INDUSTRIAL TRAINING REPORT

BEC FERTILIZERS LTD. Sirgitti, Bilaspur (C.G.)

Submitted To

Department Of Mechanical Engineering Suresh Gyan Vihar University Jaipur, (Raj.)

In the Partial fulfillment of M.Tech Dual Degree in Mechanical Engineering

Submitted By

Milan Bhatnagar
Enrollment no. SGVU081091004 Roll No. 4219

ACKNOWLEDGEMENT
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I want to thank Mr. N.S. Raju (Vice President) of BEC fertilizers who given me the opportunity to do training here.

And also very thankful to Mr. Dilip Goverdhan(Sr. Production Manager) and Mr. G.K. Shrivastava (Plant In charge), Mr. H. Arora(H.R. Department and Administration), Mr. Nitin James, Mr. N.K. Kashyap(A.G.M. Mechanical) And all the staff Members of B.E.C. Fertilizers, Bilaspur(C.G.) Who were also very helpful during my training session here.

Working ant B.E.C. Fertilizers during M.Tech Dual Degree Course has been great pleasure and work experience to me.

SUBMITTED BY:MILAN BHATNAGAR

TABLE OF CONTENTS
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CERTIFICATEI ACKNOWLEDGEMENT.1 CHAPTER 1 INTRODUCTION TO COMPONY..5

a) b) c) d)

Bhilai Engineering Corporation..5 Development of B.E.C. Fertilizers..7 Location of B.E.C. Fertilizers.8 Fertilizers industries in India...9

CHAPTER 2 PRODUCTION..10
a) b) c) d)

Production of company10 By Products10 Branches of B.E.C. Organization11 Number of Employees11

CHAPTER 3 TYPES OF PLANT...12

a) b) c) d)

S.A.P. Plant13 S.S.P. Plant13 N.P.K. Plant14 Sodium Silico Fluoride (S.S.F.)14
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CHAPTER 4 S.A.P. PLANT15 a) Process Flow Diagram15a b) Process of S.A.P. Plant16 CHAPTER 5 S.S.P. PLANT.........................................................................................................21 a) Process Flow Diagram21a b) Process of S.S.P. Plant22 CHAPTER 6 N.P.K. PLANT27 a) Process Flow Diagram27a b) Process description of N.P.K. Plant28 c) Process of N.P.K. Plant29 TRAINING OBSERVATION AND RECOMMENDATION33 REFERENCES34

TABLE OF FLOW DIAGRAMS

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1. Process Flow Diagram of Rock Phosphate Beneficiation Plant12a 2. Process Flow Diagram S.A.P. Plant..15a 3. Process Flow Diagram S.S.P. Plant...21a 4. Process Flow Diagram N.P.K. Plant..27a

CHAPTER 1 INTRODUCTION TO COMPONY

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a) BHILAI ENGINEERING CORPORATION

Bhilai Engineering Corporation was established in1960. Actually the seed of this corporation was shown in 1948, by a young and dynamic enterprising Mr. B.R. Jain. He started fabricating and erection of structural steel work in the company. M/s. Bharat Industrial works it laying the foundation of Malaysia Group of which B.E.C. the flagship. B.E.C. Fertilizers is a unit of Bhilai Engineering Corporation Ltd. (B.E.C.) that was incorporated about 29 years back in 1960 with small cast Iron foundry and sixteen trusted workers as small scale ancillary by Mr. B.R. Jain and his brother Mr. N.K. Jain, on an area of industrial town of Bhilai. From 1948 only Mr. B.R. Jain, who tried his level best for designing and construction and structural framework of steel step by step the growth of B.E.C. Was augmented in several spheres with high technology and high precious product for Indian core sector industries. Since then this company has progressed into a very large and integrated engineering complex manufacturing variety of high technology and high precision product of India. The B.E.C. has provided a vital import and service to a number of major industries in countries core sector such as steels, mines, cements, power heavy industries and railways. Out of these in November 1985 B.E.C. Fertilizers Ltd. was established and situated in Sirgitti, Industrial area, Bilaspur (C.G.) and the plant of B.E.C. Fertilizers is established in area 50 acre. Shri Vinu Jain, The Director of the B.E.C. Fertilizers, Bilaspur and Shri N.S. Raju is the Dy. General Manager of the B.E.C. Fertilizers, Bilaspur. That the B.E.C. Fertilizers, Bilaspur one of the part of B.E.C. Limited and one of the other branch of B.E.C. fertilizers, which is situated in Pulgaon, Industrial area, Maharashtra. That the B.E.C. Fertilizers purchase the raw material for the purpose of production of single super phosphate and sulphuric acid from Udaipur(Rajasthan) and Jordon.
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That the total strength which was B.E.C. Fertilizers is hundred, where fifty workers are are engaged as plant workers and remaining fifty workers are working as staff workers.

b) DEVELOPMENT OF B.E.C. FERTILIZERS

B.E.C. plant was first situated in Bhilai in 1960 and from the time the management committee of this organization did not look about their past periods and where developing at very fast speed. In the beginning they
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started with a cast iron foundry as an ancillary of B.S.P.(Bhilai Steel Plant) and not it has become a technologically advance need and having successfully mate the engineering challenges of countries core sectors industry almost 2 and decades, the group now stands on their hold of growth. This organization adding more and more requirements and machines and B.E.C. has full target of steel foundry, cast iron foundry and fabrication. The modern technology for manufacturing for sulphuric acid like DCDA (double conversion double absorption) was selected by which the production now reach to 42000 metric tonnage. The double shaft paddle mixer and rotary they were selected for single super phosphate production by which now it reach to 1.2 lak metric tonnages. The total manufacturing process is controlled by automatic process and laboratory is also constructed and equipped to test the raw material rock phosphate. This plant was fixed in safe and pollution free atmosphere. A venture scrubber is one of the most important modern technologies for production of single super phosphate in country. The B.E.C. Fertilizers has established extension service unite to provide education to farmer is using to fertilizers. This unit also given information to the farmer of area and new technology, new variety of seeds and use of crops and adsorption of mixed cropping pattern for higher yields, new cropping pattern are being use of world over. Some of the states of country such as M.P., Orissa, and west Bengal are also striving for increasing their agriculture products.

c) LOCATION OF B.E.C. FERTILIZERS

The Bhilai engineering corporation Limited (Bhilai) to established new factory name as B.E.C. Fertilizers at Sirgitti in Bilaspur. As Bhilai engineering corporation limited is developing and expanding their activities keeping in this part of C.G. and M.P. then only a new factory B.E.C.
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Fertilizers has been setup in industrial estate of C.G. in Bilaspur at Sirgitti , the localization of this industry are due to the following reasons:1)

At Bilaspur the availability of sufficient land to meet current requirement and seen of future expansion and development.

2) Transportation facilities for raw material, rock phosphate and sulphuric acid are handled by road ways by truck and transportation of finished goods. 3) The road of this plant is connected with national highways so the transportation is very easy.
4) 5)

B.E.C. Fertilizers come to Bilaspur because this area needs fertilizers. Availability of water from river.

6) As in Bilaspur division this is not much factories so it is very easy to get as much as man power resources as required. There is very good market for single super phosphate around Bilaspur, B.E.C. Fertilizers is far from the strategic work points this means that B.E.C. plant has been setup in pollution free atmosphere.

d) FERTILIZER INDUSTRIES IN INDIA

The fertilizer industry has an important role in Indias larger agriculture sector. As India is the land of agriculture based country and agriculture accounts for almost 1/3 of country GDP (gross domestic product) and employ as majority of Indian population.
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The fertilizer industry was developed during year 1940 in India. The Indian fertilizer industries divided into three sectors, they are:I. II. III. Public Sector Private Sector Co-operative sector There are main nutrient at fertilizer in consist of namely nitrogen based fertilizers, phosphorous based fertilizers and potash based fertilizers, out of which nitrogen in India. Potash needs to be imported. Total consumption of fertilizers industry is fulfilled 80% by India industry and rest 20% by import. BEC phosphorous (16%), Sulpher (12%), and calcium (21%).

CHAPTER 2. PRODUCTION
a) PRODUCTS OF COMPONY
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This organization of manufacture unit is concerned with production of fertilizers. There are basically three types of product manufacture in industry. 1. Sulphuric Acid *Raw Material: Sulpher *Availability of raw material: Reliance Petroleum, Import from Iran, Kuwait Canada, Saudi Arabia, Jordon. *Production Capacity: 42000 MT/Year. 2. Single Super Phosphate *Raw Material: Rock Phosphate, Sulphuric Acid *Availability of Raw Material: Rajasthan State Mines Mineral LTD., Udaipur, Jordon. *Production capacity: 1.2 MT/Year 3. N.P.K. *Raw Material: Urea, D.A.P., M.O.P., Gypsum, dolomite, S.S.P. Powder

b) BY PRODUCT
1. Sodium Silico Fluoride *Production Capacity: 200 MT/Year

c) BRANCHES OF B.E.C. ORGANIZATION

1. B.E.C. Fertilizer, Bilaspur is a unit of Bhilai Engineering Corporation. The other two major branches are: 2. B.E.C. Fertilizers, Pulgaon(M.H.)
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3. B.E.C. Engineering Steel Casting, Bhilai(C.G.)

d) NUMBER OF EMPLOYEES
About 200 workers works in B.E.C. Fertilizers, Bilaspur (C.G.)

CHAPTER 3. TYPES OF PLANTS

a) S.A.P. PLANT
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sulphuric acid is manufactured by double conversion double absorption(DCDA) process in which Sulpher dioxide generated by combustion of molten Sulpher in to sulphertroxide in presence of vanadiumpentaoxide and sulphertroxide is absorbed 98.4% concentrated of sulphuric acid is formed.

REACTIONS: S(s) -------steam (155-158*c) -------> S (L) S (L) + O2 -------------------------> SO2 + ^T SO2 + 1/2O2 <---------------------------->SO3 + ^T S + 3/2O2 + H2O --------------------------------> H2SO4 SO3 + H2SO4 --------------------------------> H2S2O7 (Intermediate Stage) H2S2O7 + H2O -----------------------------> 2H2SO4 + ^T

b) S.S.P. PLANT

Single super Phosphate (S.S.P.) is manufactured by the chemical reaction between rock phosphate and sulphuric acid. It is manufactured by crushing rock phosphate and mixing it with dilute sulphuric acid. It cant be used immediately store in godown and crushed to complete the reaction.
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ROCK PHOSPHATE + SULPHURIC ACID = S.S.P.

REACTIONS: CaCO3 + H2SO4 -------------------> CaSO4 + H2O + CO2^ Ca (PO4)2 + 2H2SO4 -------------------------> CaH4 (PO4)2 + CaSO4 P2O3 + 3H2SO4 ------------------------> P2 (SO4)2 + CaSO4 + 3H2O CaF2 + H2SO4 ---------------------> CaSO4 + 2HF MgCO3 + H2SO4 ---------------------------> MgSO4 + H2O + CO2^

c) N.P.K. PLANT

N.P.K. Plant is the most important part of the B.E.C. Fertilizers and it is established on 2004, area of this plant about 8000 square feet, G.S.S.P. (Granular Single Super Phosphate) and N.P.K. (Nitrogen: phosphorous: Potassium) are Prepared in this plant. Daily production of this plant is 150 MT/day about 35 employees are working for that production.
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d) SODIUM SILICO FLOURIDE (S.S.F.)

When rock phosphate and sulphuric acid react then single super phosphate are formed along with that a byproduct hydro flouro silisic acid is also formed. This on reaction with sodium chloride forms sodium Silico fluoride. This salt is very useful in glass industry.

REACTIONS:

H2SiF6 + NaCl -------------------------> Na2SiF6 + HCl HCl + Ca (OH) 2 ------------------------> CaCl2 + H2O

CHAPTER 4. S.A.P. PLANT

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SULPHURIC PLANT

ACID

b) PROCESS OF S.A.P PLANT

SULPHER PIT In the Sulpher pit the Sulpher is dumped. The boiling point of the Sulpher is 444 degree centigrade and many coiled fitted in the pit and they give heat to Sulpher and the degree of giving heat to the Sulpher is about 119 degree Celsius to 150 degree Celsius. When the heat will be more than maximum it is danger for the Sulpher and the Sulpher will be fired. The Sulpher pit
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divided into two parts and both parts are also divided into3 parts. In one side 125 tonnage of Sulpher is kept and the other parts have also 125 tonnage of Sulpher. According to the three parts of the pit one have to put Sulpher, second hold the Sulpher and in the third part the melted Sulpher will get off with the help of pumping pit. The Sulpher raw material imported from Iraq, Iran etc.

FURNACE When the melted Sulpher come out in pumping pit then it put down to the furnace with the help of Sulpher gun. There are three millimeter hole in the Sulpher gun nozzle. Then fired the Sulpher into furnace. The furnace fired up to 1000 degree Celsius and after fired the Sulpher become gas. The Sulpher gas is also known as SO2 gas.

BOILER After the process of converting Sulpher to Sulpher dioxide it is very hot and the hot gases are put to boiler and temperature will be decreased about 600 degrees Celsius. After that the gas sent to next process. At the reason of this purpose, the hot gas not going to gas super heater.

SUPERHEATER When the gas will be cooled the boiler. Then super heater will be ready to burn because cooled wasted. Then the SO2 gas gone to the hot gas filter.

HOT GAS FILTER The hot gas filter is fitted for hot SO2 gas and sent to the converter because many gases came with the SO2 and the plant should have only SO2 gas.
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After that SO2 sent to converter and the temperature of SO2 is about 450 degree Celsius.

CONVERTER It is the heart of the plant because the main work starts from here. These converters have 4 beds when the SO2 gas converter with SO3 gas. In this bed the V2O5 i.e. Vanadium Pent oxide will be drawn and the SO2 converted with SO3. Each bed works is to convert more and more SO2 to SO3. Each bed have one input and one output when SO2 comes to the hot gas filter in the first bed only 60% of SO2 converted to SO3. Then 60% of SO3 and 40% of SO2 comes to the boiler. In the second bed 28% more SO2 gas converted and SO3 also increased with 88%, remaining SO2 gas sent to the intermediate heat exchanger because the gas will protected with cooled and the gas will prepared for the next process. After processing in intermediate heat exchanger the gas comes in 3rd bed then SO2 gas decreased to 10% and the SO3 gas increased to 98% and 2% SO2 gas remains. Thereafter, the 98% SO3 and 2% SO2 sent to the economizer, in this place as per necessity the temperature provided to the gases. Steam is worked for heating the gas after that gas put down into intermediate absorption tower. When H2SO4 gas with this gas i.e. droplets will be put down over the tower and also give water and it have reaction and SO2 gas converted with H2SO4. Then remaining SO2 gas sent to mist elimination tower and moisture of the gas will be eliminate and remaining gas sent to bed 4th. Then remaining SO2 converted to So3 and gas put it in the final heat exchanger. The first heat exchanger gives heat to the gas according to gas necessity. Thereafter, the SO3 gas and SO2 which quantity is very little sent to final observation tower and converted to H2SO4. Then remaining SO2 gas sent to alkali scrubber.

BOILER II
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Converted SO3 gas and SO2 gas should come for balance of heat. The work of boiler is only to maintain the heat of the gases.

INTERMEDIATE HEAT EXCHANGER After the completion of second bed process the output were come and giving required heat and temperature. Then the gases were gone to third bed for further processes.

ECONOMIZER The water given to the boiler the economizer changed this water into steam. The steam helps to maintain the heat of the gases in the second boiler.

INTERMEDIATE ABSORPION TOWER When the SO2 gas comes with the economizer to absorption tower then firstly in this place the H2SO4made. In this H2SO4 fell down over the top of SO3 and SO2 to form H2SO4 acid after reaction and also give water in bottom and after reaction with SO3 and water found H2SO4.

MIST ELIMINATION TOWER Remaining gas which come with intermediate absorption tower to mist elimination tower. In this place the acid mist of gas will be removed then remaining gas will pass through fourth bed.

FINAL HEAT EXCHANGER In final heat exchanger fourth bed output is attached here to gas is heat and after heating it will put into final tower.
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FINAL ABSORPTION TOWER It is last stage of converting the acid. The remaining SO3 and SO2 will converted into H2SO4. Some left quantity put into alkali scrubber.

ALKALI SCRUBBER It controls the polluting gases in the plant. It means that the left SO2 gas is absorbed by caustic soda and reduces the pollution. Caustic circulation tank is at the bottom of alkali scrubber in which caustic soda dissolves. Gas is absorbed on alkali scrubber and clean gas came out of the tank.

DRYING TOWER Sulphuric acid circulated in drying tower because air given to furnace and the air given by the blower is having moisture for that reason. In drying tower sulphuric acid absorb the moisture in the air and dry air is pumped to the Sulpher combustion furnace.

COOLING TOWER For cooling acid it is put into cooling section where acid is to cool for many pipe, which is rounded. In this pipe water drop continuously to cool acid.

ACID STORAGE TANK When acid is cooled then it is soared into tank. Three tank in plant store sulphuric acids. Its length about 10 meters.

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CHAPTER 5 S.S.P. PLANT

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SINGLE SUPHER PHOSPHATE PLANT

b) PROCESS OF S.S.P. PLANT

ROCK HOPPER Phosphate rock is put into the rock hopper with the help of crane. Its capacity is 5 tonnages. One control gate is fit in to rock hopper to stop the stone and other things. 3 rock hopper in S.S.P. in which 2 of them are in use. Its length is 5 meter.

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ELECTRO MAGNET Electro magnet stops the small or bit particles of iron entering into grinding mill. It is not stop the iron pieces will enter in the grinding mill and it will destruct the mill, i.e. electro magnet fit into the top of the rock phosphate belt conveyor.

ROCK PHOSPHATE BELT CONVEYOR Rock phosphate will feed into rock feeder with the help of conveyor belt it will continuous. In every machine conveyor belt is fitted.

ROCK FEEDER The rock phosphate is feed into the rock feeder. After feeding into the rock feed it will again feed mill hood or grinding mill. It has also in every machine.

MILL HOOD OR GRINDING MILL In mill hood rock phosphate is grinding which is feed by the rock feeder. Its length is about 2 meter. There are five vertical rollers inside the mill hood to grind the rock phosphate. There are 3 mill hoods in S.S.P. pant. Its shape is cylindrical.

BLOWER Mill is sent to casing with the help of blower from these it will gone to discharge duct. Phosphate powder sent to next place for further process to
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supply air by blower. Blower is also 3 in the plant. Operator has to decide that how much powder it will run.

MILL DISCHARGE DUCT Phosphate powder will send into the cyclone by help of discharge duct from there it will store for some time and it enter into soil. The main work of this duct to take the powder from bottom to top. It will attach at the top of mill hood. This system is attached in every mill hood.

BLOWER SUCTION DUCT Some quantity of phosphate is sent to cyclone by this duct. It will attach in front of the blower. It reduces the work of mill discharge duct. It will fill powder will sent into the discharge duct then it blocks and create some problem i.e. the powder sent from the blower section into the cyclone.

WENT DUCT Those powder which not reached into the cyclone is stored in went duct which is sucked by went duct and returns to mill air starting the process again.

CYCLONE DUCT In cyclone duct phosphate powder is taken from mill discharge and blower section it and sent to silo to take it down cyclone is must because by this powder will completely sent into silo.
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DUST CYCLONE The work of dust cyclone is to store the powder and sent into the dust cyclone which is not reaches soil where the wastage is to same and sent into air casing by went duct.

SILO The stored powder in silo cyclone is kept in very large area. The phosphate powder taking out on the basis of the next process. Its length is about 7 meter. There are three silos in S.S.P. plant. Silo is most useful in this part because by silo phosphate powder is sent to different places.

SILO SCREW CONVEYOR Silo screw conveyor is fitted at the bottom of silo by which phosphate powder is sent to next common screw conveyor. It is called screw conveyor because it take screw and moves phosphate powder a bit forward. Screw conveyor is attached at the bottom in every silo. It runs slowly. Motor is there to run screw conveyor. COMMON SCREW CONVEYOR It is called common screw conveyor because it is same for all silo screw conveyor. It looks like a screw. Phosphate powder is sent to bucket elevator by conveyor. It also runs slowly and pushes phosphate powder forward.

BUCKET ELEVATOR When phosphate powder from common screw conveyor and reaches to bucket elevator. By the name only it is known that phosphate powder is stores. By the help of elevator, phosphate powder gone top at the hopper, where it prepared for the next process.
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BELT WEIGHTER When phosphate powder enters into hopper. By help of belt weighter phosphate sent into mixer to mix the powder.

MIXER When phosphate powder enters the mixer, then water and the acid is added to mix in it. In mixer water has quantity 35% and acid has 65%. It mixes well because it sticky form of Single Super Phosphate. After mixing it well sent to den. The water and acid is mixing carefully because it will not dry not to wet.

DEN S.S.P. paste which is mixed on the mixer put into den it is kept there to dry den completes its 1 round after drying the Single super phosphate is 45 minutes. Phosphate powder will put into den cutter. Its length is 4 meter slow moving of den means is that single super phosphate is to dry well which dries in 45 minutes.

DEN CUTTER It cuts the dry single super phosphate which is fit inside the den. By the help of blade it will cut the S.S.P. it cuts very quickly and it is all around the dens.

FINAL CONVEYOR BELT

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After cutting the den cutter the single super phosphate put into the store area with the help of final conveyor belt. With the help of crane single super phosphate is kept in different places.

SCRUBBER SECTION It is very important section of this plant because when S.S.P. is kept in den to dry it. Then blower sucks fluorine gas which is very poisonous. To control the pollution the fluorine gas is scrubbed by water. It is washed by 3 methods. Firstly, it washes into hopper, secondly, it washes again when the effect of fluorine is less then it comes out through stack. The washable water is too stored at one place and it used for different works.

CHAPTER 6 N.P.K. PLANT

(NITROGEN: PHOSPHOROUS: POTASSIUM)

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GRANULAR SINGLE SUPER PHOSPHATE PLANT

b) PROCESS DESCRIPTION OF N.P.K. GRANULATION PLANT

Manufacturing process of N.P.K. basically is a mixing of various straight fertilizers in proportionate quality as per specific grade and physically transforming of mixer from powder to granules form specific application. The raw material for this is urea, MOP, and DAP, SSP and filers (Gypsum / Low grade rock phosphate). In this process of manufacturing urea and DAP which is in granule form is first crushed in a crusher and mixed with the other raw material in required proportion and fed in rotary drum, called granulator. In granulator the mass is converted into granule with the help of water and then fed to another rotary drum called dryer. The dryer is
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connected to a furnace to get hot air. In dryer wet granule comes in contact with hot air having temprature about 600*C and dried up. The moisture gets evaporated and sucked by induced draft fan and went through a chimney. The dried granule is then cooled in cooler, which is also connected with an induced draft fan. The mass is then screened to get product size material. The undersize and oversize material is recycled in the system and product is collected and packed in 50 kg bags for markets.

c) PROCESS OF N.P.K PLANT

FEED HOPPER In this plant there are six feed hopper capacity of the hopper is about 5-5.5 tonnages approximately and length of every hopper is 10feet. Feed hopper required maintenance must. Mostly two hoppers are used in plant. But we can use all hoppers on requirement. We feed S.S.P. powder in hopper with the help of feed belt and it works totally manually.

COLOUR CONTAINER/HOPPER

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The main use of color container is to mix the colors. It is only container to mix all types of color. Mostly three colors are used i.e. white, maroon and black compare of white and maroon, black are less used. The size of this container is about 3 feet.

GRNULATOR DRUM After the completion of feed hopper and color container the S.S.P. powder come into the granulator drum with the help of granular belt. In granulator drum the S.S.P. powder has to convert in to the granule. How much water mixed in the powder is decided by the operator of granulator drum and he always available there. This work is done very safely because this is the most important point of this process. If you will do mistake then you will get powder and the wet powder will disturb the process.

DRYER DRUM When the product in the granule form, then it will put into the dryer drum with the help of dryer belt to dry the product, where the product is dried in the proper way the moisture is absorbed by the dryer drum. There is lifting blade in the dryer drum with the help of, lifting blade the product will be mixed well and granule product were also dried well, many hammers is attached outside the dryer drum to stop the product to stick on to the drum. Each hammers weight is about 12 K.G. and the length of the dryer drum is 13meter.

FURNACE Furnace is behind the dryer drum its mouth is attached to dryer drum by that furnace supply hot air to dryer drum. It supply the heat to dryer drum it takes the help of primary blower. The primary blower pressure the air from top and secondary blower pressure the air from bottom due to which the heat is generated now much heat is required by depending upon the product, then
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also the heat will be 830*C to 900*C approximately. Biocoal will put on furnace to produce heat.

BIO COAL Biocoal is made by different type of wastage such as ground nut, grass leaves; soya etc. to maintain the heat in furnace coal was put in every 15 minutes. Biocoal is brought from Maharashtra.

DRYER TWIN CYCLONE SEPARATOR When induced draft fan suck the heat the dust of the product store the cyclone container which is at the bottom of the induced draft fan. To store the dust in cyclone container it will create cyclone the big one is 4 meter and the small one is 3 meter.

COOLER DRUM After drying the product it will put into the cooler drum with the help of cooler belt for cooling product has need to cool because it is very hot. It has up to 80 degree Celsius. The use of induced draft fan is to cool the product; the lifting blade is also in the cooler drum to cool the product in proper way. Its length is 11 meter.

COOLER TWIN CYCLONE SEPARATOR The process of cooling cyclone container is just same as heat cyclone container. In the induced draft fan suck cool air to dust of the product and stored it into the cool cyclone container which is at the bottom of induced draft fan. To store the dust in cyclone containers the big one is 4 meter and the small one is 3 meter.
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OVER SIZE SCREEN After cooling the product it will put into the oversize screen but for distribution to 4mm and 2mm size product. And the over size of product put into the crushing machine by crushing process. Its screen length is about 3 meter.

CRUSHING MACHINE When the oversize product bring out the oversize screen. The product crushed it with the help of crushing machine. There are two crushing machine in this plant. There are also called chain mill. When the oversize grain product is crushed it then one product is reused and the product to move the recycle process. That product moved in granulator drum with the help of granulator belt to save the wastage. UNDER SIZE SCREEN After passing from over size screen the product will go to under size screen. There under size screen will accept the 2mm and 4mm product and less then 2mm product will drop into granular drum with the help of granulator belt. Here also the wastage is to save for again using it. After that the product is transfer into the packing room with the help of product belt. Its length is 7 meter.

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TRAINING OBSREVATION AND RECOMMENDATION

BEC fertilizers has the captive plant , it produces its electricity power for their own consumption. So there is no need of power from outside. BEC fertilizers has its plant setup by L & T , which has completed plant construction and for the starting of plant we have to only turn a key. Plant is working successfully since 26 years with proper and regular maintenance. It is the most maintained fertilizer plant in the country. This is the best achievement by BEC fertilizers. The fertilizers produced is supplied to countrys most states for the farming of crops. Workers of this plant work continously including the lunch break of one hour from morning 9:00AM to evening 5:00PM. All workers here are hard working, regular and of helping nature.
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But after talking to workers I come to know that there salary are too low for their monthly needs and fulfillment of family needs. Salary basis does not depend on the experience it depends on the grade of the servant or worker. In plant area there is lack of gardening and tree plantation, it is must for fertilizers plant because there is too much of pollutant like particles of rock phosphate fly in the air. And that particle goes in the respiratory system of human causes problems of breathing. So it is must for the plant to decrease those pollutants to a minimum level by using modern techniques of pollution controls. There is also supply of drinking water to different parts of the plant is not up to the mark, workers have to move from one plant to another for drinking water.

REFERENCES

1. MANUAL FOR B.E.C. FERTILIZERS BY L&T.

2. 3. 4.

WWW.WIKIPEDIA.ORG WWW.GOOGLE.COM CONTACT PROCESS FROM CHEMISTRY (NCERT).

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