SERVICE INDUSTRIES LIMITED

G.T Road Gujrat

IN THE NAME OF THE ALLAH THE MOST BENEFICIENT THE MOST

MERCIFUL

INTERNSHIP REPORT

(Laboratory & Mixing Tyre Division)

SUBMITTED TO:

Mr. Shakeel Anwar

(Human Resources Department)

SUBMITTED BY:

_____________________ (Internee)

Department of Polymer Engineering

National Textile University

Faisalabad

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 Table of Contents
Abstract ................................................................................................................................................... 4
Acknowledgments................................................................................................................................... 5
Lab Layout ............................................................................................................................................... 6
Introduction: ........................................................................................................................................... 7
History: .................................................................................................................................................... 7
Vision statement: .................................................................................................................................... 7
Raw materials.......................................................................................................................................... 8
Polymers ............................................................................................................................................. 8
Accelerator .......................................................................................................................................... 8
Fillers .................................................................................................................................................. 8
Activators ............................................................................................................................................ 8
Retarders ............................................................................................................................................. 9
Blowing agents.................................................................................................................................... 9
Curing agents ...................................................................................................................................... 9
Plasticizers .......................................................................................................................................... 9
Antioxidants ........................................................................................................................................ 9
Antiozonant ......................................................................................................................................... 9
Rubber..................................................................................................................................................... 9
Origin ................................................................................................................................................ 10
Types of rubber ................................................................................................................................. 10
synthetic rubber................................................................................................................................. 10
Natural rubber: .................................................................................................................................. 10
Rubber elasticity: .............................................................................................................................. 11
Mixing And compounding: ............................................................................................................... 11
Rubber sheet: .................................................................................................................................... 12
TYRE DIVISION LAB:............................................................................................................................... 12
Curing analyser: ................................................................................................................................ 13
Mixing grader: .................................................................................................................................. 13
Flex cracking test: ............................................................................................................................. 13
Drum Abrasion tester: ....................................................................................................................... 13
Rheometer test: ................................................................................................................................. 13
Hardness test: .................................................................................................................................... 13
Universal tensile machine: ................................................................................................................ 14

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 Tyre plunger and unseating test: ....................................................................................................... 14
Tensiometer: ..................................................................................................................................... 14
Bowl Calendaring: ............................................................................................................................ 15
AUTO CYCLE AND ULT TYRES ................................................................................................................ 15
Extruder ............................................................................................................................................ 15
Extension .......................................................................................................................................... 15
Tread ................................................................................................................................................. 15
Cushion Gum: ................................................................................................................................... 16
Working of extruder:......................................................................................................................... 16
Calendaring: ...................................................................................................................................... 16
Tyre Body ply: .................................................................................................................................. 16
Bead wire: ......................................................................................................................................... 16
Tire building: .................................................................................................................................... 17
Curing: .............................................................................................................................................. 17
Quality check: ................................................................................................................................... 18
CYCLE TYRE AND TUBES ........................................................................................................................ 18
Making of tread:................................................................................................................................ 18
Making of green tyre:........................................................................................................................ 18
Making of cycle tube: ....................................................................................................................... 18
Curing: .............................................................................................................................................. 18
Quality: ............................................................................................................................................. 18
AGRI TUBES ........................................................................................................................................... 19
Tubes:................................................................................................................................................ 19
TUBELESS TYRES .................................................................................................................................... 19
Extension: ......................................................................................................................................... 19
Green tyre: ........................................................................................................................................ 19
Curing: .............................................................................................................................................. 19
Quality and packing: ......................................................................................................................... 19
BOILER ................................................................................................................................................... 19
Definition: ......................................................................................................................................... 19
Types:................................................................................................................................................ 20
Working Mechanism:........................................................................................................................ 20
AIR COMPRESSOR ................................................................................................................................. 20

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Abstract

This report is related to making and testing of Tyre. In this report there are detailed different
sections of tyre division are discussed. All the sections are related to a tyre division laboratory.
In laboratory all the samples are checked and passed. And then further work is done on that
samples. The report also represents the visiting of compressor and boiler. At the last different
suggestion and new techniques are also listed for the further development of the industry.

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Acknowledgments

First of all, I am really thankful to my Allah Almighty who blessed me a chance to work in
this firm & to my parents who not only allow me to work in this industry but also supported
me both financially and mentally. I am really grateful to HR of service industry, Mr Shakeel
Anwar for allowing me to work as an internee in the service industry private limited Gujrat.
I am pleased to work with my supervisor, Mr Engr. Jabran, who guided me in a friendly
manner, the information he provided me would benefit me in my future professional life.

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 (Technical) Lab & Mixing
Lab Layout:

Flex Plunger Table

Cracking Test
Test

Abrasion UTM
Tester

Brookfield
UTM
Viscometer

Mixing Ektron
Grader Rheometer

DBP
Ektron
Absorption
Rheometer
Test

Melting Point
Apparatus Mooney
Viscometer

Brabender
Mixer
Alpha
Rheometer
Curing
Analyzer

Ozone Tester Cabins

Door Office

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Introduction:

Servis industry limited (SIL) is basically a rubber processing industry. The main products of
this industry are tyres and shoes. These products are not only sold in the local market but also
exported to other countries in the world. The industry is located in Gujrat, Muriel and Lahore.
SIL is also the leading exporter of footwear. Service Sales Corporation (Pvt.) Ltd. (SSC) is
today Pakistan's leading footwear retailer which is also diversifying into other businesses.

History:

The story of 'Servis' begins with a group of friends - young, energetic, fresh from college -
who established Service Industries more than 50 years ago. These young men, named
Ch. Nazar Muhammad (Late), Ch. Muhammad Hussain (Late) both from Gujrat district and
Ch. Muhammad Saeed (Late) from Gujranwala District, started business in 1941 at a small
scale in Lahore.
In 1954, they installed a shoe manufacturing plant at industrial area Gulberg, Lahore.
This started production in the same year. The industry started manufacturing various types of
shoes. Later management shifted the factory from Lahore to Gujrat. Service Sales Corporation
(Pvt.) Ltd. the Group's marketing company was established in 1959. Humility, fairness, and
respect were the values close to the heart of these founders and it were these values that led to
phenomenal success of the Group over the years.

Vision statement:

Service industry limited (SIL) is one of the leading rubber industry in Pakistan which is
providing its services to not only in the local market but also in the international market. The
vision statement of the industry is: -

❖ To be result oriented and profitable company by consistently improving market share

quality, diversity, availability, presentation, and customer acceptance.
❖ To emerge as a growth-oriented concern ensuring optimum return and value addition
to its shareholders.
❖ To ensure cost consciousness in decision making and operation without compromising
the commitment to quality.

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Raw materials

Most of the raw material required to manufacture the Tyres are imported from different
countries. Before storing these materials, different quality checks are performed on these
materials to meet the standards of the company. List of the major materials used in this industry
are given as below: -
Polymers
A polymer is a large molecule composed of many repeated sub units. Because of their broad
range of properties both synthetic and natural polymers play an essential and ubiquitous role
in everyday life. Some of the polymers used in Tyres making process are as below: -
Rubber TSRL Rubber TPC
Rubber SBR-150(R) Rubber SBR-1502(K)
NIPOFLEX ENGAGE (MET)
HISTYRENE Rubber SMR-20
Rubber RSS-415 Rubber Nitrile
Accelerator
These are chemical compounds which are responsible to reduce the overall time for the curing
of rubber. In other words, they fasten the rate of reaction for the vulcanization of the rubber. A
few of them used in this industry are listed as below: -
Accelerator-MBT Accelerator-MBTS
Accelerator-TMTD Accelerator-TMTM
Accelerator-DGR Accelerator-ZOC
Fillers
Fillers are the additives added to the rubber to obtain certain specific properties. They are also
added to the rubber to minimize the cost of the product. Some of them used in the tyres
manufacturing process are: -
ZEOSIL-45 VULKASIL-C
CaCo3. Whiting Ana
Marble powder Talcum powder
Activators
These chemical compounds are responsible to activate the accelerators. Usually they are added
in small amounts. They do not take part in the curing reaction of rubber. Some of the most
commonly used are:-
Zinc oxide active Diethylene glycol
Steric acid L.Amonia

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Retarders
These are responsible to reduce the rate of reaction for the curing of rubber. They are added to
increase the curing period of rubber. The most commonly used chemical compound for this
purpose is “Benzoic acid “.
Blowing agents
There are added to blow the rubber. When these materials are added to the rubber, it expands
and a net increase in volume is observed. Some of the blowing
agents are: -
CELLMIC-HP CELLMIC-ACPW
CELLMIC-AC3000F
Curing agents
The important step in the processing of rubber and tyre manufacturing is the curing. Curing is
a term which is used for the crosslinking of rubber molecules on heating and addition of
chemical additives. Some of these chemical additives which are used for this purpose are
Sulphur DCP (China)
Plasticizers
These are responsible for the plastic behaviour in the product such as rigidity, hardness,
toughness and brittleness. The materials which serve for these properties are: -
PETROLLEN-JELLY SEVICE OIL
DCP-OIL
Antioxidants
Oxidant is an important limiting factor's in all thermosetting and thermoplastic resins. Its
effects include adverse colour change, loss of tensile strength, reduce impact strength and
mostly cracking.
Antiozonant
An antiozonant, also known as antiozonant, is an organic compound that prevents or retards
the degradation of material caused by ozone (ozone cracking). Antiozonants are used as
additives to plastics and rubber, especially in shoe and tyre manufacturing. Some of them are:
-
P-WAX SANTOL
STRUK-EF-44. PEPTIZER A-86

Rubber

Before discussing in detail, the manufacturing of Tyres, this is mandatory to explain the all-
important aspects about rubber.

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Origin
Rubber was first discovered in Brazil. They prepare several useful products from the rubber.
The consumption of rubber in international market increase so much that they cannot further
complete the demand. To overcome these issues seeds of rubber trees are sent into several
tropical areas of the world such as Malaysia and Indonesia.
Types of rubber
There are many types of rubber available in the market depending on the nature of
classification. Rubber is classified into two different classes depending on the source of their
origin
• Natural rubber
• Synthetic rubber
synthetic rubber
Most synthetic rubbers are produced from petroleum by the same polymerization techniques
used to synthesize other polymer. Unlike thermoplastic and thermosetting polymers, which are
normally supplied to the fabricator as pellets or liquid resins, synthetic rub
Natural rubber:
Natural rubber, also called India rubber or caoutchouc, as initially produced, consists of
polymers of the organic compound isoprene, with minor impurities of other organic
compounds, plus water. Malaysia and Indonesia are two of the leading rubber producers.
Forms of polyisoprene that are used as natural rubbers are classified as elastomers.

Currently, rubber is harvested mainly in the form of the latex from the rubber tree or others.
The latex is a sticky, milky colloid drawn off by making incisions in the bark and collecting
the fluid in vessels in a process called "tapping". The latex then is refined into rubber ready for
commercial processing. In major areas, latex is allowed to coagulate in the collection cup. The
coagulated lumps are collected and processed into dry forms for marketing.

Natural rubber is used extensively in many applications and products, either alone or in
combination with other materials. In most of its useful forms, it has a large stretch ratio and
high resilience, and is extremely waterproof Rubber exhibits unique physical and chemical
properties. Rubber's stress–strain behaviour exhibits the Mullins effect and the Payne
effect and is often modelled as hyper elastic. Rubber strain crystallizes.

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Rubber begins to melt at approximately 180 °C (356 °F).

Rubber elasticity:
On a microscopic scale, relaxed rubber is a disorganized cluster of erratically changing
wrinkled chains. In stretched rubber, the chains are almost linear. The restoring force is due to
the preponderance of wrinkled conformations over more linear ones. For the quantitative
treatment see ideal chain, for more examples see entropic force.

Cooling below the glass transition temperature permits local conformational changes but a
reordering is practically impossible because of the larger energy barrier for the concerted
movement of longer chains. "Frozen" rubber's elasticity is low and strain results from small
changes of bond lengths and angles: this caused the Challenger disaster, when the
American Space Shuttle's flattened O-rings failed to relax to fill a widening gap The glass
transition is fast and reversible: the force resumes on heating.

The parallel chains of stretched rubber are susceptible to crystallization. This takes some time
because turns of twisted chains have to move out of the way of the growing crystallites.
Crystallization has occurred, for example, when, after days, an inflated toy balloon is found
withered at a relatively large remaining volume. Where it is touched, it shrinks because the
temperature of the hand is enough to melt the crystals.

Vulcanization of rubber creates di- and polysulfide bonds between chains, which limits
the degrees of freedom and results in chains that tighten more quickly for a given strain, thereby
increasing the elastic force constant and making the rubber harder and less extensible.

Mixing And compounding:

There are two methods of mixing of compound

• Direct Compounding
• Two step compounding (Master Batch, Final Batch)

Here the general procedure of mixing is as below:

• The material is in the required form e.g. either in coarse or fine form
• Weighing of each material
• Before using the rubber, it is gone through the mastication process-in which branch
chain of rubber are converted into straight chain. The mixer used in the mixing
department is automatic. Feed is supplied the top of the mixer where it is added in the
Hooper.

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A thick sheet of rubber is obtained as a product from the mixer. All-important raw material
such as activators, curing agents, fillers etc are added in the mixing department.
Different compounding sheet names are given below:

• Topping
• MRF or ULT
• Supreme, Trolley
• Bladder
• Cheetah
• Flapper
• Thread MC
• Bead wire
• Rim Blatt

Rubber sheet:
After mixing the all compounds and carbon black the sheet is made through the mixing
cylindrical machine. After making of sheet a sample also send to the TD laboratory for
the quality checking. And then send to different sections for its uses

TYRE DIVISION LAB:

In this lab there are different experiments are done. The short list of such experiments are
written in bellow

• Curing analyser
• DBP absorption
• Mixing grader
• Abrasion test
• Flex cracking test
• Rheometer test
• Hardness test
• Universal tensile machine
• Tyre plunger and unseating test

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Curing analyser:
The part of rubber is put in the curing analyser machine and heat at a specific temperature and
pressure after achieving a specific temperature the rubber is cured. And then its time and curing
temperature is noted in the computer which is connected with it.

Mixing grader:
High sensitivity binocular microscope, camera and video capture interface card

Patent specimen cutter measure carbon black agglomerates particle diameter, average particle
diameter, amount of particle, etc.

Flex cracking test:

Dynamic tester for the determination of the resistance to cracking produced either by
extension or bending in environmental chamber. This tester is intended for determine the
resistance to flex cracking and crack growth under high temperature of vulcanized rubber
Dynamic tester for the determination of the resistance to cracking produced either by extension
or bending in environmental chamber. This tester is intended for determine the resistance to
flex cracking and crack growth under high temperature of vulcanized rubber.

Drum Abrasion tester:

❖ Automatic electric lock of the rotating drum at the end of the test cycle;
❖ Mechanical unlocking of the rotating drum to facilitate replacement of the abrasive
media;
❖ Lexan drum cover with automatic safety lock;
❖ Safety push-button;
❖ Specimen holder correctly positions specimen for accurate, repeatable tests.

Rheometer test:
The unique torque tube design enables the instrument to respond to minute changes in viscosity,
mechanically transmitting a rotational torque signal out of the pressure containment area
without friction. Thus, all electronics, bearings, and other sensitive components are completely
protected from the influences of both the sample fluid and its vapour.

Hardness test:
Time is noted in rheometer equipment after putting a sample of rubber after applying a specific
temperature.

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Universal tensile machine:
The die of a tube sample is cut through the joint of tube and then put it in the sections of
machine than machine perform its work the tube sample is brake from the joint after applying
a specific force and then graph of the tensile strength is founded by the computer connected
with the tensile machine and date is printed out through printer which is connected with that
computer and saved.

Tyre plunger and unseating test:

Following are the Main Features of plunger test

❖ Plug Test functions include Radial elasticity test, Tread footprints test, Tire dimension
test, Bead unseating test, Lateral elasticity test and Pressure distribution analysis for
Footprints. (Note: Test function is different from machine's models)
❖ Wide range capacities of load cells are available for customers to select the suitable
ones to test the different sizes of tires.
❖ Different operations modules are designed in accordance with different test functions.
They can simplify the procedures of operation settings and efficiently manage the
massive data.
❖ Software provides three types of mean calculations, including Arithmetic mean,
Weighted mean, and Median mean.
❖ During the test, data and curves will be displayed on the monitor and then they will be
saved automatically into the memory device such as hard dish.

Tensiometer:
Tensiometer is a device used to evaluate the tensile properties of materials such as their Young's
modulus (i.e. the degree to which they stretch under stress) and tensile strength. It is usually a
universal testing machine loaded with a sample between two grips that are either adjusted
manually or automatically to apply force to the specimen. The machine works either by driving
a screw or by hydraulic ram.

some time because turns of twisted chains have to move out of the way of the growing
crystallites. Crystallization has occurred, for example, when, after days, an inflated toy balloon
is found withered at a relatively large remaining volume. Where it is touched, it shrinks because
the temperature of the hand is enough to melt the crystals.

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Vulcanization of rubber creates di- and polysulfide bonds between chains, which limits
the degrees of freedom and results in chains that tighten more quickly for a given strain, thereby
increasing the elastic force constant and making the rubber harder and less extensible.

Bowl Calendaring:
In four bowl calendaring machines four roller are used. Nylon card is mixed with rubber sheet.
It provides strength to rubber. Nylon coated is the main weight resistive part of tyre where
whole weight tyre is lying. Nylon card is measure in term of (EPI) end per inch. Type of nylon
card is as follow:

• 20 EPI used for motor cycle

• 22 EPI used for cycle or trolley
• 28 EPI used for ULT.

AUTO CYCLE AND ULT TYRES

Extruder:

The machine which is used to compress by heating the rubber to make a specific form
through its die. Die has specific width, length and height etc. It compress and heat the rubber
to make a rubber sheet which is called tread.

Extension:

Extrusion is a process used to create objects of a fixed cross-sectional profile. A material

is pushed through a die of the desired cross-section.

Extrusion may be continuous (theoretically producing indefinitely long material) or semi-

continuous (producing many pieces). The extrusion process can be done with the material hot
or cold. Commonly extruded materials include metals, polymers, ceramics, concrete,
modelling clay, and foodstuffs. The products of extrusion are generally called "extrudates".

Tread:

The tread is a thick extruded profile that surrounds the tire carcass. Tread compounds include
additives to impart wear resistance and traction in addition to environmental resistance. Tread
compound development is an exercise in compromise, as hard compounds have long wear
characteristics but poor traction whereas soft compounds have good traction but poor wear
characteristics.

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Cushion Gum:
Many higher-performing tires include an extruded component between the belt package and
the tread to isolate the tread from mechanical wear from the steel belts.

Working of extruder:
Feed (rubber) is entered in the extruder a standard speed of roller of extruder is set. By
applying specific pressure and heat roller mix the rubber and make a sheet of rubber. Tread is
made with a specific length and standard weight. After this great is send to making of green
tyres.

Calendaring:
Ply is made by the process of calendaring the further detail is given below

Tyre Body ply:

The body ply is a calendared sheet consisting of one layer of rubber, one layer of reinforcing
fabric, and a second layer of rubber. The earliest textile used was cotton; later materials
include rayon, nylon, polyester, and Kevlar. Passenger tires typically have one or two body
plies. Body plies give the tire structure strength. Truck tires, off-road tires, and aircraft tires
have progressively more plies. The fabric cords are highly flexible but relatively inelastic.

Plies are layers of relatively inextensible cords embedded in the rubber to hold its shape by
preventing the rubber from stretching in response to the internal pressure. The orientations of
the plies play a large role in the performance of the tire and is one of the main ways that tires
are categorized.

Bead wire:
The tire bead is the part of the tire that contacts the rim on the wheel. The bead is typically
reinforced with steel wire and compounded of high strength, low flexibility rubber. The bead
seats tightly against the two rims on the wheel to ensure that a tubeless tire holds air without

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leakage. The bead fit is tight to ensure the tire does not shift circumferentially as the wheel
rotates. The width of the rim in relationship to the tire is a factor in the handling characteristics
of an automobile, because the rim supports the tire's profile.

Tire building:
Building is the process of assembling all the components onto a tire building drum. Tire-
building machines (TBM) can be manually operated or fully automatic. Typical TBM
operations include the first-stage operation, where inner liner, body plies, and sidewalls are
wrapped around the drum, the beads are placed, and the assembly turned up over the bead. In
the second stage operation, the carcass of the tire is inflated, then the belt package and tread
are applied.

All components require splicing. Inner liner and body plies are spliced with a square-ended
overlap. Tread and sidewall are joined with a skived splice, where the joining ends are bevel-
cut. Belts are spliced end to end with no overlap. Splices that are too heavy or non-symmetrical
will generate defects in force variation, balance, or bulge parameters. Splices that are too light
or open can lead to visual defects and in some cases tire failure. The final product of the TBM
process is called a green tire, where green refers to the uncured state.

Curing:
An opened tire mild being cleaned. The deflated rubber bladder is on the central post. Curing
is the process of applying pressure to the green tire in a mild in order to give it its final shape
and applying heat energy to stimulate the chemical reaction between the rubber and other
materials. In this process the green tire is automatically transferred onto the lower mild bead
seat, a rubber bladder is inserted into the green tire, and the mild closes while the bladder
inflates. As the mild closes and is locked the bladder pressure increases so as to make the green
tire flow into the mild, taking on the tread pattern and sidewall lettering engraved into the mild.

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 The bladder is filled with a recirculating heat transfer medium, such as steam, hot water, or
inert gas. Temperatures are in the area of 350 degrees Fahrenheit with pressures around 350
PSI. Passenger tires cure in approximately 16 minutes. At the end of cure the pressure is bled
down, the mild opened, and the tire stripped out of the mild. The tire may be placed on a PCI,
or post-cure inflator, that will hold the tire fully inflated while it cools.

Quality check:
After making of tyre the quality is checked and the categorised the tyres in A B C types.

CYCLE TYRE AND TUBES

Making of tread:
Tread is made of extruder as we read in MC and ULT sections.

Making of green tyre:

Green tyre can be recycling so it is called trend tyre it’s all process are the same as the MC and
ULT tyres and tubes.

Making of cycle tube:

The tubes are also made by the method extension.

Curing:
As we discussed in above that the curing section is related to the making of tyre and tubes.
After specific temperature, pressure and heat the tyre and tube are made.

Quality:
After curing section, the tyre and tubes are categorised and packed.

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AGRI TUBES

Tubes:
There is none a major difference between making of MC ULT and bicycle tubes. Its only size
is large but it’s curing making and extrusion is same as MC tubes and bicycle

Due to large size of grain tubes the size of die in extruder is larger than the others.

TUBELESS TYRES

There are different ways to make the tubeless tyres which are enlisted below

• Extrusion
• Green tyre
• Curing
• Quality

Extension:
Though the extruder the tread for the tubeless tyres are made and then send to the tyre building
machines.

Green tyre:
Green tyre is made in tyre building machines where workers work on tyre building machines
with applying the 3 or 4 PR depending the brands of tyre.

Curing:
After making the green tyre the tyre is kept in the moulds of heavily heated steam and also hot
and cold water is provided to the moulds for curing the tubeless tyres.

Quality and packing:

After making and curing the tyres the quality is Checked and send for the A B and C category
packing.

BOILER

Definition:
Fluidization is a method of mixing fuel and air in a specific proportion, for obtaining
combustion. A fluidized bed may be defined as the bed of solid particles behaving as a fluid. It

19
operates on the principal that when an evenly distributed air is passed upward through a finely
divided bed of solid particles at low velocity, the particles remain undisturbed, but if the
velocity of air flow is steadily increased, a stage is reached when the individual particles are
suspended in the air stream. If the air velocity is further increased, the bed becomes highly
turbulent and rapid mixing of particles occur which appear like formation of bubbles in a
boiling liquid and the process of combustion as a result is known as fluidized bed combustion.

Types:
Fluidized Bed combustion can be in 2 variants, namely

Vertical type FBC: These are generally used in smaller plant and has the capacity to produce
steam of up to 6 tonnes per hour only. Their vertical shape reduces the overall dimension of
the steam boiler, and is extremely efficient in plants, where space provision is limited.

Horizontal type FBC: There are almost 10 times in capacity when compared to vertical type
fluidized bed combustion. They can produce as much as 60 tonnes of steam per hour and are
placed horizontally with respect to the boiler tubes. The high capacity of the horizontal type
Fluidized boilers coupled with their high efficiency, makes them an extremely desirable choice
for the coal fired thermal power generating station.

Working Mechanism:
The concept of burning coal that has been pulverized into a fine powder stems from the belief
that if the coal is made fine enough, it will burn almost as easily and efficiently as a gas. The
feeding rate of coal according to the boiler demand and the amount of air available for drying
and transporting the pulverized coal fuel is controlled by computers. Pieces of coal are crushed
between balls or cylindrical rollers that move between two tracks or "races." The raw coal is
then fed into the pulveriser along with air heated to about 650 degrees F from the boiler. As
the coal gets crushed by the rolling action, the hot air dries it and blows the usable fine coal
powder out to be used as fuel. The powdered coal from the pulveriser is directly blown to a
burner in the boiler.

AIR COMPRESSOR

An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air (compressed air). By one of several
methods, an air compressor forces more and more air into a storage tank, increasing the
pressure. When tank pressure reaches its upper limit the air compressor shuts off. The

20
compressed air, then, is held in the tank until called into use. The energy contained in the
compressed air can be used for a variety of applications, utilizing the kinetic energy of the air
as it is released and the tank depressurizes. When tank pressure reaches its lower limit, the air
compressor turns on again and re-pressurizes the tank.

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