1.0 ACKNOWLEDGEMENT
1.0 ACKNOWLEDGEMENT
In the name of Allah the Beneficent, the Merciful, In the name of Allah the Beneficent, the Merciful,
I would like
I would like to express my deepest appreciation to all those to express my deepest appreciation to all those who provided me the possibility to complete thiswho provided me the possibility to complete this industrial training programme. I would to thank all Schaefer alk Sdn Bhd staffs for your help and guidance industrial training programme. I would to thank all Schaefer alk Sdn Bhd staffs for your help and guidance throughout these !" weeks of my internship programme. I am grateful to my supervisor, Mr #airuo$e %oslin throughout these !" weeks of my internship programme. I am grateful to my supervisor, Mr #airuo$e %oslin whos
whose e expexpertiertise, se, undunderstaerstandinnding, g, gengeneroerous us guidguidance and ance and suppsupport made ort made is is posspossible for ible for me me to to have ahave a meaningful internship throughout the process. I am hugely indebted to Mr Mu$akkir A$i$ for finding out time meaningful internship throughout the process. I am hugely indebted to Mr Mu$akkir A$i$ for finding out time to give me some guidance and advice about the process.
to give me some guidance and advice about the process.
I also would like to express my deepest appreciation to all those who provided me the possibility to complete I also would like to express my deepest appreciation to all those who provided me the possibility to complete this
this indindustrustrial ial traitraining prograning programmemme. . SpecSpecial ial thanthanks ks go go to to Mr Mr Mohd &usMohd &usof, of, BusiBusiness 'eness 'echnichnical cal SuppSupportort Ma
Mananageger r fofor r his advihis advicesces. . MrMrs s #a#arah (ahrah (ahida and ida and MisMiss s )ur)urul ul *ud*uda, a, alsalso o nonot t forforgeget t to to Mr Mr SyuSyukrikri, , thethe +roduction ng
+roduction ngineer of Schaefer alk that give me a lot of new ineer of Schaefer alk that give me a lot of new knowledgknowledge and to al 'ee and to al 'echnical Staff. chnical Staff. 'he'he conducive working environment and the good working culture in the company are difficult to come by.
conducive working environment and the good working culture in the company are difficult to come by.
Also I
Also I would like would like to extend my to extend my sincere thanks to sincere thanks to lecturers from #aculty of lecturers from #aculty of -hemical ngineeri-hemical ngineering, niversityng, niversity '
'eechnchnoloology gy MaMara ra esespecpecialially ly MiMiss ss *ab*absasah h for for coocoordirdinanatinting g ththis is intinterernshnship ip prprogogramramme me to to gagain in somsomee knowledge an
knowledge and working experd working experience, ience, for her willingnefor her willingness to spend her time visiting me durinss to spend her time visiting me during my internshipg my internship period. Also to our /ean, +rof /r )ora$ah Abd %ahman and others who encourage and motivate us, share, period. Also to our /ean, +rof /r )ora$ah Abd %ahman and others who encourage and motivate us, share, knowledge and experience.
knowledge and experience.
0ast but not the least, special thanks to my mother, Mrs Mariam 1antan and my sibling for their support, 0ast but not the least, special thanks to my mother, Mrs Mariam 1antan and my sibling for their support, encouragement and endless prays given to me. #inally, I would like to thank to my friends and to who have encouragement and endless prays given to me. #inally, I would like to thank to my friends and to who have contributed directly or indirectly to me until my industrial training have been completed
contributed directly or indirectly to me until my industrial training have been completed
2.0 TABLE OF CONTENT
2.0 TABLE OF CONTENT
P
PA
AGE
GE
1
1..0
0
A
AC
CK
KN
NO
OW
WL
LE
ED
DG
GE
EM
ME
EN
NT
T
1
1
2
2..0
0
T
TA
AB
BL
LE
E
O
OF
F
C
CO
ON
NT
TE
EN
NT
T
2
2
3.0 INTRODUCTION
3.0 INTRODUCTION
3.1
3.1 INDUSTRIAL
INDUSTRIAL TRAINING
TRAINING
3.2
3.2 TRAINING
TRAINING SCHEDULE
SCHEDULE
3
3
4
4
4.0
4.0 COMPA
COMPANY
NY BACKGROUND
BACKGROUND
4.1
4.1 COMPA
COMPANY
NY ORGANIZATION
ORGANIZATION CHART
CHART
5
5
7
7
5
5..0 T
0 TA
AS
SK
K 1
1
R
RE
EA
AC
CT
TO
OR
R P
PE
ER
RF
FO
OR
RM
MA
AN
NC
CE
E
!
!
"
"..0
0 T
TA
AS
SK
K 2
2
F
FU
UN
NC
CT
TIIO
ON
N O
OF
F P
PH
HO
OS
SP
PH
HA
AT
TE
E
1
13
3
7.0
7.0 TASK
TASK 4
4 DESIGN PRO#ECT
DESIGN PRO#ECT ON KILN DUST
ON KILN DUST SILO 5
SILO 5
1"
1"
!
!..0
0 T
TA
AS
SK
K 5
5
$
$U
UIIC
CK
K L
LIIM
ME
E R
RE
EC
CY
YC
CL
LE
E P
PR
RO
O##E
EC
CT
T O
ON
N S
SIIL
LO
O 5
5
2
23
3
%
%..0
0 E
EF
FF
FE
EC
CT
T O
OF
F S
SIIZ
ZE
E P
PA
AR
RT
TIIC
CL
LE
E O
ON
N D
DR
RU
UM
M F
FIIL
LT
TE
ER
R
2
2"
"
1
10
0..0
0 S
SU
UG
GG
GE
ES
ST
TIIO
ON
N O
ON
N IIM
MP
PR
RO
O&
&E
EM
ME
EN
NT
T
2
27
7
1
11
1..0
0
C
CO
ON
NC
CL
LU
US
SIIO
ON
N
2
2%
%
2
2
P
PA
AGE
GE
1
1..0
0
A
AC
CK
KN
NO
OW
WL
LE
ED
DG
GE
EM
ME
EN
NT
T
1
1
2
2..0
0
T
TA
AB
BL
LE
E
O
OF
F
C
CO
ON
NT
TE
EN
NT
T
2
2
3.0 INTRODUCTION
3.0 INTRODUCTION
3.1
3.1 INDUSTRIAL
INDUSTRIAL TRAINING
TRAINING
3.2
3.2 TRAINING
TRAINING SCHEDULE
SCHEDULE
3
3
4
4
4.0
4.0 COMPA
COMPANY
NY BACKGROUND
BACKGROUND
4.1
4.1 COMPA
COMPANY
NY ORGANIZATION
ORGANIZATION CHART
CHART
5
5
7
7
5
5..0 T
0 TA
AS
SK
K 1
1
R
RE
EA
AC
CT
TO
OR
R P
PE
ER
RF
FO
OR
RM
MA
AN
NC
CE
E
!
!
"
"..0
0 T
TA
AS
SK
K 2
2
F
FU
UN
NC
CT
TIIO
ON
N O
OF
F P
PH
HO
OS
SP
PH
HA
AT
TE
E
1
13
3
7.0
7.0 TASK
TASK 4
4 DESIGN PRO#ECT
DESIGN PRO#ECT ON KILN DUST
ON KILN DUST SILO 5
SILO 5
1"
1"
!
!..0
0 T
TA
AS
SK
K 5
5
$
$U
UIIC
CK
K L
LIIM
ME
E R
RE
EC
CY
YC
CL
LE
E P
PR
RO
O##E
EC
CT
T O
ON
N S
SIIL
LO
O 5
5
2
23
3
%
%..0
0 E
EF
FF
FE
EC
CT
T O
OF
F S
SIIZ
ZE
E P
PA
AR
RT
TIIC
CL
LE
E O
ON
N D
DR
RU
UM
M F
FIIL
LT
TE
ER
R
2
2"
"
1
10
0..0
0 S
SU
UG
GG
GE
ES
ST
TIIO
ON
N O
ON
N IIM
MP
PR
RO
O&
&E
EM
ME
EN
NT
T
2
27
7
1
3.0
INTRODUCTION
3.0
INTRODUCTION
3.1
3.1
INDUSTRIAL
INDUSTRIAL TRAINING
TRAINING
Industrial 'raining program is one of the important components in the degree syllabus offered by Bachelor of Industrial 'raining program is one of the important components in the degree syllabus offered by Bachelor of -hemical ngineering, niversiti 'echnology Mara 2i'M Shah Alam3. 'he industrial training program is -hemical ngineering, niversiti 'echnology Mara 2i'M Shah Alam3. 'he industrial training program is compulsory to all engineering students as they will be trained at any selected engineering company, covering compulsory to all engineering students as they will be trained at any selected engineering company, covering a wide range engineering fields and industries. 'he training at Schaefer alk Sdn Bhd was commenced from a wide range engineering fields and industries. 'he training at Schaefer alk Sdn Bhd was commenced from 45
45rdrd 1un until 6 1un until 6thth September 4"!7. 'he duration was !! weeks. 'he main reason for this industrial training September 4"!7. 'he duration was !! weeks. 'he main reason for this industrial training
program is to help students to achieve ob8ectives stated below9 program is to help students to achieve ob8ectives stated below9
!3'o provide early exposure to students in order to adapt to the working environment. !3'o provide early exposure to students in order to adapt to the working environment.
43'o create a special bond or relationship between the employment sector and universities. 43'o create a special bond or relationship between the employment sector and universities.
53
53''o o intintroroducduce e futfuturure e grgradaduauates tes witwith h the the :u:ualiality ty of of the the fiefield ld anand d thethemsemselvelves s to to prprospospectectivivee employers.
employers.
73'o give students opportunity to put into practice the theories they have learned in the real 8ob 73'o give students opportunity to put into practice the theories they have learned in the real 8ob situation.
situation.
63'o improve student;s skills and increase the efficiency of communication with employers and 63'o improve student;s skills and increase the efficiency of communication with employers and working colleagues.
working colleagues.
<3'o increase self=confidence to act as a professional engineer in the working environment. <3'o increase self=confidence to act as a professional engineer in the working environment.
3.2
3.2
TRAINING
TRAINING SCHEDULE
SCHEDULE
3
3
WEEK
DATE
SUMMARY
ACTIVITIES
1
18/07/2016-22/07/2016
•
Briefing !"#$ %fe$& n' $(e )"*+n&
•
Vi%i$ r"#n' $(e +,n$ ,i*e%$"ne %$"rge. i,n.
(&'r$i"n. CC. +)ing +,n$ n' re("#%e
2
2/07/2016-24/07/2016
•
Briefing "n i,n n' (&'r$i"n +,n$
•Ki,n n' 5&'r$i"n +,n$ n,&%i%
•Dr n' #n'er%$n' +r")e%% f,"
3
01/08/2016-03/08/2016
•
Briefing "n CC n' %$e $er $re$*en$
+,n$ WWT
•
CC n' %$e $er $re$*en$ +,n$ n,&%i%
•Dr n' #n'er%$n' +r")e%% f,"
0/08/16
•Briefing "n (&'r$i"n n' CC +)ing +,n$
•Dr n' #n'er%$n' +r")e%% f,"
0/08/16
•Briefing "n re("#%e %&%$e* (&'r$i"n n'
CC
•
Dr n' #n'er%$n' +r")e%% f,"
08/08/2016-10/08/2016
•
Briefing "n *in$enn)e +,n$ "+er$i"n n'
engineering re("#%e %&%$e*
•
Briefing "n engineering +,n$ n' in$ern,
+,n$ +r"e)$
11/08/2016-12/08/2016
•Briefing "n ,!"r$"r&
•Briefing "n +,n$ #,i$& )"n$r",
1/08/2016
•Briefing "n +,n$ #,i$& )"n$r",
16/08/2016-14/08/2016
•
Briefing "n +,n$ $e)(ni), Ki,n n' (&'r$i"n.
CC n' %$e $er $re$*en$ +,n$9
6
22/08/2016-26/08/2016
•
A$$)(*en$ $" CC n' WWT
•
A$$)(*en$ $" i,n n' (&'r$i"n +,n$
•A$$)(*en$ $" +)ing +,n$
7
24/08/2016-02/04/2016
•
A$$)(*en$ $" CC n' WWT
•
A$$)(*en$ $" i,n n' (&'r$i"n +,n$
•A$$)(*en$ $" +)ing +,n$
8
0/04/2016-04/04/2016
•
A$$)(*en$ $" CC n' WWT
•
A$$)(*en$ $" i,n n' (&'r$i"n +,n$
•A$$)(*en$ $" +)ing +,n$
4
12/04/2016-16/04/2016
•
A$$)(*en$ $" CC n' WWT
•
A$$)(*en$ $" i,n n' (&'r$i"n +,n$
•A$$)(*en$ $" +)ing +,n$
•re%en$$i"n +re+r$i"n
10
14/04/2016-23/04/2016
•re%en$$i"n +re+r$i"n
•re%en$$i"n $" SKM
4.0 COMPANY BACKGROUND
stablished in !>>6, Schaefer alk 2M3 Sdn Bhd is !""? owned by Schaefer alk @mb* -o. @, @ermany. Based on /ie$, " kilometres northwest of #rankfurt, Schaefer alk has been involved in producing calcium products since !C<". 'he @erman company employs "" staff and produces a wide range of high=:uality calcium=based products. 'he research and development department based in *enstatten develops many products to match specific demands from costumers, as does Schaefer alk 2Malaysia3;s research and development facilities in uala etil, edah. Schaefer alk has established a fully automatic production process to produce high :uality calcium products. -apacity is 6" """ tons annually of precipitated calcium carbonate 2+--3, C" """ tons per year of calcium hydroxide with purity above >C ?.
+roducing *igh Duality +recipitated -alcium -arbonate and highly reactive -alcium *ydroxide using the highest technology, with customers being worldwide leaders in various ranges of applications from paper, toothpaste, paint and plastics to pharmaceuticals, oil refinery processes and waste treatment. 'his company runs 5 plant in producing high :uality precipitate calcium carbonate and highly reactive calcium hydroxide. 'he process involve are9
REACTION IN KILN:
CC:
3C: ; C:
2<#i),i*e
REACTION IN HYDRATED LIME PROCESS:
C: ; 5
2:
C:5
25&'r$e' =i*e
REACTION IN PCC PLANT:
C :5
2; C:
2CC:
3; 5
2:
CC
S-*A#% A0 has been producing precipitated calcium carbonates since !>67. 'hey are marketed under the brand name S-*A#% +%-A%B.
In our modern production plants we are able to manufacture a range of :ualities that meet the exacting re:uirements of our customers.
(e always focus on our customers and their individual needs. (e develop specific solutions to products and processes in close cooperation with them.
Crystal Design
+recipitated calcium carbonate 2+--3 can be produced as various crystal modifications and granule forms. 'he physical parameters for each of these precipitation products are optimi$ed according to desired
application, e.g.
• particle si$e and granule si$e distribution
• single particles or agglomerations of primary crystals
4.1 COMPANY ORGANIZATION CHART
7
MILL 1 AND 2:
T" re'#)e %i>e "f $(e gri$% $" ?@*
5.0 TASK 1: REACTOR PERFORMANCE
Objective:
• 'o find how many +-- produced from each reactor and power used for each reactor • 'o find whether amount of +-- produced is in range amount
MILL 1 AND 2:
T" re'#)e %i>e "f $(e gri$% $" ?@*
5.0 TASK 1: REACTOR PERFORMANCE
Objective:
• 'o find how many +-- produced from each reactor and power used for each reactor • 'o find whether amount of +-- produced is in range amount
Above are the sample images of reactor. %eactors are only used in +-- plant. 'here are < reactor available in the plant. 'here are small reactors and large reactors. %eactor !, 5 and 6 are labelled as small reactor which only consist of feed pump and agitator which uses power. %eactor 4, 7 and < are labelled as large reactor which uses blower and agitator as source of power.
very sample from each reactor needs to be taken and then those samples are used to find how many solid contents are available in those samples. 'hree trials were taken for each sample and thus average was obtained.
TRIAL 1
REACT
OR
UNIT
R1
R2
R3
R4
R5
R6
TOTA
L
Ca(OH)2
Solid
Content,
g/L
200.2
215.52
192.09
173.27
186.49
164.66
Volue
!e"
#at$%,
m3/batch
16.5
36.19
12.5
40.57
14
31.47
L/batch
16500
36190
12500
40570
14000
31470
Total
&at$%in
' Tie
(min/batc
h)
195
199
158
224
173
181
Rate o
*"odu$ti
on
g/min
16940 39194.3
2
15196.
99
31381.
98
15091.
68
28629.
01
146434
ton/day
24.40
56.44
21.88
45.19
21.73
41.23
210.87
A+e"a'e
1.02
2.35
0.91
1.88
0.91
1.72
8.79
TRIAL 2
REACT
OR
UNIT
R1
R2
R3
R4
R5
R6
TOTA
L
Ca(OH)2
Solid
Content,
g/L
226923
14798
220912
142964
140914
2098
Volue
!e"
#at$%,
m3/batch
16.4
35.84
13.67
34.35
13.89
27.02
L/batch
16400
35840
13670
34350
13890
27020
Total
&at$%in
' Tie
(min/batc
h)
175
203
165
182
138
170
Rate o
g/min
21200.
34921.
18236.
36367.
19143.
32551. 162421
*"odu$ti
on
98
93
61
59
04
15
ton/day
50.29
26.26
52.37
27.57
46.88
233.89
50.29
A+e"a'e
1.23
2.10
1.10
2.18
1.15
1.95
9.75
TRIAL 3
REACT
OR
UNIT
R1
R2
R3
R4
R5
R6
TOTA
L
Ca(OH)2
Solid
Content,
g/L
220.7
2
226.73
226.53
220.22
221.02
211.51
Volue
!e"
#at$%,
m3/batch
16.88
6
35.9
13.6
34.57
21.06
30.7
L/batch
16886
35900
13600
34570
21060
30700
Total
&at$%in
' Tie
(min/batc
h)
196
210
152
233
195
232
Rate o
*"odu$ti
on
g/min
19015
.7
38760.0
3
20268.
47
32673.
84
23870.
16
27988.
61
162576.
8
ton/day
27.38
55.81
29.199
47.05
34.37
40.30
234.11
A+e"a'e
1.14
2.32
1.21
1.96
1.43
1.67
9.75
All these three trial were taken at different time and date. It is to ensure that these reactors are applicable and can be investigate. 'hen, the average was calculated from these trials. #rom there the value of 'on +--can be obtained. #or a day, range of +-- obtained from +-- plant are 4"" ton +--. 'hus, the ob8ectives in this experiment are to obtain the value of ton +-- must above 4"".
AVERA
E
UNIT
R1
R2
R3
R4
R5
R6
TOTA
L
Ton/day
27.44
54.18
25,77
48.20
27.89
42.80
226.29
Ton/hr
1.14
2.26
1.07
2.01
1.16
1.78
9.43
Ton !!
3.6
7.7
2.8
7.1
3.3
5.7
30.20
In conclusion from this performance, it shows that total of 'on +-- per day exceeds 4"" which are 44<.4> 'on +--. )ext we going to discuss on the power used for each reactor.
AMOUNT OF POWER USED B EAC! REACTOR
%eactor !,5 and 6 is small reactor thus it only used feed pump and agitator as the power source while reactor 4, 7 and < used blower and agitator as its power source due to its largeness.
TRIAL
R1
R3
R5
EED
UM
AITAT:R
EED
UM
AITAT:R
EED
UM
AITAT:R
1
16
832
14
8
28
63
2
17
62
10
11
2
42
3
20
72
11
32
702
AVERA
E
17
733
10
72
28
66
-.HR
7
30
146
12
268
TOTAL
311
200
280
TRIAL
R2
R4
R6
EED
UM
AITAT:R
EED
UM
AITAT:R
EED
UM
AITAT:R
1
228
367
203
169
149
299
2
300
0
183
04
16
262
3
27
378
211
82
210
21
AVERA
28
16
144
20
168
24
11
MILL 1 AND 2:
T" re'#)e %i>e "f $(e gri$% $"
E
-.HR
300
0
183
04
16
262
TOTAL
311
614
27
TOTAL AERAGE FOR POWER USED
REACTO
R
R1
R2
R3
R4
R5
R6
!W"#$%&'
PCC
().*
(+.*
+0,+
(+.3
(4.)
+4.4
'he above data shows that the most efficient reactor between those < reactor is %5 because it used less power to produce +-- and to conserve energy.
).0 TASK 2: FUNCTION OF PHOSPHATE
Objective:
E +hosphate is one of the agent or catalyst which are added in +-- to control the structure to be much more refined.
E 'o investigate whether phosphate can reduce p* of +-- or not.
Above is the flowchart where phosphate are added
At first, the p* was directly taken from +-- tank and %eceiving tank. +- tank is where before phosphate added and %eceiving tank is where phosphate was been added. Below are the data that shows the result.
TRIAL
!H VALUE
CC
TAK
RECEIVI TAK
1
10910
1091
2
493
4946
3
4976
4914
'he data shows that even after phosphate added, the data still shows an increasing p* value although it should shows decreasing value. 'hus another experiment was conducted which include Buchner funnel
E-PERIMENT USING BUCHNER FUNNEL
+rocedure
" Shake the sample vigorously and pour the solution through the Buchner funnel onto the filter paper
" #ilter the solution with the aid of vacuum pump or water pump 8et until the water is filtered out
" 'hen dry those sample in oven about ! hour
" Mix the powder with distilled water and p* value was measured.
MILL 1 AND 2:
T" re'#)e %i>e "f $(e gri$% $" ?@*
CC TAK
RECEIVI TAK
1
498
4967
2
492
4986
3
492
496
'he data still shows no decreasing sign thus in conclusion phosphate cannot reduce the p* value. +hosphate only acted as buffer solution to control viscosity.
+.0 TASK 3: KILN DUST SILO 5
Objective:
E 'o loading kiln dust silo 6 in bulk truck
E 'o increase the expenditure of kiln dust in silo 6
#0F(-*A%' #F% I0) /S'
17
PROPOSAL 1: ATTACHED SCREW BELT CONEYOR TOWARDS SILO 4
Silo 7 was unused due to construction of kiln 5 in one year. By attaching screw belt conveyor connected to silo 7 area, bulk truck can be pass underneath silo 7. 'hese are the most approvable design between other two proposal which include less costly and can use recycle screw belt conveyor
.
Silo 6 area needs to be enlarged thus screw belt conveyor can be attached. 'he screw belt conveyor transports the kiln dust directly to rotary feeder. 'he bulk truck can pass through underneath silo 6 and the loading of kiln dust can be achieved. Actually these proposals are the most re8ected due to area of silo 6 cannot fir screw belt conveyor.
PROPOSAL 3: USE HOPPER AND BLOWER
A new hopper 5" meter cube is attached at hydration plant with purpose loading kiln dust into bulk tank. Blower from pendulum mill section is alternately used to transport kiln dust from silo 6 to the hopper.
'hese are the additional +#/ in terms of proposal 5. In conclusion, between all these three proposal, the most effective proposal will be proposal will be +roposal ! due to less costly, less renovation and less work compare to other two proposal.
HAZOP
GUIDEWORDS PROCESS DEIATION POSSIBLE CAUSES OF DEIATION POSSIBLE CONSEUENCES E-ISTING SAFEGUARDS RECOMMENDED ACTION0LO.
NO
o#$r o%tag$ Lo&& o' rod%ction a*$ &%r$ bac*% o#$r ha& r$ar$d " +r"'#)$i"n in %i," ="%% "f i,n '#%$ =ee, ,r* in %i," M"ni$"r $(e ,r* Trn%fer )(#$e !,")ge In#rie% $" $(e "+er$"r M"ni$"r $(e )#rren$ n' ,r* D" reg#,r )(e)-#+% "n $rn%fer )(#$eLESS
R: ,e%% f," '#e $" f,ig($ "rn "#$ ="%% "f +r"'#)$i"n reen$ie *in$enn)e% M"n$(,& )(e)-#+% "n R: r$i,,& !,")ge in )(#$e In#rie% $" $(e "+er$"r :+er$"r )(e),i%$In%$,, +ne#*$i) ir n")er
HIGH
Mn#, %,i'e g$e fi,% :erfee' "f i,n '#%$ :+er$"r $rining A,&% )(e) n' *"ni$"r %,i'e g$e In#rie% $" $(e S$"+ $(e D" *in$enn)e%MILL 1 AND 2: "+er$"r +r"'#)$i"n in %i," +r")e'#re GUIDEWORDS PROCESS DEIATION POSSIBLE CAUSES OF DEIATION POSSIBLE CONSEUENCES E-ISTING SAFEGUARDS RECOMMENDED ACTION
PRESSURE
5I5
T"" *#)(
ir re,e%e'
$
$rn%fer
)(#$e
In#rie% $" $(e
"+er$"r
Wer E
S$"+%
$(e
,"'ing "f i,n
'#%$
"#$ TAS% &: 'U(C% )(ME REC)CE PRO*ECT S()O + Objective:
E 'o recycle waste from big bag into silo 6
E 'o save and increase the profit of kiln dust by using unused vibrating screen in warehouse
PROPOSAL DESIGN
'his design is based on proposal 5. 'his idea is to collect all the waste from big bag back into silo
6. It will be mixed with kiln dust and can be selling. 'his design will be using unused screening
which obtained from warehouse to reduce cost of renovation.
23
5YDRATI:
Above is the image of unused screening that can be recycle to use for kiln dust silo 6. Besides
these e:uipment, the hopper that we gonna use in this design are also recycle so that the cost can
be reduced. 'his pro8ect will be hold until the renovation of kiln 5 that will be added next year.
HAZOP
GUIDEWORDS PROCESS DEIATION POSSIBLE CAUSES OF DEIATION POSSIBLE CONSEUENCES E-ISTING SAFEGUARDS RECOMMENDED ACTION0LO.
HIGH
5"++er
"erfi,,%
S+i,, $" $(e
!#i,'ing f,""r
An& %+,i$ )n
!e %e+$ n'
re+r")e%%e'
LOW
T(ere re
),#*+% in
("++er
"$en$i, $"
'*ge $(e
("++er n'
)#%e% !,")ge%
S$ee+ %i'e'
("++er
*ini*i%e% $(e
ri% "f
*$eri,
(",'-#+ "n $(e
("++er ,,%9
" f#r$(er )$i"n
re#ire'
NO
5"++er
e*+$&
" +r"'#)$i"n
r")e%%
)"n$r",% )"*e
in$" effe)$ $"
$ri+
'"n%$re*
fire'
++,in)e%
" f#r$(er )$i"n
re#ire'
ee'er fi,%
5"++er f#,, "f
*$eri,9
C"nfine' %+)e
en$r& $" #n!,")
R"#$ine
)(e)% "n !e,$
fee'er '#ring
%(#$'"n%.
reen$ie
*in$enn)e
+r")e'#re%
2
*.0 TASK 5: EFFECT ON SIZE PARTICLE ON DRUM FILTER
Fb8ective9 'o study the effect of si$e and moisture content in drum filter
Schaefer alk 2M3 Sdn Bhd runs 6 products of +--. But in our task, we use only 4 products which different is si$e for study purpose. +!!" is one of the +-- products where the si$e is small and +45" is the products that have larger si$e. 'hese 4 products are from reactor where -a 2F*3 4is converted to -a-F5. 'hen the
products from reactor are transfer to drum filter to absorb water before it will enter a dryer.
'his study is based on effect of si$e on moisture content in a cake sample taken from drum filter.
r"'#)$%
230
110
Te
M"i%$#re
)"n$en$
1
6933
0974
2
91
292
3
6932
0927
697
2942
+!!" has small in si$e, thus moisture content is high around 6"=66?. (hile, +45" has bigger si$e, thus moisture content is low around 76=7C?. 'hus, +45" has higher productivity than +!!" per day.
Bigger si$e will give lower moisture content because the water trapped inside together with the products easily suck in into central duct. Bigger si$e gives larger void space. 'herefore, water molecules easily diffuse out through the filter cloth while water is hardly pass through the small si$e particles.
By using mass balance, the water removal from dryer is high for high moisture content 2small si$e particle3. 'hus, larger amount of product are produced from the dryer as less water contain in the cake.
10.0 SUGGESTION ON IMPROEMENT
• Acc,racy H 'o successfully park in a bay within the lines and not too close to a car on either side. • C-ntr-l H By keeping the cars speed under control by use of clutch control and by use of effective
steering.
• Observati-n H -onstant all=round observation throughout the bay parking manoeuvre.
!. +urchase more land area
/ue to the company becomes more demand, the company needed to enlarge the company by purchasing more land area so that more process and more products can be produced. 'he company needs to extend stockyard, storage and improve material transportation
4. Install sensor that indicates I+
%egarding dust pollution incident, i propose that SM install sensor that indicates dust pollution index or I+ 2indeks pencemaran udara3 on top of each building from time to time. 'his dust pollution index or I+ 2indeks pencemaran udara3 need to be monitored from time to time.
5. sing stacker and reclaimer system
It is to enhance material transportation system and homogeni$ing the chemical content of limestone. 'hese processes were worldwide used in other large companies and can make the limestone more high :uality
11.0 CONCLUSION
'hese !! weeks of internship programme starting from !Cnd 1uly 4"!< to 45rd Sept 4"!< had ended with a
success. I have gained a lot of technical and non=technical skills which will help me to prepare for working environment. I have learned much unit operation, wastewater treatment and to verify the specification that we need in lab. Actually, the industrial training program has strengthened my soft skills include adaptability and flexibility, time management, priority management and problem solving skill.
As conclusion, I would like to say that Schaefer alk 2M3 Sdn Bhd is one of the best places for niversity 'echnology Mara student especially those who pursue chemical engineering to do their internship programme. I strongly believe the experience gained will prepare me as a better engineer in the future.