin Division and
sulphuric acid and phosphoric acid plant of marketing capacity.
Cochin Division
3.3. PETROCHEMICAL DIVISION
FACT diversified into petrochemicals in 1990 with the production of caprolactam.
This versatile petrochemical is the raw material in the manufacture of nylone-6, which finds
extensive application in textiles, tyre cord and engineering products. Thanks to its high
quality the products have been acknowledge as among the best in the world.
The division is located adjacent to the Udyogamandal division. Co-product
ammonium sulphate is transferred for processing to the fertilizer plant of udyogamandal
division. Petrochemical Division is ISO 9002 and 14001 certified.
11
B.Tech Mech Engg., University of Kerala
3.4. CAPROLACTAM
FACT Petrochemical Division is one of the only two manufacturers of Caprolactam in
India. For FACT customer satisfaction through excellence in quality of products and services
comes first. This is why we have strictly adhered to documented quality systems. In February
1996, FACT Petrochemical Division was certified to ISO 9002 (1994) and ISO 14001
(1996). This prestigious certification was conferred by RWTUV, the reputed German Quality
Audit firm.
FACT Caprolactam plant was built with licence and know-how from the world
leaders in Caprolactam technology - M/s Stamicarbon, the engineering subsidiary of DSM of
Netherlands. Sourcing of technology from a single source ensured unified package and
excellent consistent quality right from the time of commissioning. Detailed engineering of the
plant was undertaken by Chiyoda Corporation of Japan in association with FACT
Engineering and Design Organisation (FEDO), a subsidiary unit of FACT.The plant can
produce 50,000 TPA of Caprolactam and 2,25,000 TPA of Ammonium Sulphate as co-
product.
12
B.Tech Mech Engg., University of Kerala
3.4.1. Caprolactam Process
CYCLOHEXANONE, the main intermediate, is produced from benzene by
hydrogenation to cyclohexane and subsequent oxidation.
HYDROXYLAMINE, the second intermediate, is obtained in the form of its stable
sulphate salt, from ammonia, sulphur-di-oxide and ammonium nitrite by the proven, easy-to-
operate and efficient Raschig route.
CAPROLACTAM is produced by the Beckmann rearrangement of the OXIME in the
presence of oleum. The subsequent neutralisation step yields ammonium sulphate as co-
product. The crude CAPROLACTAM is purified by solvent extraction, ion-exchange,
hydrogenation, evaporation and vacuum distillation to obtain products of extremely high
purity and consistent quality.
13
B.Tech Mech Engg., University of Kerala
3.4.2. Packing Of Caprolactam
FACT Caprolactam is available in 25 Kilograms packed in a multilayer bag.
Inner Bag - Transparent LDPE loose bag, 150 microns thick, heat sealed at the top and
bottom.
Outer Bag - Brown kraft paper bag laminated with HDPE woven fabric.
Middle Paper Layer - Brown loose craft paper 60 gsm, separating outer and inner bag.
Caprolactam is filled in the inner LDPE bag and heat sealed at top.
The middle paper layer and the outer bag are stitched with Rayon thread and crepe paper
tape.
For export, Caprolactam bags will be loose stuffed in 20'(T.E.U) containers each of which
will contain 16.5 / 17 MT of Caprolactam.
3.4.3. Caprolactam Export
10,000 to 12,000 Metric tons per year of Caprolactam is earmarked for
meeting Export orders. FACT Caprolactam is currently being exported to USA, China,
Korea, Taiwan, Philippines, Australia, Slovenia and Sri Lanka. Response from our buyers
indicate that they consider FACT Caprolactam at par with the best available anywhere in the
world. They are also appreciative of the high consistency in the quality parameters that we
maintain and the strict adherence to committed schedules and trade terms.
3.4.4. Application of Caprolactam
Caprolactam is the popular monomer for the versatile Nylon-6 polyamide.
Nylon 6 offers excellent properties like high strength-to-weight ratio, good chemical and
thermal stability and durability. Textile yarn manufactured from Nylon-6 exhibits fine drape,
resistance to abrasion, high flexibility, chemical and biological stability etc. Nylon-6 is
widely used in manufacture of fishing nets, tyre yarns, sewing threads, industrial drive-belts
etc. As an engineering plastic, it finds wide application in castings, injection moulding and
extrusion. Items manufactured using Nylon-6 offer excellent engineering properties.