Report Internship

1.0 ACKNOWLEDGEMENT

In the name of Allah the Beneficent, the Merciful,

I would like to express my deepest appreciation to all those who 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 throughout these !" weeks of my internship programme. I am grateful to my supervisor, Mr #airuo$e %oslin whose whose experti expertise, se, understa understandin nding, g, genero generous us guidance guidance and support support made is possible possible for me to have a meaningful internship throughout the process. I am hugely indebted to Mr Mu$akkir A$i$ for finding out time to give me some guidance and advice about the process.

 I also would like to express my deepest appreciation to all those who provided me the possibility to complete this industr industrial ial training training programme programme.. Special Special thanks thanks go to Mr Mohd &usof, &usof, Business Business 'echni 'echnical cal Support Support Mana Manage gerr for for his advices advices.. Mrs Mrs #arah #arah (ahida (ahida and Miss Miss )urul )urul *uda, *uda, also also not not forge forgett to Mr Syukri Syukri,, the +roduction ngineer ngineer of Schaefer alk that give me a lot of new knowledge knowledge and to al 'echnical 'echnical Staff. 'he conducive working environment and the good working culture in the company are difficult to come by.

 Also I would like to extend my sincere thanks to lecturers from #aculty of -hemical ngineering, ngineering, niversity 'echnolo chnology gy Mara Mara espec especial ially ly Miss Miss *absa *absah h for coordi coordina natin ting g this this inter internsh nship ip prog program ramme me to gain gain some some knowledge and and working experience, experience, for her willingness willingness to spend her time visiting me during during my internship period. Also to our /ean, +rof /r )ora$ah Abd %ahman and others who encourage and motivate us, share, knowledge and experience.

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 contributed directly or indirectly to me until my industrial training have been completed

2.0 TABLE OF CONTENT 1

 PA  PAGE  1 2

1.0 ACKNOWLEDGEMENT 2.0 TABLE OF CONTENT 3.0 INTRODUCTION 

3.1 INDUSTRIAL TRAINING

3

3.2 TRAINING SCHEDULE  4.0 COMPANY COMPANY BACKGROUND

4 5

4.1 COMPANY COMPANY ORGANIZATION CHART  5.0 TA TASK 1  REACTOR PERFORMANCE ".0 TASK 2 FUNCTION OF PHOSPHATE

7  ! 13

7.0 TASK 4 DESIGN 4  DESIGN PRO#ECT ON KILN DUST SILO 5

1" 

!.0 TASK 5 $UICK LIME RECYCLE PRO#ECT ON SILO 5

23

%.0 EFFECT OF SIZE PARTICLE ON DRUM FILTER

2"  

10.0 SUGGESTION ON IMPRO&EMENT

27  

11.0 CONCLUSION

2%

2

 PA  PAGE  1 2

1.0 ACKNOWLEDGEMENT 2.0 TABLE OF CONTENT 3.0 INTRODUCTION 

3.1 INDUSTRIAL TRAINING

3

3.2 TRAINING SCHEDULE  4.0 COMPANY COMPANY BACKGROUND

4 5

4.1 COMPANY COMPANY ORGANIZATION CHART  5.0 TA TASK 1  REACTOR PERFORMANCE ".0 TASK 2 FUNCTION OF PHOSPHATE

7  ! 13

7.0 TASK 4 DESIGN 4  DESIGN PRO#ECT ON KILN DUST SILO 5

1" 

!.0 TASK 5 $UICK LIME RECYCLE PRO#ECT ON SILO 5

23

%.0 EFFECT OF SIZE PARTICLE ON DRUM FILTER

2"  

10.0 SUGGESTION ON IMPRO&EMENT

27  

11.0 CONCLUSION

2%

2

3.0

INTRODUCTION 3.1

INDUSTRIAL TRAINING

Industrial 'raining program is one of the important components in the degree syllabus offered by Bachelor of  -hemical ngineering, niversiti 'echnology Mara 2i'M Shah Alam3. 'he industrial training program is 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 45rd 1un until 6th September 4"!7. 'he duration was !! weeks. 'he main reason for this industrial training 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.

43'o create a special bond or relationship between the employment sector and universities.

53' 53'o intro introduc duce e futur future e grad gradua uates tes with with the :uali :uality ty of the field field and and themse themselve lves s to prosp prospect ectiv ive e employers.

73'o give students opportunity to put into practice the theories they have learned in the real 8ob situation.

63'o improve student;s skills and increase the efficiency of communication with employers and working colleagues.

e "f $(e gri$% $" ?@* '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.

PCC PRODUCED FOR EACH REACTOR 

8

TRIAL 1

REACT

UNIT

R1

R2

R3

R4

R5

R6

OR

TOTA L

g/L

200.2

215.52

192.09

173.27

186.49

164.66

m3/batch

16.5

36.19

12.5

40.57

14

31.47

L/batch

16500

36190

12500

40570

14000

31470

Total

(min/batc

195

199

158

224

173

181

&at$%in

h)

16940

39194.3

15196.

31381.

15091.

28629.

2

99

98

68

01

24.40

56.44

21.88

45.19

21.73

41.23

210.87

1.02

2.35

0.91

1.88

0.91

1.72

8.79

R1

R2

R3

R4

R5

R6

TOTA

Ca(OH)2 Solid Content, Volue !e" #at$%,

' Tie Rate o 

g/min

*"odu$ti on

ton/day

A+e"a'e

146434

TRIAL 2

REACT

UNIT

OR

L g/L

226923

14798

220912

142964

140914

2098

m3/batch

16.4

35.84

13.67

34.35

13.89

27.02

L/batch

16400

35840

13670

34350

13890

27020

Total

(min/batc

175

203

165

182

138

170

&at$%in

h)

21200.

34921.

18236.

36367.

19143.

32551.

Ca(OH)2 Solid Content, Volue !e" #at$%,

' Tie Rate o 

g/min

4

162421

*"odu$ti on

ton/day

A+e"a'e

98

93

61

59

04

15

50.29

26.26

52.37

27.57

46.88

233.89

50.29

1.23

2.10

1.10

2.18

1.15

1.95

9.75

R1

R2

R3

R4

R5

R6

TOTA

TRIAL 3

REACT

UNIT

OR Ca(OH)2

L g/L

220.7

226.73

226.53

220.22

221.02

211.51

35.9

13.6

34.57

21.06

30.7

2

Solid Content, Volue

m3/batch

16.88 6

!e" #at$%,

L/batch

16886

35900

13600

34570

21060

30700

Total

(min/batc

196

210

152

233

195

232

&at$%in

h)

19015

38760.0

20268.

32673.

23870.

27988.

162576.

.7

3

47

84

16

61

8

27.38

55.81

29.199

47.05

34.37

40.30

234.11

1.14

2.32

1.21

1.96

1.43

1.67

9.75

' Tie Rate o 

g/min

*"odu$ti on A+e"a'e

ton/day

 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"".

10

AVERA

UNIT

R1

R2

R3

R4

R5

R6

TOTA

E

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 '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 EED

R3

AITAT:R

UM

EED

R5

AITAT:R

UM

EED

AITAT:R 

UM

1

16

832

14

8

28

63

2

17

62

10

11

2

42

3

20

72

11



32

702

AVERA

17

733

10

72

28

66

7

30



146

12

268

E -.HR TOTAL

311

200

280

TRIAL

R2

R4

R6

EED

AITAT:R

UM

EED

AITAT:R

UM

EED

AITAT:R 

UM

1

228

367

203

169

149

299

2

300

0

183

04

16

262

3

27

378

211

82

210

21

AVERA

28

16

144

20

168

24

11

E -.HR

300

TOTAL

0

183

311

04

16

614

262 27

TOTAL AERAGE FOR POWER USED

REACTO

R1

R2

R3

R4

R5

R6

().*

(+.*

+0,+

(+.3

(4.)

+4.4

R !W"#$%&' PCC

'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

MILL 1 AND 2: to be +hosphate is one of the agent or catalyst which are added in +-- to control the structure T" re'#)e %i>e "f $(e gri$% $" much more refined. ?@*

12

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 TAK

1

RECEIVI TAK   10910 13

1091

2

493

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.

NU/&ER O0 TRIAL

!H VALUE 1

CC TAK

RECEIVI TAK  

1

498

4967

2

492

4986

3

492

496

'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

1

MILL 1 AND 2: T" re'#)e %i>e "f $(e gri$% $" ?@*

FG%GI( F# +#/ I0) /S'

16

#0F(-*A%' #F% I0) /S' 17

PROPOSAL 1: ATTACHED SCREW BELT CONEYOR TOWARDS SILO 4

PROPOSAL 1: ATTACHED SCREW BELT CONEYOR 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 .

PROPOSAL 2: SCREW BELT CONEYOR  18

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  14

 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.

20

'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

POSSIBLE

POSSIBLE

E-ISTING

RECOMMENDED

DEIATION

CAUSES OF

CONSEUENCES

SAFEGUARDS

ACTION

DEIATION

0LO.

NO

 

o#$r

Lo&&

o'   a*$

o%tag$

rod%ction

&%r$

bac*% o#$r

ha&

r$ar$d  " +r"'#)$i"n

LESS

="%% "f i,n '#%$

=ee, ,r* in

M"ni$"r $(e ,r*

in %i," Trn%fer )(#$e

In#rie%

%i," M"ni$"r

$(e

D" reg#,r )(e)-

 !,")ge

"+er$"r 

)#rren$

n'

#+%

="%% "f +r"'#)$i"n

,r* reen$ie

)(#$e M"n$(,& )(e)-#+%

*in$enn)e%

"n R:

:+er$"r 

In%$,, +ne#*$i) ir 

)(e),i%$

n")er 

:+er$"r 

A,&% )(e) n'

$rining S$"+

*"ni$"r %,i'e g$e D" *in$enn)e%

R: ,e%% f,"

$"

$(e

'#e $" f,ig($ "rn "#$ r$i,,&  !,")ge

HIGH

)(#$e Mn#, g$e fi,%

In#rie% in

"+er$"r 

%,i'e

:erfee' '#%$ In#rie%

21

$"

"f $"

$(e

i,n $(e

$(e

"n

$rn%fer 

"+er$"r

+r"'#)$i"n

in  +r")e'#re

%i,"

GUIDEWORDS

PROCESS

POSSIBLE

POSSIBLE

E-ISTING

RECOMMENDED

DEIATION

CAUSES OF

CONSEUENCES

SAFEGUARDS

ACTION

DEIATION

PRESSURE

5I5

T""

*#)(

In#rie% $" $(e Wer E

S$"+%

$(e

ir re,e%e' "+er$"r 

,"'ing "f i,n

$

'#%$

$rn%fer 

)(#$e

"#$ TAS% &: 'U(C% )(ME REC)CE PRO*ECT S()O + Objective:

22

MILL 1 AND 2: T" re'#)e %i>e "f $(e gri$% $" ?@*

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

5YDRATI: =AT

'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

 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

POSSIBLE

POSSIBLE

E-ISTING

RECOMMENDED

DEIATION

CAUSES OF

CONSEUENCES

SAFEGUARDS

ACTION

5"++er 

S+i,, $" $(e

An& %+,i$ )n

"erfi,,%

 !#i,'ing f,""r 

 !e %e+$ n'

T(ere re

"$en$i, $"

re+r")e%%e' S$ee+ %i'e'

 " f#r$(er )$i"n

),#*+% in

'*ge $(e

("++er 

re#ire'

("++er 

("++er n'

*ini*i%e% $(e

)#%e% !,")ge%

ri% "f 

DEIATION

0LO.

HIGH

LOW

*$eri, (",'#+ "n $(e ("++er ,,%9

2

NO

5"++er 

 " +r"'#)$i"n

e*+$&

r")e%%

 " f#r$(er )$i"n

)"n$r",% )"*e

re#ire'

in$" effe)$ $" $ri+ '"n%$re* fire' ee'er fi,%

5"++er f#,, "f 

++,in)e% R"#$ine

reen$ie

*$eri,9

)(e)% "n !e,$

*in$enn)e

C"nfine' %+)e

fee'er '#ring

 +r")e'#re%

en$r& $" #n!,")

%(#$'"n%.

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 4 is converted to -a-F 5. '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

Te

110 M"i%$#re )"n$en$ 

1

6933

0974

2

91

292

3

6932

0927



697

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 IMPROEMENT !.

%everse parking procedure is to avoid accident at parking space

26

•

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 SM 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

27

I/ / &6 7%8! '9 #8/# 7;7%/

28

11.0 CONCLUSION 'hese !! weeks of internship programme starting from !C nd 1uly 4"!< to 45 rd 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.

24