TECHNO INDIA NJR INSTITUTE OF TECHNOLOGY

PROJECT REPORT ON LEVEL RADAR TRANSMITTER

Practical Training At HINDUSTAN ZINC LIMITED ZINC SMELTER, DEBARI

UDAIPUR

Submitted to: Submitted By:

TRAINING INCHARGE GEETANJALI RATNU

HZL, Debari, Udaipur

ACKNOWLEDGEMENT

I wish to acknowledge the encouragement received from Prof. Pradeep Chhawcharia (Director Research & New Initiatives, Techno India NJR Institute of Technology, Udaipur), for initiating my interest in training. First of all its my privilege to acknowledge with gratitude Mr.Sonal Prabhakar (Head Human Resource and Development, Hindustan Zinc Limited) for his kind permission to undergo practical training in their esteemed organization.

I am also grateful to all the workers of various departments who have helped me to improve practical knowledge.

PREFACE

Practical training is a way to implement theoretical knowledge to practical use. To become a successful engineer it is necessary to have a sound practical knowledge because it is the only way by which one can acquire proficiency & skill to work successfully in different industries. It is proven fact that bookish knowledge is not sufficient because things are not as ideal in practical field as they should be.

Hindustan Zinc Ltd. is one of the best examples to understand the production process & productivity in particular of Zinc.

It is a matter of great pleasure that our college authorities have recommended a practical training of 30 days to supplement our theoretical knowledge acquired in the college.

This report is an attempt made to study the overall production system & related action of Zinc Smelter, Debari a unit a HZL. It is engaged in the production of high grade Zinc metal & other byproducts viz. Cd, Sulphuric acid etc. since 1968 adopting hydro metallurgical technology.

CONTENTS

1. 2. 3. 4. 5. 6. 7. 8. 9.

Acknowledgement Preface Certificate About HZL,Debari Project Profile How to use the Project Functions Description Program Coding Sample Outputs

ABOUT HZL ,DEBARI

Hindustan Zinc Limited was incorporated from the erstwhile Metal
Corporation of India on 10th January 1966 as a Public Sector Undertaking. In April 2002,

Sterlite Industries ( India ) Limited made an open offer for acquisition of shares of the
company consequent to the disinvestment of Government of Indias stake (26%) including management control to Sterlite and pursuant to the regulations of SEBI Regulations 1997 acquired additional 20% of shares from public. In August 2003, Sterlite Industries acquired additional shares to the extent of 18.92% of the paid up capital from Government of India (GOI). The Zinc business of Vedanta is managed within Hindustan Zinc Limited.

Hindustan Zinc Limited HZL is Indias only integrated zinc company,

operating from mine to finished metal and supplied around 73% of Indias zinc requirements in 2005-06. At the base of the company is the and consistently high grade ore.

Rampura Agucha mine with its low cost

Zinc smelter Debari, is a unit of HZL. It was started in 1968. It was the
first Zinc smelter of HZL. In this plant,zinc along with its products viz. Silver, Cadmium, Sulphuric acid etc. are produced from Zawar Mines and other mines of the company. Initially this Smelter started with 18,000 tonnes per annum capacity, but at present the capacity of plant is 49,000 tonnes per annum, the recovery of Zinc in this plant is 99.52%.

Zinc Smelter Debari is a Hydrometallurgucal zinc smelter situated at Debari, about 13 kms from Udaipur, in Rajasthan, India. The primary product of Debari is High Grade (HG) zinc and it also recovers cadmium as by-product

Zinc Smelter Debari employs state-of-the-art Roast Leach Electro-winning Technology at its Hydro metallurgical zinc smelter. The plant has three roasting facilities, one leaching and purification section, one electrolysis and one melting and casting sections. It produces extra calcine an intermediate product which is supplied to the rest of the Hydro metallurgical zinc smelters.

Zinc Smelter Debari also has 14.81 MW captive power plants (Diesel Generation units) to supply the power requirements for its metallurgical operations; it also sources additional power requirements from our captive thermal power plants located at Chanderiya and at Zawar. It also has 6.5 MW of power generation capacity from Waste Heat Recovery.

Certifications:

The management system of Zinc Smelter Debari comprises of: the Quality System ISO 9001:2008, the Environmental System ISO 14001:2004, Occupational Health Safety and Assessment Series OHSAS 18001:2007, Social Accountability SA 8000 - 2008; and is also a 5S Certified unit.

Processes: Roast Leach Electro-winning (RLE) process description:

The hydrometallurgical smelting process is a roast, leach and electro-winning(RLE) process. In this process zinc concentrate is first oxidized in the roaster and the gases generated are cleaned and sent to the sulphuric acid plant. The primary output from the roaster, called calcine, is sent to the leaching plant to produce a zinc sulphate solution that is then passed through a cold/hot purification process to produce purified zinc sulphate solution. The purified zinc solution then goes through an electrolysis process to produce zinc cathodes. Finally, the zinc cathodes are melted and cast into zinc ingots.

In HZL Various Departments (Plants) as under:

Roaster and Acid plant Leaching plant Zinc Electrolysis plant Zinc Dust plant Instrumentation plant Finance Department
Project Department

ROASTER AND ACID PLANT:-

The raw materials used for production of zinc is named blend which is prepared by the concentrate which comes from various mines. The main constitute present in the blend is ZnS. For the leaching of ZnS it is necessary to first convert it into oxide i.e. roasting of ZnS is done here at roaster.

LEACHING AND PURIFICATION:Leaching is a selective dissolution of ore minerals /oxide minerals in acid or solution of other reagents according to the condition adjusted in a manner to leave maximum gangue in the insoluble residue. Calcine comes into the hopper from roaster with the help of bucket elevators. The average rates of calcine consumption is 11MT/hr, whereas the rate of solution supply is 90 m3/hr;this corresponds to 140-150MT of Zinc ingots per day.

ZINC ELECTROLYSIS AND MELTING:Electrolysis of zinc sulphate solution take place in electrolysis cell with aluminium sheet as cathode and silver lead alloy as anode: The reaction can be represented as: At cathode (reduction) Zn2+ +2e-Zn At anode (oxidation) So42 +H2O H2So4 + 2e

Over all reaction 2ZnSO4 + 2H2O 2Zn + 2H2SO4 + O2

The zinc gets deposited on the Al cathode and is stripped after 24 hours of deposition whereas oxygen is given off at the anode. As SO42- ions have strong affinity for hydrogen ions this results in formation of sulphuric acid. The oxygen which

is liberated oxidizes the MnSO4 in solution to MnO2 which deposits as anode mud which is cleaned out periodically.

Solution cooling and storage:

Neutral electrolyte from purification shall be available at 60-70% as hot purification process has been adopted for expansion. The neutral solution is fed directly to atmospheric coolers where solution is cooled to 35oC, coolers have been provided for this circulating spent solution cooled in separate 5nos. coolers out of which normally three are in services and two are standby. Here temperature drop is from 42oC to 35o. Gypsum deposit take place in these coolers.

ELECTRICAL DEPARTMENT:-

Power situation in any industry is alarming. The gap between demand and supply keeps widening day by day. The energy SBU thus determines how each business unit or process consumes power. This helps to promote accountability, increase efficiency and productivity. Electrical energy acts as a raw material for industry. It implies energy saving through various ways after all energy saved is energy generated.

PRODUCTS:
Refined zinc metal is produced which is used in a number of applications including galvanising, oxides, die castings and alloys. They produce zinc in a variety of grades

Special High Grade (SHG) High Grade (HG)

Prime Western (PW)

Their Special High Grade zinc products are LME registered products under the brand names

HZL SHG 99.995 Vedanta SHG 99.995 Special high grade and high grade zinc are available in standard ingots of 25 kgs

and Jumbo ingots of 1,000 kgs each.. Prime Western is also available in the standard ingots form of 25 kgs. Over 11 million tonnes of zinc is produced annually worldwide. Around 48% of the amount is used for galvanizing to protect steel from corrosion. Approximately 17% is used the production of zinc base alloys like die castings etc. Nearly 10% of the zinc is also utilized for compounds such as zinc oxide and zinc sulphate and about 11% is used in the alloys especially brass.

Galvanising:

Zinc is one of the best forms of protection against corrosion and is used extensively in building, construction, infrastructure, household appliances, automobiles, steel furniture, and more. Galvanising accounts for around 48% of global zinc usage.

Zinc Oxide:
The most widely used zinc compound, zinc oxide is used in the vulcanisation of rubber, as well as in ceramics, paints, animal feed, pharmaceuticals, and several other products and processes. A special grade of zinc oxide has long been used in photocopiers. 10% of global zinc usage is in this segment.

Die Castings:
Zinc is an ideal material for die casting and is extensively used in hardware, electrical equipments, automotive and electronic components. 17% of zinc used in the word is through Die Castings.

Alloys:
Zinc is extensively used in making alloys, especially brass, which is an alloy of copper and zinc. Alloy accounts for around 11% of global zinc usage.

Rolled Zinc:
Zinc sheets are used extensively in the building industry for roofing, flashing and weathering applications. These are also used in graphic art to make plates and blocks, as well as battery callouts and coinage.

LEAD
They produce refined lead at our Chanderiya Smelting Complex, which is LME registered under the brand name of "Vedanta 99.99". Lead metal is used in a number of applications including battery segment, lead-based pigments, and cathode ray tubes. Our refined lead metal is available in standard 24 kgs ingots.

The battery sector is the single largest consumer of lead, accounting for around threequarters of the demand. It can be sub-divided into the following groups: SLI (Starting-Lighting-Ignition) batteries, which currently accounts for around half of the total lead demand. These are mainly used in cars and light vehicles, but are also found in other applications such as golf carts and boats. SLI battery demand in turn can be split into original equipment and replacement, with replacement demand outstripping original equipment demand by about 4:1 in mature markets. Industrial batteries, which currently consumes around a quarter of the total lead produced. This sector can be split roughly 50:50 into stationary and traction batteries. Stationary batteries are principally used in back up power supply systems; traction batteries are used for motive power in equipment such as forklift trucks and motorised wheelchairs. The remainder is used in non-battery applications. The second largest current end use of lead for non-battery applications, accounting for around 8% of lead consumption, is the chemical industry, in the form of lead-based pigments and other

compounds. Principal markets are for cathode ray tubes used in television screens and computer monitors, and for Poly Vinyl Chloride (PVC) stabilisers.

BYPRODUCTS
SILVER They are India's largest and one of the world's leading primary silver producer. We produce refined silver at Chanderiya Smelting Complex; it is recovered as a by-product of lead metal.

We produce high quality silver bullion having a minimum purity of 98.5% to 99.5% of silver; it is casted in the form of bricks weighing 30 kgs.

Silver is used in a number of varied applications like the most important uses of silver being the industrial and decorative uses, photography, and jewellery & silverware; together, these three categories represent more than 95 percent of annual silver consumption. Silver's unique properties restrict its substitution in most applications. Industrial applications: Brazing alloys, electrical contacts, high capacity silver-zinc or silvercadmium batteries, printed circuits and other electronic applications. Other applications: Silverware, jewellery, Silver plating, photography, Dental alloys and more

LEVEL RADAR

Level measurement
In continuous level measurement, the instantaneous level at a measuring point in a process vessel is detected and converted into an electronic signal. The level signal is either displayed directly on site or fed into a process control or management system. Liquids, pastes, powders and bulk solids are measured with this method. Typical applications for continuous level measurement are process tanks, storage tanks, silos or mobile containers in the process industry, such as the chemical and pharmaceutical industries, as well as in environmental engineering, water and sewage systems, power generation, metal production and offshore systems

Every industry places its own specific demands on measurement technology. VEGA offers many different physical measuring principles for level measurement. VEGA provides a continuous level sensor perfectly adapted to the properties of the medium as well as the individual process conditions at the measuring point.

METHODS OF MEASUREMENT
1.MEASUREMENT BY RADAR

The measuring instrument sends out short microwave pulses in the direction of the medium and thus measures the distance to the surface. The measurement is not affected by temperature, pressure or product properties.

Advantages:
This non-contact technology produces highly accurate measurements in storage tanks and some process vessels. Radar is an excellent, but fairly expensive technology (1k to 5k per measurement) for continuous level measurements. Several manufacturers have reduced the cost/price of the technology with various process radar

offerings. These systems do not have the accuracy (and associated cost) of radar used for inventory 2.GUIDED MICROWAVE

Microwave pulses are guided along a rod or cable probe and reflected by the product surface. The probe ensures that the signal reaches the medium undisturbed.

3.ULTRASONIC

This instrument emits ultrasonic pulses in the direction of the medium, which reflects them. The time required for the signals to get back to the sensor varies depending on the level. This is the ideal solution for simple standard applications. 4. CAPACITIVE The rod or cable probe and the vessel wall form the two electrodes of a condenser. When the level of the medium changes, the electrical capacitance between the electrodes also changes.

5. HYDROSTATIC

A measuring cell at the vessel bottom detects slight changes of the hydrostatic pressure which varies dependent on the level.

6. RADIATION BASED

The rays emitted by the gamma source are damped when penetrating the medium. A sensor on the opposite side of the vessel detects the radiation and calculates the measured value out of the radiation strength.

RADAR LEVEL MEASUREMENT

Areas of application
In almost every industrial process, the levels of liquids, muds, pastes, powders and bulk solids have to be measured continuously in tanks, silos, containers and pipelines. The requirements placed on the measuring instrument are as different as the types of products whose levels must be recorded, no matter whether its process water or sewage, food, lye or acid, oil, cement or mining debris. External influences, such as very low or high temperatures, under- or overpressure, vibration or abrasion, are also factors the respective measuring instruments have to cope with when measuring the filling level.

CONTACT RADAR (GWR)

Pulses of electromagnetic energy are emitted from the base of the transmitter down the wave guide. When the signal reaches a point down the wave guide where a change in dielectric constant occurs, usually the media surface, some of this signal is reflected back. The amount of signal reflection from the media is therefore proportional to the difference in dielectric constant between the waveguide and the media. Fundamentally medias with a higher dielectric / conductivity, provide stronger return signals, this however is true for all types of radar. The actual level measurement itself is a function of the time taken from when the electromagnetic signal is emitted to the time at which the resultant receive echo is received. As such this radar technology is often referred to as Time Domain Reflectometry or TDR radar. The propagation of the signal along a wave guide does eliminate false echoes and helps minimise signal loss due to vapours or dust, plus operation is possible in applications with changing vapour space humidity or fluctuating product dielectric constant. It should be noted though that like all radar gage types low dielectric materials, and low dielectric materials that stratify can be a cause for concern.

AIR BORNE RADAR:

It use microwave signals fired into the vapour space above the media, the return signal processing, manipulation and resultant distance calculation vary significantly. It can be broadly broken down into two distinct categories pulsed wave time of flight and frequency modulated continuous wave (FMCW).

FMCW
FMCW systems, continuously emit a swept frequency signal and distance is inferred from the difference in frequency between the transmit and receive signals at any point in time. This technique whilst providing an inferential measurement can be highly accurate and is in fact the only method that is suitable for the high accuracy demanded for tank gauging and custody transfer. In such applications gauges are required to accept temperature and pressure inputs for compensation The level of signal processing associated with FMCW radar gauges and the resultant power requirements means that two wire gauges of this type are suitable only for the simpler applications, with most applications being fulfilled by four wire devices. Essentially FMCW radar utilises a microwave frequency transmission sweep that changes within a specified time. This signal is transmitted toward the media, which produces an echo back toward the gauge. The return signal is then combined or subtracted from the outgoing signal at that instant resulting in a low frequency signal that is proportional to the distance between the gauge and the product surface. In the case of hydrocarbons, an accurate water bottom measurement must be made for precise inventory control. Typically, another technology, such as RF Admittance is used to make the interface measurement between water and hydrocarbons.

The FM-CW radar technique is an indirect method of level measurement. fd is proportional to which is proportional to distance = 2*R/C t t Where R is distance to media surface C is the speed of light

PULSE RADAR
These gauges work on a time-of-flight principle (transmission to reception) and in many respects are similar to ultrasonic level devices differing mainly in the use of a higher frequency electromagnetic signal. Level measurement is based on the time taken for a non continuous pulse to be transmitted to and reflected from the media surface with signals being evaluated by sampling and building up a historical profile of the echoes. As microwaves travel at the speed of light, the time taken for a signal to travel the distances involved in most applications is measured in nanoseconds.

Due to the difficulties associated with making accurate measurements over these short time periods various methods exist and are combined to provide successful measurement. These include regimented progressive sampling, which effectively provides a slow motion expanded snap shot of the actual echo, and the use of a reference signal for cross correlation when sampling the send and return signals.

Pulse radar in particular can encounter difficulties when the media is in close proximity to the antenna because the time difference between send and return signals is too fast to measure accurately. ABLE can provide a number of alternatives for these type of applications including gauges with differing frequencies or antenna types, whilst for really small spans close to the gauge, technology such as RF Admittance should be considered. Pulse radar operated purely within the time domain. Millions of pulses are transmitted every second and a special sampling technique is used to produce a time expanded output signal

Antenna Types
Antennas are available in a multitude of different configurations and sizes, and correct selection plays an important role in ensuring that the maximum amount of signal is launched at, and echoed from the media surface. In general terms it can be stated that a larger antenna results in a larger return echo being received at the gauge. Antenna types can be broken down into five main categories; the parabolic antenna, the cone or horn, the rod, isolation windowed or flush mount and the planar. Each antenna type emits microwave energy in a characteristic footprint which must also be considered during gauge specification.

Cone Antennas:
Cone antennas are the most commonly deployed of all radar gauge antennas due to their modest size (when compared to parabolic gauges), ability to fit on flanges as small as 2, reasonable signal propagation and reception capabilities. Whilst cone antennas are widespread and suitable for a large cross section of applications this is partly because of the variety of configurations that have been developed to meet the demands of the individual applications. Common examples include extended wave

guides for high temperature applications or where entry to the vessel is available from the side only. For dirty and dusty environments such as reactor vessels variants are available with purging connections to allow the antenna to be periodically cleaned without necessitating gauge removal. In addition cone antennas are often used in conjunction with still pipes (wave guides), particularly for floating roof tank applications such as LPG and LNG. Here a number of reference pins may be added to the still pipe design to allow verification of the gauge without removal. Rod antennas tend to be used in the simplest of applications or where vessel entry is restricted. Unlike the other antenna types, rod antennas are available on a screw thread and in a number of differing designs to suit the individual requirements of an application. In general rod antennas offer the least focused microwave beam of all the antennas, this limits their applicability. When specifying this type of antenna ABLE consider the associated signal dispersion in conjunction with frequency to be used and the vessel conditions, before making a recommendation.

Window Antenna
Another antenna style available is the windowed antenna, which although basically a horn antenna with a low dielectric process window separating the gauge and the process, has become recognised as an antenna in its own right due to its wide spread use. Windowed gauges are predominantly utilised in applications where the gauge needs to be protected from the conditions within the vessel or where coating of the antenna may be a problem. These are available with an angled surface to help disperse any condensation on the window, again this is application dependant. Like wave guides or still pipes these should only ever be considered as a potential solution where the product to be measured has a high enough dielectric constant.

The parabolic and planar type antennas:

The parabolic and planar type antennas are used predominantly in high accuracy applications for instance where fiscal accuracies are required and as such are a common feature on tank farms. These antennas are relatively bulky and as standard are supplied on flanges of 6 or above, although specials are available. Due to their physical size these gauges often require installation via a man way. The parabolic

antenna results in a highly focused signal that is characterized by the large return signal present where installed successfully. This in part also contributes to their high sensitivity which is perfect for the slow moving tanks associated with fiscal gauging, but not always suitable for smaller process vessels.

INTERNAL STRUCTURE
Objects such as agitators and mixers provide a source for false echos. Whilst the selection of the best fit radar frequency and antennas may help in the focusing of the microwave beam to avoid a disturbing echo the presence of an unwanted return signal is often unavoidable. ABLE available for disturbance echo handling which may be applied during commissioning and throughout gauge operation. Initially software will be used to determine the best possible orientation and, where possible, location for the gauge. Strong false echoes can thus be minimised. Once physical installation is completed, software can be programmed to ignore unwanted echoes from any internal structures whether fixed, or mobile as is the case with mixers.

Radar Level Transmitters

Introduction
1. Radar technology is mainly put into use for detection of level in continuous level

measurement applications. Radar level transmitters provide non contact type of level measurement in case of liquids in a metal tank. They make use of EM i.e. electromagnetic waves usually in the microwave X-band range which is near about 10 GHz. Hence, they can be also known as microwave level measurement devices. However there are some differences between radar and microwave types.

Types of Radar Level Measurement Systems

Noninvasive Systems
Two types of noninvasive systems exist. One is the frequency-modulated continuous wave i.e. FMCW technology and the other one is Pulsed radar technology.

FMCW systems From an electronic module on top of the tank, a sensor oscillator sends down a linear frequency sweep, at a fixed bandwidth and sweep time. The reflected radar signal is delayed in proportion to the distance to the level surface. Its frequency is different from that of the transmitted signal, and the two signals blend into a new frequency proportional to distance. This new frequency can then be used for accurate determination of fluid level. The major benefit of employing FMCW technique for level measurement in a tank is that the signals transmitted are frequency modulated i.e. FM instead of amplitude modulated i.e. AM signals. Now, the major part of noise in a tank falls in the AM range which does not influence the FM signals. Hence, FMCW happens to be the only system which can be suitably used for meeting high accuracy requirements of tank gauging. Pulsed radar systems

Radar antennas employed for noninvasive measurement systems are available in following two major designs: 1. 2. Parabolic dish antenna Cone antenna

Invasive Systems The invasive method used for liquid level measurement is called Guided-wave radar i.e. GWR method. In this method, a cable or rod is employed which act as a wave guide and directs the microwave from the sensor to the surface of material in the tank and then straight to its bottom. The basis for GWR is time-domain reflectometry (TDR), which has been used for years to locate breaks in long lengths of cable that are underground or in building walls. A TDR generator develops more than 200,000 pulses of electromagnetic energy that travel down the waveguide and back. The dielectric constant of the process material will cause variation in impedance and reflects the wave back to the radar. Time taken by the pulses to go down and reflect back is determined to measure level of the fluid. In this method, the degradation of the signal in use is very less since the waveguide offers extremely efficient course for signal travel. Hence, level measurement in case of materials having very low dielectric constant can be done effectively. Also in this invasive measurement method, pulses are directed via a guide; hence factors like

surface turbulence, foams, vapours or tank obstructions do not influence the measurement. Through-air Radar Systems Non-invasive systems of measurement are basically known as the throughair radar systems. They usually employ a horn antenna or a rod antenna for sending microwave beams onto the surface of the liquid being measured. These antennas mounted at the top of the tank then receive the reflected microwave signal back from the fluid surface. A timing circuit is incorporated in the systems which measures the time of flight and hence the distance between the antenna and the fluid level is determined. These systems can pose measurement problems if the dielectric constant of the fluid being measured is very low. The reason is that the amount of reflected energy at microwave (radar) frequencies is dependent on the dielectric constant i.e. r of the fluid, and if r is low, most of the radar's energy enters or passes through. Water ( r = 80) produces an excellent reflection at the change or discontinuity in r..

Guided Wave Radar v/s Through-air Radar

To overcome the measurement problems faced by through-air radar systems, guided wave radar systems are generally employed since they offer air radar systems:As with through-air radar, a change from a lower to a higher r causes the reflectionThese systems offer and efficient and clear path for signal travel.

The performance of GWR systems is not disturbed by vapours, foams, high These systems can operate in vacuum too without requiring any recalibration. Beam divergence issues and false echoes resulting from tank walls and

temperature or pressure conditions.

obstructions are not present in these guided wave radar systems.

In case of pulse radar, one usually faces problem in getting accurate

measurement results if the fluid being measured is very near to the radar antenna.