To study The dross generation

Tata AutoComp GY Batteries Pvt. Ltd.

Project report on Dross Generation in the Casting Section

Project by-Abhishek Roy

Project Head-Mr. Suvrajit Banerjee

Under the supervision of Mr. Mohit Bhakal


Acknowledgement I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them. I am highly indebted to Mr. Suvrajit Banerjee, Mr. Mohit Bhakal for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I would like to express my gratitude towards operators of Casting section of TATA AutoComp GY Batteries Pvt. Ltd for their kind co-operation and encouragement which help me in completion of this project and for giving me such attention and time.


Company Profile

Tata AutoComp Systems Limited, promoted by the Tata Group, provides products and services in the automotive industry to Indian and global customers, including Ashok Leyland, BMW India, Mercedes-Benz India, EicherMotors, Fiat, Force Motors, Ford India, General Motors India, Hero Honda, Hindustan Motors, Honda Scooters, Honda Siel Cars India Ltd, International Tractors John Deere India, Mahindra and Mahindra, Mahindra Renault, Man-Force Trucks, New Holland, Piaggio, Punjab Tractors, Royal Enfield, Skoda, Swaraj Mazda, Tata Motors, Toyota Kirloskar Motor Pvt. Ltd., Tractors and Farm Equipment Limited.


Company Profile (TATA AutoComp GY Batteries)

TATA Green Batteries are a product of TATA AutoComp GY Batteries Pvt. Ltd. (TGY), a joint venture between TATA AutoComp Systems Ltd, India's leading auto component manufacturer and GS Yuasa International, Japan, one of the world's largest automotive battery manufacturers. These batteries are a combination of TATA AutoComp’s extensive experience in the Automotive Industry and GS Yuasa International’s superior technological know-how. With a low top-up requirement and being 90% recyclable, Tata Green Batteries allow a hassle free battery running experience


Different Sections In the Plant

CASTING

Pasting

Assembly

Charging

Dispatch

*The project is undergone under this section


Wal

king

Are

a Walking Area

Wal

king

Are

a

Way to the PASTING section

Raw Material Section Calcium –ve Alloy

Antimony Alloy Calcium +ve Alloy

Sb +

ve

Emergency Exit

Ca +veCa -ve

CASTING SECTION

Ca +ve

Cork Preparation Area

CAST

ING

Secti

on E

ntry

Offi

ce

Dross dumping

area

B1 B2 B3 B4 B5 B6 B7 B8

A1 A2 C6 C5 C4 C3 C2 C1C10 C9 C8 C7

Ca -ve

Ca -ve

Ca -ve

Ca -ve

Ca -ve

Ca -ve

Ca -ve

Ca -ve

Ca -veSb +

ve

Sb +

ve

Sb +

ve

Sb +

ve

Sb +

ve

Sb +

ve

Sb +

ve


Gravity Casting Machine


Working Of the machine

1

2

6

5

4

3

7


Process

POT (Where The molten

lead is present)

FEEDLINE(which transfer the molten lead)

LADDLE

TRIM DIE SECTION

(to cut excess part of the panel)

COLLECTING AREA (The final product is kept

here )

MOULD(which give shape to the

molten lead)

ROLLER

1 2

6

5

4

3

7

The excess part is send back to the Pot


Type Pot Temp. Ladle Temp. Moving mould Temp. Fixed Mould Temp. Feed Line Temp.

Sb +ve 420±30 600±30 200±30 200±30 490±30

Ca -ve 420±30 600±30 200±30 200±30 490±30

Ca +ve 420±30 600±30 200±30 200±30 490±30

Grid information


Grid Nomenclature

Y M 83A

Plate thickness (100-83)/10=1.7±0.1mm

Grid thickness ((100-83)/10)-0.2=1.7±0.1mm

Small

Calcium

OTHER NOTATIONS:-C Antimony

G Big

In case ofPlate thickness=(100- )/10=2.1±0.1mm Grid thickness=((100- )/10)-0.2=1.8±0.1mm

C G 80A 79

79

80


DrossDross is a mass of solid impurities floating on a molten metal or dispersed in the metal, such as in wrought iron. It forms on the surface of low-melting-point metals such as tin lead zinc or aluminium or alloys by oxidation of metals as tin, lead, zinc or aluminium or alloys by oxidation of the metal(s). Dross, as a solid, is distinguished from slag, which is a liquid. Dross product is not entirely waste material; for example, aluminium dross can be recycled and is used in secondary steelmaking for slag deoxidation.

Dross


16 Major Losses In a Company

8 Availability LossesMachine LossSetup & adjustingTool changeStart-up lossesMinor stoppageSpeed lossDefect and reworkShutdown

5 Productivity lossesManagement lossesOperating MotionLine organisationLogisticsAdjustments

3 Production losses•Loss of energy•Die-tool losses•Yield loss


Time Study of the Machine (B3-B4)

Total sample time for the production- 180 minutesNo of panels to be produced– 3690 panels

Actual Time taken for production- 144 minutesNo of grids produced- 3168 panelsMajor losses occurred during the process-• Shut Down Loss/Defect and rework- 20 min• Setup Loss-5 min• Die/Tool Loss- 5 min• Line organisational loss-6 min


Date April'16 May'161st 237 02nd 432 4093rd 385 3414th 427 2855th 426 3216th 471 3237th 373 4078th 0 3949th 457 41210th 379 34211th 431 42512th 292 55713th 341 44414th 397 49715th 324 29916th 431 49317th 418 26618th 300 46419th 206 42820th 289 51121st 436 51522nd 300 44223rd 430 45924th 304 45125th 366 36326th 417 027th 455 028th 398 029th 367 8930th 323 45231st n/a 470

possible reasons-- temperature variations-manpower variation-Impurities in the ingot

highest amount of dross generated


Dross Generation Data

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th 17th 18th 19th 20th 21st 22nd 23rd 24th 25th 26th 27th 28th 29th 30th 31st0

100

200

300

400

500

600

Dros

s (in

kg)

highest amount of dross gen-erated


Action PlanThere are ways by which we can reduce the generation of

dross-• By induction heating- induction heating helps in reducing

dross generation and also helps in energy saving. The idea is being proposed and is in a prototype position.

• By minimising the surface area of the opening of the pot- The opening present in the pot is the reason for the generation of dross as more amount of air can enter through it to oxidise with the lead. If the conveyor length is increased so that it ends at the inside the opening and the opening is made small enough so as to make the dross removal easier for the operator and putting a cover on it, the dross generation can be reduced by 5%.

Documents

To study The dross generation