project report - COMPLETE

I
Annexure A
PRODUCTIVITY AND QUALITY IMPROVEMENT IN
7-SERIES GRADES
BITS ZG629T: Dissertation
By
AMIT KUMAR VERMA
ID NO: 2011HZ79637
Dissertation work carried out at
M/s Hi-Tech Carbon (Birla Carbon)
(Aditya Birla Group)
Renukoot, Distt Sonebhadra, UP (INDIA)
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE
PILANI (RAJASTHAN)
November 2013

II
Annexure B
PRODUCTIVITY AND QUALITY IMPROVEMENT IN
7-SERIES GRADES
BITS ZG629T: Dissertation
By
AMIT KUMAR VERMA
ID NO: 2011HZ79637
Dissertation work carried out at
Submitted in partial fulfillment of M.S.Manufacturing Management degree
programme
Under the Supervision of
R.K.RAGHUVANSHI (AGM-Production & Utility)
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE
PILANI (RAJASTHAN)
November, 2013

V
ABSTRACT
This project is related to innovation & break through step which has been carried out by student of this
dissertation who is the Employee of M/s Hitech carbon (Birla Carbon) Renukoot, (located in the
District of Sonebhadra,UP) under the Guidance of Mr R.K.RAGHUVANSHI who is supervisor of this
project. Objective of this study is to reduce the grit level of 7-series grade by application of systematic
approach of quality improvement. By performing systematic analysis of problem and implementing the
best possible solution we able to meet out our customer requirement and also retained our company
image as well.
In India, only Renukoot is producing this grade among the all three unit of Birla carbon in India, We
producing this grade since year 2000 for non-tyre segment only where the grit range was acceptable up
to 900 ppm.In January 2013, suddenly the demand came for Tyre-segment also for low grit 7-series
production i.e. 500 ppm max while our process capability was 700 to 800 ppm only. So this becomes
the challenge for Renukoot team because we had various problems in 7-series grades production, Like-
frequent coke formation, high cost, short run hrs, high grit and low photo.
By review of each and every process condition step by step, work out the probable and vital causes of
coke formation in Rx, made some new action plan and SOP. And by this way, we started closely
monitor the flame pattern, vertex formation and oil atomization pattern in Rx. Beside this, based on
pareto analysis, we found that our conventional “jacket position set up for production of 774”, which
was @ -250 mm distance from flush point of ring (ring which is located in combustion chamber)
creating big hindrance for proper oil atomization. Then we decide to change the jacket position and to
take the trial at new setup of Rx.
The first trial taken with jacket position @+50 mm and found that there is drastic change in product
quality. Grit level comes down in the range of 300 to 400 PPM from 800 PPM.After getting this result it
has been decided to take some more trial with same jacket position. Then we have taken 7-8 run and it is
the beauty of success that Renukoot plant able to achieve almost same range of grit level in “all runs”
without any coke flushing in Rxs.Finally we able to meet out our customer requirement and also
retained our company image as well.

VI
ACKNOWLEDGEMENT
First I offer my sincerest gratitude to my Supervisor Mr. R.K.RAGHUVANSHI
(AGM-Production & Utility), Hi-Tech Carbon, Renukoot, who has not only given me
an opportunity to carry out this project but also extended the support throughout
my thesis work and allowing me the suitable time to work on this project. I
attribute the level of my Masters degree to his encouragement and effort and
without him this thesis, possibly could not be completed. I also like to thanks
Project Guide Prof. BK Rout (Faculty of BITS Pilani) and Dr S.Ganguly (AGM-
Quality control & ware house), Hi-Tech Carbon, Renukoot, for time to time
guidance and support.
Finally, I would like to thanks all team of production dept and Quality control for
supporting me throughout the study and analysis related to quality improvement
of 7-Series grade.
Date : 31.10.2013 AMIT KUMAR VERMA
Place : Renukoot

VIII
TABLE OF CONTENTS
Ch
no DESCRIPTION
Page
no
1 Introduction 1-7
1.1- Introduction of the organization 2
1.2- Product Introduction (CARBON BLACK) 2
1.3- Classification of Carbon Black 3
1.4- Physico-chemical properties of carbon black 5
2 PROCESS DESCRIPTION 8-11
3 Objective, Scope and background the project 12-16
3.1- Objective 12
3.2- Scope of the work/project 12
3.4- Back ground of 7-series (N774/762) Grades 13
3.5- Key focused area 15
3.6- Methodology, Activity schedule and result target 15
4 Defining of problem and Data collection 17-21
4.1- Defining of problem 17
4.2- Quality performance before modification (Data collection) 19
5 Problem analysis and Root cause identification 22-25
5.1- Identification of causes 22
5.2- validation of causes 24
5.3- Root cause identification 25
6 Exploring of alternate solution 26-28
6.1- Analysis of Reactor flame and condition 26
6.2- Action plan made for execution of trial run 26
6.3- Execution of trial run 27
6.4-Result after implementation of solution 28
7 Regular implementation 29-32
7.1- Data collection after modification 29
7.2- Graphical presentation of Before-After performance 30
8 Productivity improvement and savings 33-35
8.1- Productivity improvement 33
8.2- Productivity gain 33
8.3- Saving in Auxiliary fuel oil 34
8.4- Other Tangible/Intangible benefits 34

IX
9 Standard operating procedure (after implementation of solution) 35
10 Conclusion and Summary of the project 36-38
10.1- Conclusion 36
10.2- Summary 37
10.3- Scope for future work 37
11 References 39
Check list 40
LIST OF FIGURE
Fig
no DESCRIPTION
Page
no
1 Plant overview 2
2 Carbon Black 4
3 Structure of Carbon Black 4
4 Mechanism of Carbon Black formation 7
5 Process flow sheet 8
6 Background: Low grit N774 13
7 Defining of problem 17
8 Average grit (Before modification) 20
9 Average CpK (Before modification) 20
10 Why-Why analysis 22
11 Causes analysis by pareto diagram 25
12 Reactor picture 29
13 Graphical presentation of Before-After performance 30
14 Performance Comparison for grit level 31
15 Reactor peabody setting: Before-After (Cross sectional view) 31
16 Reactor peabody setting: Before-After 32

X
LIST OF TABLES
Table no DESCRIPTION Page no
1 Background: Activities carried out 15
2 Action plan: Activity Schedule 16
3 Oil Quality 18
4 Quality Parameter of Product before modification 19
5 Data collection-Before 21
6 Root cause identification 25
7 Result after implementation of solution 28
8 Data collection after modification 29
9 Change in operating parameters (Before-After) 32

1
1 Introduction
Globalization and liberalization of Indian economy have led to Indian industries
to a highly competitive environment in the global market. The expectations of
customers are quite high and choices are wide. Indian industries especially
manufacturing industries are facing challenges in competing with the
multinationals due to dumping of material and opening of facilities in India. As
many foreign companies are setting up their base in India, suppliers to these
multinationals have to meet their high procurement standard on quality without
any compromise and hence in this way the Indian manufacturing industries are
always in pressure to improve the product quality, reduce cost and to make
customer delight. To survive in this highly competitive & customer oriented
market, manufacturers should consider the following activities-
Offer their products with distinct features and services
Tracking & satisfy the changing taste of the customers
Reach the market in time
Be economical
The above activities lead to transform the Industry by
Cost reduction
Quality Enhancement
Elimination of NVA (non value added activity)
Productivity enhancement
Delivery enhancement

2
1.1- Introduction of the organization
M/s Hitech Carbon, Renukoot (An Aditya Birla Group company)firmly known as “BIRLA CARBON”
as its Brand name, located in Sonebhadra Distt of Uttar Pradesh (INDIA), commenced operation in
1988, is a pioneer in the Carbon black industry. Present capacity of plant is 61,200 MT/Anuum.Capacity
of plant strategically increased by phase wise expansion from initial capacity of 20,000 MT/Annum at
inception. Birla Carbon is the world’s largest producer of carbon black with total 17 plants across the
world. The Unit is certified by BSI Management Systems India for the quality systems-TS16949:2009,
ISO14001:2004, OHSAS18001:2007, ISO27001:2005 & SA 8000:2008.The quality control laboratory
of the company is also accredited for ISO17025:2005 certification by National Accreditation Board of
Laboratories (NABL), Govt. of India for its carbon black testing facilities.
Fig no-1 PLANT OVERVIEW
1.2- Product Introduction (CARBON BLACK)
Carbon black is used as filler in rubber compound for making the tyre. Besides
giving the various physico-chemical properties Carbon black provide the
reinforcing ability to rubber compound and hence life of tyre increased
significantly. Apart from wide consumption in Automotive Industry, Carbon black
also used in other industries like- Paint, pigment, specialty and fine chemical
industries. At Renukoot, beside various ASTM grades, Carbon black is also
produced as customized grade based on specific customer requirement. Carbon

3
black being produced by thermal cracking of highly aromatic feed-stock (known as
conversion oil and it is the key raw material for production of carbon black) at high
temp and pressure in specially designed Reactors (Refractory lined, long tubular
reactor).
1.3- Classification of Carbon Black
Major classification of Carbon Black as Hard Black and Soft Black (also known as
Trade and Carcass respectively). For producing both kinds of blacks, two different
kinds of reactors are used. In Soft Black Reactors the heat required is supplied by
partial burning of CBFS while in case of Hard Black heat is supplied by complete
combustion of auxiliary fuel oil and partial burning of CBFS. Hard Black grade
particles are finer and gives higher abrasion resistance where as soft black grades
are coarser and exhibits better flexibility.
Common Hard Black grades:-
N110/115, N220, N234, N231, N326, N330, N347/N339, N375
All these grades of Carbon Black are used in the treads of tyres as these are highly
abrasion resistant.
Common Soft Black grades: -
N550, N650, N660, N774/N762 (7-SERIES)
All these grads are general purpose or fast extruding Carbon Blacks and find their
use in the side walls of tyres and in the manufacture of tubes also.
First digit of the number denotes particle size. For example, N774 grade Carbon
Black particle diameter around 70 NM i.e. 70x10-9
M/s Hitech Carbon, Renukoot is producing more than 18 ASTM grades. Name of the some key grades
are N115/N220/N234/N330/N550/N660/N774 etc

4
Fig no-2 Carbon Black
Fig no-3 Structure of Carbon Black

5
1.4- Physico-chemical properties of carbon black
hysical and Chemical Properties
Primary Particle Size Arithmetic mean diameter calculated
by electron microscope.
Nitrogen Absorption Surface Area
Specific area characteristics
calculated by using low-temperature
nitrogen absorption method.
Generally, the larger the value, the
smaller the particle size.
Tinting Strength
Carbon black is milled together with
zinc oxide to make a paste, the color
of which is compared with a
standard specimen.
Using and absorpometer, the
amount of oil (DBP) absorbed per
100g is measured when DBP is
added to carbon black.Oil Absorption
The higher the structure, the higher
the value.
Volatile Content
Percent by weight which is reduced
when carbon black is heated to
950°C for 7 minutes. The more the
surface functional groups, the larger
the value.
pH Value
Value measured with glass electrode
pH meter when carbon black is
mixed with distilled water.
Ash Content
Remaining percentage by weight
when carbon black is burned at
750°C.
Surface Area
Very important in carbon black because it defines how much surface is available
for interactions with other materials present in a rubber compound. Small particle-
size black will have higher surface area, but the texture or nature of the surface
area can also influence the surface area.
BET method (ASTM D3037) being used to determine surface area of particles.
Adsorption of a gas, usually nitrogen, on the surface. Surface area can be

6
measured from electron micrographs also. Specialty furnace blacks require a
devolatilization step to remove residual oils present on the surface of the blacks.
Volume of void space between aggregates per unit weight of carbon black
increases with the number of particles per aggregate. Average particle size can be
estimated from statistical equations that relate tint strength and structure to
particle size as measured from electron micrographs.
Chemical Properties
Chemical nature of a carbon black is variable. Evidence for the presence on the
surface of at least four oxygen containing groups, carboxyl, phenol, quinone, and
lactone. Chemical surface groups affect the rate of cure with many vulcanization
systems. Physical adsorption activity of the filler surface is of much greater overall
importance for the mechanical properties of the general-purpose rubbers than the
chemical nature. Oxygen content influences the cure rate. Increased oxygen gives
longer scorch period, a slower rate of cure, and a lower modulus at optimum cure.
Amount of oxidation during the pellet drying operation can affect the cure rate and
modulus of rubber compounds. Carbon blacks are generally electrically conductive
because of the highly conjugated bonding scheme in crystalline regions.

7
Fig no-4 Mechanism of Carbon Black formation
Mechanism of Carbon Black formation in Reactor
Thermal Cracking of
CBFS
(In the stream of high temp
& high Velocity hot gases)
Carbon-Hydrogen gets
decomposed
Carbon atom gets released
(Also called tiny particle)
(size 1-2nm) (A0)
Primary Particle formed
(Also called CB particle)
(size 10-100nm)(A0-nm)
Primary Particle Fused together
(with the help of K+ ion and hence
Aggregation started)
Carbon Black Aggregates
formed
(Also called CB Structure)
Structure became stable after application of
quench
Agglomeration started
(Size 500-1000nm) (micron-mm)
Carbon black in pallet form
(Size 0.5mm-1.5 mm)

8
2 PROCESS DISCRIPTION
In carbon black manufacturing process following are the key sections:
• Feedstock storage and pumping
• Reactor Section
• Bag Filter Section
• Pelletisation and drying Section
• Purge gas filter Section
• Conveying and Storage Section
• Packing and dispatch Section
Fig no-5 PROCESS FLOW SHEET
REACTOR MBF MICRO PCB
CYCLONE
TANK
CYCLONE
R / V
SURGE
TANK
WET MIXER
R / V
WET MIXER
SCREW
FEEDER
DRYER
BUCKET
ELEVATOR
CONVEYER SILOPGF
PGB
PACKING

9
A brief description of each section is given to understand the process-
Feedstock storage and pumping:
Carbon Black feedstock and auxiliary fuel received from the refineries are
unloaded in the storage tanks separately. Since the feedstock is quite viscous in
nature, special type of pumps and steam heating of the fluid is required for ease of
handling and pumping. Temperature of storage tanks maintained at about 60 - 80
°C temp. In the tank through external steam heating through steam coil.
Feedstock and auxiliary fuel supplied to the plant at high pressure of 25 - 30 kg/
cm² through pumps suitable for handling high viscosity fluids. The feedstock is
filtered through a fine mesh strainer/ filters to remove extraneous materials before
injecting to Reactors. Feedstock header pressure is maintained by automatic
controls by means of suitable control valves and controlling stations.
Reactor Section:
Since various types of Carbon Black can be produced by FURNACE BLACK
PROCESS under varying reaction conditions, two different designs of reactors are
employed for manufacturing of all grades of CB which are required by rubber,
plastic and pigment Industries. Preheated feedstock at about 170 - 240°C is finally
atomized and sprayed inside the reactor through specially designed nozzles made
of special material and water cooled guns. The reaction chamber which is lined
with high temperature chrome - alumina refractory is at a temp. Of approx. 1500 -
1900°C.
Partial burning of feedstock in case of SB Reactors, in presence of Air inside the
reactor raise the temperature about 1500°C and provide the endothermic heat for
thermal cracking reaction. The reaction products moving at very high velocities
are quenched with water sprays at predetermined locations inside the reactor to
about 700- 950°C. Sufficient length of refractory lined tunnel downstream of the
reactors is provided for complete vaporization of quench water. Energy from this
hot stream is recovered by heat transfer from product gasses laden with Carbon
Black particles to Cold air in a specially designed Air Preheater. The hot air at 650
- 800°C is used in the reactor thereby making substantial savings in the fuel

10
requirements in the reactor operation (Reactor is hereafter denoted as
Rx).Feedstock oil passed through the heat exchanger known as oil pre heater for
raising its temperature in the range of 170- 240 °C for better atomization of
feedstock and hence increasing the process efficiency and reduction in grit level
also. Product gases laden with Carbon Black particles ( now here after referred as
smoke) are cooled down to 280 - 290°C in a stainless steel quench tower and they
enter the MBF (Main bag filter) section for separation of Carbon Black from smoke
( a mixture of CO, CO2, CH4,C2H2,N2,H2, Air and water vapours).
Main Bag Filter Section:
Bag filter house is a large rectangular house having 7 compartments and a
hopper. Each compartment has 492 bags made of graphite + silicon treated fiber
glass bags. The bags have only bottom opening and are fixed securely to the
bottom thimbles and the top closed ends are secured to the hangers.
Smoke coming from reactor section at 270 - 290°C enters through the bottom of
bags and CB particles are deposited inside the bags. Clean gas filters off and goes
to "off gas header”. Cleaning of filter bag is done by reverse flow technique in
which each compartment is subjected to reverse flow of clean off gas through the
bags causing the deposited CB particles inside the filter bags to drop down into the
hopper. The reverse flow of off gas is achieved by sucking off gas from off gas
header and charging into each compartment by a repressure blower installed on
the ground. To keep the filter bags clean in all the compartment and continuous
separation and collection of Carbon Black, the reverse flow cleaning of each
compartment is done at regular intervals. The opening / closing of valves in each
compartment are regulated by a timer and through automatic control systems for
efficient utilization of bag filters.
CB material collected in the hopper section of bag filter is recovered through a
pneumatic blower and cyclone system to a surge tank (fluppy carbon holding tank)
for pelletizing and drying section. Before conveying, the material passes through
a Micropulverizer which crushes some hard carbonaceous particles and lumps. Off
gases collected in the off gas header are sent to pelleting and drying section and

11
energy conservation section for their 100 % utilization and thus eliminate the risk
of Atmospheric pollution.
Pelletizing and Drying section:
Carbon Black material collected in a large surge tank is sent to a pelletiser at a
constant rate through rotary valve to a pelletiser where it is mixed with water and
molasses solution to form wet pellets. Specially designed pelletiser is equipped
with a rotating shaft fixed with sharp edge pins in a double helix configuration. The
close gap between the pins and the inner smooth surface of pelletiser
accompanied by the conveying and rotating action of pins converts the mixture of
floppy CB powder and water into wet and strong spherical pellets. These wet
pellets are fed into a long rotary dryer through a dryer feeder. Pellets are dried
inside the hot rotating dryer by slow tumbling and falling action without damaging
the pellets. Dryer shell is enclosed in a refractory lined box all along its length and
the heat is supplied by burning of off gases received from the MBF section in a
specially designed refractory lined combustor furnace. Dry pellets with moisture
less than 0.5 % exit at the other end of the dryer for storage in the silos.
Purge gas filter section:
Water evaporated due to drying of wet pellets in the dryer along with some fines
material is removed by a purge gas blower at the feed end of the dryer. These
dust & moisture loaded hot gases are sent through a cylindrical bag filter house
called purge gas filter to remove and collect the CB particles and let out into the
atmosphere very clean, purge gases. Carbon Black collected in the conical hopper
is fed to the surge tank through a rotary valve and no carbon black loss is there in
the drying operation.
Conveying and storage section:
Dried pellets coming out at the exit end of the dryer are fed into a bucket elevator,
made of SS buckets to carry the material to the top of the silos. There are
numbers of silo to store the various grades of products.
Packing & Dispatch section: Material stored in the silos is packed through an
automatic packing machine. Packed bags are stacked on steel pellets for storage
and subsequent dispatch materials in truck to the consumers.

12
3 Objective, Scope and background the project
3.1- Objective
The objective of this project is to meet out the customer requirement in terms of
low grit, Productivity enhancement and reduction in cost of production by
elimination of NVA (non-value added activities), with the help of following measure
Detail analysis of problem
Probable and root cause identification
Finding out of solutions
To make the customized action plan to eliminate coke flushing activity
Tracking of desired quality parameters of feed stock
To make the customized SOP based on performance
3.2- Scope of the work/project
One of our key & valuable customer (name is not disclosed) beside other
customers, we have very stringent quality spec mainly sieve residue- less than
500 ppm (0.0500 in #325 mesh size with 100 gm sample).Since a long time we
are facing frequent coke formation problem in Rx during the N774/762 production
(Coke is undesired carboneous material formed inside the Rx which is the result of
un-decomposed oil droplet due to poor atomization and hence grit level increases
as impurity in finished product) and we need to do the coke flushing in both Rxs
(Unit has two nos of Soft black Rxs) at least once in each 24 hrs run result in high
off spec, quality variation and low CpK mainly in grit and Iodine/DBP beside other
tangible-intangible losses like-productivity loss and unwanted fuel oil consumption
etc due to frequent Rx inert(term “Rx Inert ” is referred as Rx is not under
production and only auxiliary fuel is being used in place of conv oil).For grade
N774 we are able to produce only about 20 % of total production volume in each
run for our said specific customer which meeting the sieve residue- less than 500
ppm and hence it is the big challenge for Hitech Carbon Renukoot to maximize the
production of low girt N774.Concerend student has taken this challenge as scope

13
and opportunity for taking this problem as a project for Quality & productivity
improvement.
3.4- Background of 7-series (N774/762) Grades
In 7 series grade N774 is one of most valuable product because only Hi-Tech
carbon, Renukoot is producing this grade among the all three unit of Birla carbon
in India. Though competitors In India are producing this grade but they are
producing with jumbo Rx only but Renukoot unit do not have jumbo Rx.N774 is
one of the typical grade in carcass black due to low iodine no, low photolemtric
value and high grit formation problem (Iodine no. is one of the key quality
parameters of carbon black denoting surface area while photolemtric value
indicating presence of un-decomposed oil in carbon black) and grit level (sieve
residue) is impurity which are present in traces amount in the finished product and
it is undesirable as it affecting end product by various ways. Minimization of grit
level in finished product is one of the key indicators for sound process operation
and performance of the Rx also.
BACKGROUND : LOW GRIT N774
GRIT @ 325 MESH
P
P
M
CHALLENGES
•NEW TYRE APPROVAL CAME IN FEB
2013 (<500 PPM GRT)
•RKT IS THE ONLY ERSTWHILE BC
PLANT PRODUCING N774 IN INDIA
•PROCESS CAPABILITY WAS FOR NON
TYRE (>500 PPM GRT)
•ONLY 15-20% OUT PUT < 500 PPM :
MEETING NEW APPROVAL
•FREQUENT COKE FORMATION
•FREQUENT INERT : HIGH COST
•SMALLER RUN 12-16 HRS : MAX 40 MT
IN EVERY RUN
•BULK SUPPLY OF LOWER GRIT
MATERIAL TO NEW CUSTOMER?
Fig no-6 Background: Low grit N774

14
At Renukoot plant N774 being produce since year 1996 for non-tyre segment only
where the grit range (average total grit level in 325 mesh size) was acceptable up
to 1000 ppm .In January 2013, suddenly the demand came for Tyre-segment also
for low grit 774 i.e. 500 ppm max while process capability of HTC-R was 700 to
800 ppm only. So this becomes the challenge for Renukoot team because of
various problems in 774 production like- frequent coke formation, high cost, short
run hrs, high grit and low photo. Coke is undesired carboneous material formed
inside the Rx which is the result of un-decomposed oil droplet due to poor
atomization and hence grit level increases as impurity in finished product) and we
need to do the coke flushing in both Rxs (Unit has two nos of Soft black Rxs) at
least once in each 24 hrs run result in high off spec, quality variation and low CpK
mainly in grit and Iodine/DBP beside other tangible-intangible losses like-
productivity loss and unwanted fuel oil consumption etc due to frequent Rx
inert(term “Rx Inert ” is referred as Rx is not under production and only auxiliary
fuel is being used in place of conv oil).For grade N774 we are able to produce only
about 20 % of total production volume in each run for our new customer of tyre
segment which meeting the sieve residue- less than 500 ppm.
3.4.1-Various activities carried out to reduce grit level
Before taking this problem as project by the student of this Dissertation, various
effort and activities has been carried out by Renukoot team which is listed in
bellow mentioned table. Though the reduction in grit level observed but it was not
consistently in the range

15
Table no-1 Background: Activities carried out
Background-Activities carried out
PARAMETERS ACTION RESULT
FEED STOCK Changed the Oil Blend of CBFS: FO from
20:80 to 10:90
Marginal
improvement
BLEND
PREPARATION
Increased Blend Circulation time from 2
days to 4 days
Marginal
improvement
CLEANED OIL Used Centrifuge Showed
improvement, no
consistency
INCREASED
ATOMIZATION
PRESSURE
Increased Atomizing steam Pressure from
20 – 22kg/cm2g
Marginal
improvement
AIR TEMP Reduced Air Temperature up to 350 deg C Marginal
improvement
NEW NOZZLE Used TCB Nozzle No Change
STEAM FLOW Increased Steam Flow through by pass Line Marginal
improvement
Chronic problem taken as project
Student of this course has taken initiative to take this project and to fix the target
for at least 60% volume to produce N774 grade with grit level less than 500 ppm
in 325 mesh.
3.5- Key focused area
To bring down the sieve residue below 500 ppm
To maximize low grit production volume up to 70% in every run.
To meet the internal & external customer requirements in time.
3.6- Methodology, Activity schedule and result target
A- Techniques & Methodologies:
Data collection and compilation.
Feasibility study

16
Studying the present system being followed
Exploring the alternative ways of Rx setup & operating condition
Project Proposal preparation and approval for implementation
Action plan/Process parameters/Feed stock Quality
Work force /Investment (If any)
B-Action plan: Activity Schedule Table no-2
C- Result Target:
5% increase of productivity in N774 by reducing Rx inert hrs for coke flush.
Up to 75% reduction of fuel consumption in N774 due to coke flushing
Production of more than 70 % low grit material in each run to cater specific
customer requirement.
50% reduction of non-value added activities (Reprocessing of non-
conformance product).
Target to improve product CpK of key quality parameters
(Iodine/DBP/Grit/Photo) by two fold.
1-15 16-31 1-15 16-28 1-15 16-31 1-10 10-20
1 Data Collection
2 Feasibility Study
3
Explore the alternative
Solution
4
Develop the new
process
5
Evaluation &
Implementation
Sl. No Activity
Aug-13 Sept-13 Oct-13 Nov-13

17
4 Defining of problem and Data collection
4.1- DEFINING OF PROBLEM
Fig no-7 DEFINING OF PROBLEM
4.1.1- Data Collection (Before solving the problem)
In the way of data Collection first need to take the parameter at different stage of
process like Raw material Quality (conversion oil), Reactor Condition (Jacket
setup, flame condition), and Operating Parameter etc.
Current Scenario
Oil Temperature in Tank – 55-60 deg C
START
Change Peabody gun,
nozzle & fire the reactor
On smoke the reactor at 600 deg
smoke to APH
Is test
result
OK?
Take carbon sample from
dryer end & send for testing
Is test
result
OK?
Divert material to on
spec silo
END
YES
NO
YES
NO
Is grit in
permissible
limit?
NO
YES
Change jacket position as per
requirement & check alignment
Maintain input parameters
(oil, air, additive etc.)
Take carbon sample from
reactors & send it for testing
PROBLEM
AREA

18
4.1.2- Oil Quality
Table No. 3 (Oil Quality)
Parameter Range
Blend oil ratio
80% FO (furnace oil) & 20% CBFS
(Carbon black feed stock-Imported)
Sp Gravity @
(15.56 deg C) 1.0182-1.0184
Viscosity 93-98
BMCI 90-95
API 5.0 to 6.0
Moisture 0.5-0.7
4.1.3- Reactor Setup
Jacket Position- -225 mm (minus Distance from Ring)
Atomization Media- Steam or compressed Air (Pressure 12.0 kg/cm2,
Temperature 50-60 deg C)
Quench Water Gun Position- Co-current/counter current of Stream Flow
Operating Parameter
Oil Temperature 160-175 deg C
Reactor Inlet Air Temp 480-510 deg C
Flow of Atomization Media (steam/Air) 150 kg/hr
Quantity of Additive (KNO3) used as per requirement
(Additive is a potassium compound solution with water of Sp. gravity 1.10, which
used in reactor to maintain the desired structure of carbon black)

19
4.2- Quality performance before modification (Data collection)
To analyze quality parameter, data has been collected for 3 month of various run-
Table No. 4 (Quality Parameter of Product before modification)
Avg. Oil
ratio
Avg. Grit Level at Diff.
Mesh Size
CpK
Lot No.
Rx
A Rx B
#325 #100 #35 Iodine DBP #325 #100 #35 photo
R041A2C 7.8 8.2 0.049 0.0109 0.0002 -0.13 0.55 1.65 1.81 0.67 0.56
R043A2C 8.5 8.2 0.068 0.0129 0.0006 0.01 0.65 0.7 0.81 0.44 1.31
R046A2C 7.6 8 0.096 0.0219 0.0013 -0.04 0.78 0.04 0.06
-
0.06 2.59
R051A2C 8.4 8.1 0.103 0.0166 0.0005 0.2 0.92 0.03 -0.52 0.42 4.77
R054A2D 8.3 8.2 0.0801 0.0191 0.001 0.14 0.93 0.29 0.22 0.00 1.14
R062A2D 7.3 8.05 0.0855 0.0166 0.0011 0.35 0.64 0.17 0.31
-
0.03 0.69
R064A2D 8 7.7 0.111 0.0236 0.0025 0.33 1.17 -0.14 0.05
-
0.25 2.79
R066A2D 7.6 7.5 0.0844 0.019 0.0023 0.07 0.57 0.22 0.33
-
0.29 2.34
R068A2E 7.4 6.5 0.0671 0.0112 0.0007 0.42 1.04 0.65 2.3 0.17 1.71
R072A2E 7.8 7.7 0.089 0.015 0.002 0.09 0.44 0.16 0.39
-
0.11 1.22
R075A2E 7.0 7.8 0.085 0.015 0.001 0.03 0.66 0.27 0.54 0.06 -0.16
R077A2E 6.5 7.0 0.063 0.017 0.001 0.35 0.7 1.03 0.58 0.17 0.35
R079A2E 6.9 7.2 0.087 0.026 0.002 0.2 0.63 0.15 -0.03
-
0.21 2.14
R081A2E 6.8 7.3 0.071 0.017 0.002 0.14 0.47 0.46 0.37
-
0.33 0.42

20
Average Grit Level
Avg grit level-Dryer stage (#325 mesh)
0.049
0.068
0.096
0.103
0.0801
0.0855
0.111
0.0844
0.0671
0.089
0.085
0.063
0.087
0.071
0
0.02
0.04
0.06
0.08
0.1
0.12
R041A2C R043A2C R046A2C R051A2C R054A2C R062A2D R064A2D R066A2D R068A2D R072A2E R075A2E R077A2E R079A2E R081A2E
Lot No.
gritlevel
Fig no-8 Average Grit (Before modification)
CpK of All Parameter
CpK-Iodine/DBP/grit- Dryer
-0.13
0.01
-0.04
0.2
0.14
0.35 0.33
0.07
0.42
0.09
0.03
0.35
0.2
0.14
0.55
0.65
0.78
0.92 0.93
0.64
1.17
0.57
1.04
0.44
0.66 0.7
0.63
0.47
1.65
0.7
0.04 0.03
0.29
0.17
-0.14
0.22
0.65
0.16
0.27
1.03
0.15
0.46
1.81
0.81
0.06
0.22
0.31
0.05
0.33
2.3
0.39
0.54 0.58
-0.03
0.37
-0.5
0
0.5
1
1.5
2
2.5
R041A2C R043A2C R046A2C R051A2C R054A2C R062A2D R064A2D R066A2D R068A2D R072A2E R075A2E R077A2E R079A2E R081A2E
CpK
Iodine DBP #325 #100
Fig no-9 Average CpK (Before modification)

21
Quality performance-grit level
Table no-5 Data Collection before ProblemSolving
Lot No
Grit @325 mesh
Avg Grit(ppm) Cpk
R075A2E 850 0.27
R077A2E 630 1.03
R079A2E 870 0.15
R081A2E 710 0.46
Overall Average 765 0.48
Lot No
Grit @325 mesh
Avg Grit(ppm) Cpk
R075A2E 850 0.27
R077A2E 630 1.03
R079A2E 870 0.15
R081A2E 710 0.46

22
5 Problem analysis and Root cause identification
Study has been carried out at different stages of process & finish Product quality
parameter which found from 14 runs of N774 production. During why-why analysis
numbers of probable causes of Coke formation in reactor were emerged out.
5.1- Identification of causes
( Why Why Analysis )
WHY?
Oil accumulation on
surface
Coke formation in Reactor
Poor flame pattern
WHY?
Jacket
position is
-250mm
Improper
Jacket
Alignment
Secondary air flow
is not proper
Peabody nozzle
chokage
WHY?
WHY?
Low oil
temperature
Flame striking
the 500mm ring
Wrong indication of
secondary air flow or
leakage from damper
Insufficient flow of
atomization media
WHY?
High grit level in N774
Improper
atomization of oil
WHY?
WHY?
Foreign
contaminationin
oil
Choked or damage
oil strainer
High air
temp
High
additive flow
Fig no-10 Why-Why analysis

23
So potential causes were emerged out by why-why analysis are-
1. Low oil temperature
2. Low pressure & insufficient flow of atomization media
3. Choked or damage oil strainer
4. Jacket position is -250mm
5. Improper Jacket Alignment
6. High air temp
7. Wrong indication of secondary air flow or leakage from damper
Role of some of the causes has been discussed here-
1- Low oil temperature
Low oil temperature may be a cause of Coke formation in reactor, because due to
low temp oil is not getting atomized properly due to higher viscosity of oil.
In current Scenario Peabody jacket position was -225 mm from ring. It may be a
cause of Coke formation, because in this case spray of atomized oil gets hindrance
with 500 mm dia ring which is located inside the Rx.
2- Low pressure & insufficient flow of atomization media
If atomizing media pressure & flow is not sufficient oil will not get atomize which is required for
proper cracking of oil and result in formation of coke.
3- Choked or damage strainer
Choked strainer will cause the insufficient oil flow while damage strainer will cause the passing of
foreign contamination along with oil and result in chokage of Peabody gun tip (nozzle) and hence
poor spray of oil which is responsible for coke formation.
4-Jacket position is -250mm
Since beginning (when the 7-series production started at Renukoot plant) we are running jacket
position with this setup i.e. in the range of -200 to -250 mm. So we have to further analyze that
whether this position of jacket is responsible for coke formation or not and for its analysis we have
to closely monitor the flame pattern and reactor condition after the completion of 7-series
production for each and every run.
5- Improper Jacket Alignment
Improper Jacket Alignment will cause of heating the spray on the wall of ring or/and shell hence
instead of cracking it stick on the surface and result in formation of coke. However this cause is
not the reason of coke formation as in current scenario jacket has been tightened with tie rod
which will always keep the jacket remain intact on the properly aligned position

24
6- High air temp
During production of N774, when very high grit level started coming in dryer sample When we
analyzed the grit nature (physical appearance of grit) we found that in most of the run grit was very fine,
powdery and ash type material. One of the major reasons of such type of grit formation is possible
only, when the oil droplet will get burn in maximum amount in place of desired partial combustion
which is important for thermal cracking of atomized oil. Inlet air temperature plays an
important role in carbon black production. Desired temperature for cracking is
provided by the preheated air which is coming in Rx through APH (Air
Preheater).Different grade of carbon black will produce at different cracking
temperature. In combustion chamber higher % burning of conversion oil (before the minimum
required time to get oil droplet atomized with atomizing media) is due to oil droplet get interact with
very high temp air flow than desired air temp for 7 series grade.
7-Wrong indication of secondary air flow or leakage from damper
In case there is insufficient flow of secondary air due to wrong indication or leakage from damper
flame will not established properly which is important for forming the proper vertex & whirling
effect for getting better flame profile.
5.2- Validation of causes
We reviewed each and every process steps start from raw material unloading in oil
storage tanks to atomization of oil in Rx based on potential causes emerged out
from why-why analysis except one causes that is jacket position -250 mm,
because if there is any contribution of existing jacket position we have to work out
that where we have set the new position of jacket. For this we have decided to
take some reference from old CFD (computational fluid dynamics) study. We
followed to adopt all possible activities to eliminate the effect of all potential
causes one by one for observing the improvement contribution. We analyzed the
result and observed that there was considerable improvement in grit level
reduction but we still not able to get desired quality range for low grit production.
Then we decided to take the advantage of 80-20 principle by doing the Pareto
Analysis to work out that out of all identified potential factor/causes from why-why
analysis, which factor is giving maximum % of impact.

25
5.3- Root cause identification (Table no-6 )
Finding of Root cause by pareto analysis
Causes Observation
Cum
observation
percentage Cumulative
percentage
Jacket position is -250mm 11 11 55 55
Low oil temperature 3 14 15 70
High air inlet temperature 3 17 15 85
Insufficient flow of atomization media 2 19 10 95
Wrong indication of secondary air flow 1 20 5 100
Damage oil strainer 0 20 0 100
Improper Jacket Alignment 0 20 0 100
Total 20
Cause analysis by Pareto Diagram
11
3 3
2
1
0 0
55
70
85
95
100 100 100
0
2
4
6
8
10
12
Jacketpositionis
-250mm
Lowoil
temperature
Highairtemp
Insufficientflow
ofatomization
media
Wrongindication
ofsecondaryair
flow
Damageoil
strainer
ImproperJacket
Alignment
Causes
Frequency
-10
10
30
50
70
90
110
Cumulative%
Vital few Useful many
Fig no-11 cause analysis by pareto diagram

26
6 Exploring of alternate solution
6.1-Analysis of Rx flame and location
Based on the finding of vital cause i.e. Jacket position “-250 mm’ emerged out
from Pareto analysis which was contributing more than 55% , we have started
close monitoring of flame pattern and location of coke formation in every run for
finding the solution of above mentioned “vital cause”. We found that flame is
striking on the ring and coke is forming near the area of secondary air inlet point.
Beside this we have taken the reference of old CFD result as we planed in
“validation of causes” These observation is now validated the list out of probable
causes under the head- “poor flame pattern’ during the why-why analysis
exercise.
So we decided to keep the jacket position at +50 mm (i.e. placing jacket at just
outer edge of ring) and make a robust action plan to take one trial run.
6.2- Action plan made for execution of trial run
Besides taking the action on high contributing factor i.e. jacket position we have
decided to take in consideration of other contributors- Oil temperature and high air
temperature which are having each one 15% impact to get the maximum benefit
for successful production of low grit material.
Following action plan made for trial run-
1. Keep both Rx jacket Position “+50” mm
2. Maintain Air Temp – between 425- 450 in both Rx (Start reduce air temp
before grade change in such a way that during on-smoke temp should not
more than 450 deg
3. Blend sample to be check and try to maintain viscosity around 80-85 which
will help in better atomization.(this viscosity may achieve with 70/30 blend
ratio)
4. Based on the Rx grit, proactively disturb the jacket position in the range of
“+25” to “+75 mm“(avoid to cross this limit) for half an hour and again

27
revert to original position “+50”. Use this activity only when dryer grit going
above 0.04/0.05
5. If grit level touching to 0.07 skip step #4 activity and based on Rx girt result
(in 100 gm sample), do the coke flushing of the Rx which is having high grit
to avoid silo contamination
6. Initially, Start production with low rating i.e. 5000 air flow in both Rx.To
increase rating instead of increasing in one shot, increase 250 nm3 rating in
both Rxs at once and next increase in 2 hrs gap to maintain grit level.
7. Tank temp to be maintain between 75-80 (earlier it was running 60 deg
approx in N774) it will help in increase of TIC temp as N774 TIC normally
running quite low specially in RxA.
8. After on-smoke, If desired girt level not achieved set jacket position
+75mm instead +50 mm
9. Increase strainer cleaning frequency of blend tank when tank circulation
started.
10. Ensure there is no any air leakage form 2ndry air damper
6.3- Execution of trial run
The first trial taken with jacket position @+50 mm and found that there is drastic change
in product quality. Grit level comes down in the range of 300 to 400 PPM from 800
PPM.After getting this result it has been decided to take some more trial with same jacket
position. Then we have taken 7-8 run and it is the beauty of success that Renukoot plant
able to achieve almost same range of grit level in “all runs” without any coke flushing in
Rxs.Finally we able to meet out our customer requirement and also retained our company
image as well.

28
6.4 Result after implementation of solution
Table no-7
Lot No Grit @325 mesh
Avg Grit (ppm) Cpk
R111A2G 321 3.84
R122A2G 373 3.80

29
7 Regular implementation
Fig no-12 Reactor picture
7.1 Data collection after modification (Table no-8)
Data collection after regular implementation of solution
Avg Grit CpK
Avg Oil
ratioLot no
RxA RxB
#325 #100 #35 Iodine DBP #325 #100 #35 photo
R086A2F 6.40 6.40 0.041 0.010 0.000 1.08 0.91 2.41 1.9 0.78 0.87
R095A2F 6.90 6.80 0.036 0.012 0.001 0.62 0.98 2.48 1.1 -0.04 2.02
R099A2F 7.04 7.00 0.039 0.012 0.000 0.71 0.91 4.4 2.12 0.78 3.13
R102A2F 7.30 7.20 0.0297 0.0086 0.0004 1.28 1.59 4.78 2.73 0.5 3.78
R104A2F/R105A2G 7.20 7.00 0.0323 0.0097 0.0002 1.305 1.305 4.91 3.845 1.78 3.845
R111A2G 7.00 7.15 0.0321 0.0091 0.0005 0.66 0.66 3.84 1.96 0.42 1.62
R117A2G 7.25 7.25 0.0443 0.0101 0 0.78 1.31 2.99 2.07 0 0.62
R122A2G 7.10 7.03 0.0373 0.0106 0.0004 0.75 0.8 3.8 2.82 0.67 0.63
R142A2I 7.19 7.16 0.0425 0.0095 0.0004 0.55 0.89 2.15 2.15 0.33 0.04
Solution implemented in all runs of 7-series grade
SOP: - Change Peabody jacket position to +50 in 7-series production

30
7.2 Graphical presentation of Before-After performance
CpK Trend - Iodine/DBP/GRIT-#325 MESH
0.03
0.35
0.2 0.14
1.305
0.66
0.78 0.750.66 0.7 0.63
0.47
1.305
0.66
1.31
0.8
0.27
1.03
0.15
0.46
4.91
3.84
2.99
3.8
0
1
2
3
4
5
6
R075A2E R077A2E R079A2E R081A2E R105A2G R111A2G R117A2G R122A2G
Lot no
CpKValue
CpK Iodine CpK DBP CpK #325
performance after
implimentation of solution
BEFORE
AFTER
Avg Grit #325 mesh (retained in grams out of 100 gm sample)
0.085
0.063
0.087
0.071
0.0323 0.0321
0.0443
0.0373
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
0.090
0.100
Lot no
gritrange
performance after
implimentation of solution
(0.085 gm means 850 PPM)
BEFORE
AFTER
Fig no-13 Graphical presentation of Before-After performance

31
7.1- Follow-up and review
Fig-14 Performance Comparison for grit level
7.2- Changes after modification
ModificationModification
Fig no-15 Reactor peabody setting: Before-After (Cross sectional view)
performance Comparison for grit level
765
500
347
0
200
400
600
800
1000
Before Target After
Average grit level @ 325 mesh in N774

32
2424
BEFORE
AFTER
Soft Black Reactor
Soft Black Reactor
Jacket position
-250 mm
Jacket position
-250 mm
Jacket position
+75 mm
Jacket position
+75 mm
Fig no-16 Reactor peabody setting: Before-After
Table no-9 change in operating parameters (Before-After)
Before-After details for change in operating parameters for low grit production
ACTIVITY BEFORE AFTER REMARK
1 Jacket position
-200 to -250 mm from
ring
+50 to
+75mm For hindrance free oil atomization
2
Tank oil temperature in charge
tank 55-60 C 75-80 ºC
To reduce oil viscosity for easy
atomization
3
Oil temperature after oil pre
heater 160-175 C 185-210 C
To reduce oil viscosity for easy
atomization
4 Air inlet temperature to Reactor 470-510 425-460
To control high % of early combustion of
conv oil so that oil get time to atomized

33
8 Productivity improvement and savings
8.1- Productivity improvement by elimination of coke flushing activities-
Hitech carbon, Renukoot having two nos Soft black Rxs. Maximum/allowable run
hrs in each run of N774/N762 is 24 hrs.In each run we have to flush the Rx due to
coke formation for at least 1.0 hr one by one for both Rx.Daily production rate (in
case of 24 hrs run) is 58 MT.Renukoot unit is producing 4 runs of 24 hrs in every
month on an average basis.
Amount of production in 1 hr = 58/24
= 2.416 MT
So, every month production enhancement = 2.416*4
= 9.66 MT
Annual production enhancement (expected) = 9.66*12 = 115.968 MT
Annual production @ 58 MT/DAY = 58*4*12= 2784 MT
Hence % of expected productivity improvement every year by elimination of coke
flushing activity = (115.968*100)/2784
= 4.16%
% productivity improvement in 7-series grade = 4.16%
8.2- Productivity gain (Monetary benefit due to extra production):
Annual production enhancement (expected) = 9.66*12 = 115.968 MT
Productivity gain (Realization) with 1.0 MT of N774/762 = Rs 6950 (Approx)
So Annual productivity gain (Realization) with total 115.968 MT production
enhancement = 115.968*6950
= Rs 8, 05,977 (Approx)

34
8.3- Saving in Auxiliary fuel oil due to elimination of coke flushing
activity:
Numbers of Reactors= 2
Each run coke flushing time= 60 min* 2 Rxs = 120 min
Auxiliary fuel oil flow during coke flushing = 4.5 liter/min
So, total non productive fuel oil consumption = 4.5*120
= 540 liter
Or, each run non productive fuel oil consumption = 0.540 KL
Approx numbers of run annually = 12*4 = 48 runs
So, expected saving in Auxiliary fuel oil due to elimination of coke flushing activity
= 48*0.540
= 25.92 KL
Average price of fuel oil = Rs 42,000/KL
So, expected money saving in Auxiliary fuel oil due to elimination of coke flushing
activity = 25.92*42000
= Rs 10, 88,640.00
So, Total annual saving (expected) = productivity gain + saving in auxiliary fuel
= 8, 05,977+10, 88,640
= Rs 18, 94,617.00 (Approx)
8.4- OtherTangible/Intangible benefits by Innovation in N774 production
Customer satisfaction
1 100 % delivery of required volume (earlier we able to seggrigate only 15-20% low grit material)
2 100% meeting of Quality as per customer spec
3 On-time dispatch (zero delay due to quality and volume)
5 Uninterrupted gas supply to internal customer i.e. Utility Dept
Off-spec reduction
1 Significant reduction in off spec in high grit both at dryer stage and FG stage
3 Elimination of silo contamination and off spec due to inert-down for coke flushing
Saving of fuel oil
1 Saving of fuel oil in Boiler also which was incurred in earlier case due to frequent coke flushing
Run hrs increased
1 Able to increase run hrs (from 24 hrs to 27 hrs)
Better House keeping
1
Able to maintain better house keeping and 5S activity as there is no oil spillage during Peabody gun changeover
and pocking rod requirement in every run of N774

35
9 Standard operating procedure (after implementation of solution)
Based on performance study and follow-up observation, action plan made for trial
run has been reviewed with some changes and following SOP has been made for
flaw less execution of 7 series production in every run. SOP’s are as follows-
1. Keep both Rx jacket Position “+50” mm
2. Maintain Air Temp – between 425- 450 in both Rx (Start reduce air temp
before grade change in such a way that during on-smoke temp should not
more than 425 for low grit material (for nomal grit 450c is ok).
3. Keep atomizing steam and 2ndy air damper in both Rxs full open
4. Blend sample to be check and maintain viscosity around 80-85 which will help
in better atomization.(this viscosity may achieve with 70/30 of oil blend ratio)
5. For low grit production if dryer grit level increases above 400/500 PPM
immediately check the Rx grit (in 100 gm minimum) & photo.
6. Based on the Rx grit, proactively disturb the jacket position in the range of
“+25” to “+75 “(avoid to cross this limit) for half an hour and again revert
back at “+50”. Use this activity only when dryer grit going above 400/500
7. During low grit production if dryer grit level touching to 700 skip step #6
activity and based on Rx girt result (in 100 gm sample), do the coke flushing
of the Rx which is having high grit to avoid silo contamination which normally
happen due to continuous 0.1 grit during Rx inert activities at high girt level.
8. Initially, Start production with low rating i.e. 5000 air flow in both Rx (This is
much important if we are producing low grit material).To increase rating
instead of increasing in one shot, increase 250 nm3 rating in both Rxs at once
and next increase in 2 hrs gap to maintain grit level.
9. Tank temp to be maintain between 75-80 it will help in increase of TIC temp
as N774 TIC normally running quite low specially in RxA (It observed that
tank temp is increasing very slow even after opening of bypass valve, so start
increasing temp 2-3 days before to get desired temp during production)
10. L-2 Oil cooler keep stop if required to get desired tank temp.
11. Increase the photo & grit testing at Rx end throughout the N774 run.
12. After on-smoke, If desired girt level not achieved set Rx-A jacket position
+75mm instead +50 mm
13. Quench gun to be kept co current and avoid end location guns (towards
APH) to prevent APH fouling (at 425-450 deg air temp there is possibility of
quick fouling of APH)
14. Change Rx strainer one by one during Rx inert and get maximum oil flow
through off smoke valve.
15. Increase 20 kg steam pressure (21/22) from utility when production start.
16. Increase strainer cleaning frequency of blend tank when tank circulation
started.
17. After following all above mentioned SOP, if there is coke formation problem.
Check the atomizing steam flow and 2ndry air flow indication.

36
10 Conclusion and Summary of the project
10.1- Conclusion
Uninterrupted atomization of conversion oil inside the Rx mainly in carcass Rx is
prime condition which is responsible for proper cracking of oil droplet for getting
desired quality and to avoid coke formation. Production of 7 series grade
(N774/762…) required utmost care for “hindrance-free” oil atomization as it is the
most typical grade in carcass black due to low iodine, low photo and high grit
formation problem.
Methodology/ Approach adopted to solve this chronic issue of coke formation by
concerned student was application of different problem solving tools and technique
like- why-why analysis, pareto diagram, adopting of best practices and break
through action.
Why “+50 to +75” is best jacket position for N774/N762
“+50 to +75” mm jacket position will provide hindrance-free best mixing rate
(instead +100/ +150 and so on…) because in this setting of jacket, main air just
at exit point of outer face of ring (also known as choke/orifice, provided for
increasing air velocity and turbulence for getting better air temp and better mixing
respectively) will have maximum whirling and it will decrease as jacket go away
from ring (towards ring discharge) while at flush position or at any minus position
of jacket setting (up to the edge of inlet face of ring) main air will create
hindrance for oil atomization however in this zone air oil mixing rate will be
maximum and hence oil ratio will also increase but due to hindrance in atomization
coke formation will occur rapidly.

37
10.2- Summary of the project
This project has resulted in major benefits in terms of Productivity, Quality and
Cost. Enhanced the Internal and External Customer delightness in terms of on-
time delivery of right quality & quantity product and elimination/reduction of
rework & reprocessing of non-conformance material respectively. Beside this, out
come of this project also greatly reduce the mental stress of shift team of both
production and Utility dept due to significantly reduction in frequent reactor inert-
down and coke flushing activities.
Based on the experiments conducted, it is clearly evident that the Process
optimization, modification and deep study/analysis resulted in
“ZERO” defects in product.
10.3- Scope for future work
Step wise future plan can be made for further benefit in 7-
Series production
1) - Use of Tank no-1283 as charge tank for 7-series production after
circulation line modification.
Explanation (Why) - Tank no-1283 & 1284 circulation line connected
with drain line of tank. Accumulated/settled foreign material or slurry
will mixed in tank through tank circulation and hence all the time oil in
Rx comes with this suspended material.
Suggestion- For tank no- 1283 one suction point available at 500 mm
height from base but this point is normally not in use for circulation so
to avoid mixing of bottom oil we should use this point for circulation
(there is no issue for using this point, same is already checked)
Benefit- Bottom oil/accumulated foreign material if any at the tank
bottom can be prevent to mix in tank via tank circulation during the
N774 production and hence probability of coke formation can be
eliminated.
2) - Trial to be taken with 60:40 blend (FO: Imp) in place of 70:30 for
yield gain
3)- Trial to be taken with atomizing air initially in one Rx (to be done
after steam coil tracing in atomizing air line to increase temp of

38
atomizing air so that better atomization can be achieved which will
contribute in further quality enhancement and yield gain)
5) - It has been observed that oil temperature of existing charge tank
is increasing very slowly (probably due to scaling on steam coil, tube
cleaning plan can be made as futue plan). So to get the desired
temperature in the range of 75 deg C to 80 deg C, plan to open the
steam control valve 2-3 days before of actual production plan
Note- a) For better performance we should use GA-9.5W or 14W
nozzle as wide angle will give maximum distribution/coverage on WHB
tube)
b) Tracking of Rx back pressure consistency will helpful in taking alert
for coke formation symptoms

39
11 References
1- J. B. Donnet, R.P. Bansal, and M. J. Wang. Carbon Black: Science and Technology. New
York: Marcel Dekker Inc, 2003.
2- J.M.Juran. Juran on Planning for Quality. The Free Press, 9th
Impression edition, 1988

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