KAUTILYA INSTITUTE OF TECHNOLOGY & ENGINEERING JAIPUR

A SUMMER TRAINING REPORT

AT HINDUSTAN COPPER LIMITED KHETRI COPPER COMPLEX KHETRI NAGAR RAJASTHAN (FROM 23 may 2016 TO 23 july 2016)Submitted in partial fulfillment of the requirement for the degree of B.Tech in

Mechanical Engineering from RTU, Kota

Submitted To:- Submitted By:-Mr. NAVIN H. YADAV MAHENDRA BAGRIYA

(13EKTME034) MECHANICAL (4thyear)

DEPARTMENT OF MECHANICAL ENGINEERING

KAUTILYA INSTITUTE OF TECHNOLOGY & ENGINEERING

SITAPURA INDUSTRIAL AREA, JAIPUR www.kautilya.net

ACKNOWLEDGEMENT:- I would like to thank HINDUSTAN COPPER LIMITED (KHETRI NAGAR) for providing me a golden opportunity to work with them. The support and the env i ronment prov ided to me dur ing my pro jec t was more than what anyone would have expected. I would also like to thanks Mr. SAJU C.SAM a n d m y instructors of A.K.SHARMA and divisions without them I would not be able to perform such a delightful job.  And at last I would like to thanks all the people involved in the training that helped me in accomplishing it in such a wonderful way.

PREFACE:- The summer training of an engineering student pays an important role in

developing has as a well-groomed professional. It allows a student to give theoretical

concepts a practical stand in the field of application. It gives the candidate an idea of

dynamic & versatile professional world as well as exposure to the intricacies and

complexities of corporate world.

Doing the summer training at HINDUSTAN COPPER LIMITED was a great experience. An

opening experience to the concepts of engineering which helped me lot in understanding

the concepts that are applied in the organization. This organization since its inception has

progressed a lot & is walking on the guidelines of success .As the organization is marching

with the tenacious speed towards the horizon.

This report deals with the production of plant ,equipment used to extract ore ,its type ,grade

of ore, primary crusher and its reduction ratio ,secondary and tertiary crusher and their

reduction ratio .

In a period of 60 days exposure to the corporate environment, I got a learning of

organizational structure, its protocols, etc. Being a student of mechanical, the

training contributed a lot in gaining knowledge about the actual business environment. This

report deals with the production of plant ,equipment used to extract ore ,its type ,grade of

ore, primary crusher and its reduction ratio ,secondary and tertiary crusher and their

reduction ratio .Main process unit consist of milling of

ore ,flotation ,cleaner ,recleaner ,thickner ,filter .In Hindustan copper project only mining

and benefication has been done ,the final product is transported to ,INDIAN COPPER

COMPLEX for smelting ,refining precious metal recovery.

TRAINING SCHEDULE:-

DEPARTMENT PERIOD ENGAGEMENTS REPORTINGOFFICER

TRANING CENTER 23-05-2016TO

23-05-2016

OFFICAL FORMLITIES

MR. P. Bhat.A.G.M. (MECH.)

Concentrator Plant 24-05-2016TO

04-06-2016

Plant Study MR. PARVEENC.M.(MECH.)

MB&R, A&RFOUNDRY SHOP

05-05-2016TO

15-06-2016

MACHINE/JOB STUDY

MR. A.K.ShowaC.M. (MECH.)

GARAGE 16-06-2016TO

23-06-2016

MACHINE/JOB STUDY

MR. A.K. Sharma

Gas Turbine/Power House

24-06-2016TO

04-07-2016

Machine/ Job Study MR. Praveen KumarC.M.(MECH.)

A. R. WAY 05-07-2016TO

15-07-2016

PLANT STUDY MR. B.K. BamboouaC.M.(MECH.)

Mining Machine Shop

16-07-2016TO

22-07-2016

MACHINE/JOB STUDY

MR. Narendra Singh

Training Centre 23-07-2016TO

23-07-2016

PLANT STUDY MR. P. Bhattacharyee

CONTENTS1.0 CHAPTER ONE

ABOUT HCL KCC………………………………………..1 1.1 INTRODUCTION…………………………………………….1 1.2 VISION, MISSION AND CORE VALUES………………...2

2.0 CHAPTER TWO CONCENTRATOR PLANT……………………….…….3

2.1 CRUSHING SECTION……………………………………...3

2.2 GRINDING SECTION………………………………….……6

2.3 FILTRATION & TAILING DISPOSAL……………………8

3.0 CHAPTER THREE

MINING MECHANICAL SHOP……………………….103.1 MWS & MMR SHOP………………………………………..103.2 COMPRESSER HOUSE………………………………...…12

4.0 CHAPTER FOUR ABOUT MB&R, A&R AND FOUNDRY SHOP………154.1 MB&R SHOP………………...……………………………..154.2 A&R SHOP………………………………………… ……..16

5.0 CHAPTER FIVE 5.1 FOUNDARY SHOP……………………………………….....17

6.0 CHAPTER SIX 6.1 GARAGE………………………………………...…..197.0 CHAPTER SEVEN 7.1 REFERENCES………………………………………………20

INTRODUCTION

OF HINDUSTAN COPPER LIMITED

Hindustan Copper Ltd. is a Government-owned corporation in the Central Public Sector

Enterprise under the Ministry of Mines (India), Government of India. HCL is the only

vertically integrated copper producer in India engaged in a wide spectrum of activities

ranging from Mining, Beneficiation, Smelting, Refining and Continuous Cast Rod

manufacturer.

Hindustan Copper Ltd. (HCL) was incorporated on 9 November 1967to take over the plants

and Mining mines at Khetri, Kolihan in Rajasthan. HCL also produces gold, silver, nickel

sulphate, selenium, tellurium and fertilizer as by products. It is the first Indian Copper

Producer to be accredited with ISO 9002 certification for Continuous Cast Rod

Manufacturer at its Taloja Plant and for manufacture of cathode at its refineries both at

Indian Copper Complex, Ghatsila, Jharkhand and Khetri Copper Complex, Khetri,

Rajasthan

1Units:-

Khetri Copper Complex (KCC) Indian Copper Complex (ICC) Malanjkhand Copper Project (MCP) Taloja Copper Project (TCP)

Capacity of KCC:- 31,000 tpa copper cathode(the smelter and acid plant at KCC are

under shutdown since late 2008 due to the slump in global commodity prices witnessed in

2008 and old machinery. Currently, only Concentrator for production of copper concentrate

is working in addition to associated mines.)

Mines - Khetri and Kolihan (producing 9,500 mt metal in concentrate / annum)

Reserve

Khetri 34.56 million tones @ 1.13% cu

Kolihan 22.45 million tones @ 1.33% cu

Banwas 24.97 million tones @ 1.69% cu

PLANT LOCATION FACILITIES

Khetri Copper Complex Khetrinagar, Mining ,Ore beneficiation

Rajasthan ,Smelting(not in use),

Refining (not in use)

Indian Copper Complex Ghatsila, Mining ,Ore beneficiation

Jharkhand ,Smelting ,Refining, Precious

metal recoveryMalanjkhand Copper Malanjkhand, Mining ,Ore beneficiation

Project Madhya

Pradesh

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CONCENTRATOR PLANT

CRUSHING SECTION

GRINDING SECTION

FILTRATION & TAILING DISPOSAL

CRUSHING:- A Crushing plant is one-stop crushing installation, which can be used for

rock crushing, garbage crushing, building materials crushing and other similar operations.

Crushing plants may be either fixed or mobile.

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Components:- Crushing plants make use of a large range of equipment, such as a pre-

screener, loading conveyor, intake hopper, magnetic separator, crushing unit, such as jaw

crushers and cone crusher etc.

Vibration feeder

Jaw crusher

Impact crusher

vibrating screen

Belt

Conveyor

Central electric control system

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Process:- Raw materials are evenly and gradually conveyed into jaw stone crushing

equipment for primary crushing via the hopper of vibrating feeder.

The crushed stone materials are conveyed to crushing plant by belt conveyor for secondary

crushing before they are sent to vibrating screen to be separated.

After separating, qualified materials will be taken away as final products, while unqualified

materials will be carried back to the stone crushing equipment for recrushing. And

customers can classify final products according to different size ranges.

All the final products are up to the related standards within and beyond China. Of course,

according to different requirements, customers can adjust the size of their final products

from this stone crushing plant.

Process of Stone Crushing Plant Clients will get the satisfactory products after objects

being crushed for several times. Dust is generated during the working process while the

dust control units are needed.

OTHER Pulany side. The switch is operated. Unless and until the handle is reset

to normal position manually, the switch remains in operated condition.

Crusher Gap in the section is 50mm.

Initial ore is 0-150mm.

Weight of “Mental” is 18tons.

“Mental” tool used in crusher for crushing stonesl cord switch is mounted

on the walkway side of the conveyor belt,

preferably at about every 20 meters. When the rope is pulled from

5GRINDING:-

COMPONENT BALL MILL

A Ball Mill is a type of grinder used to grind and blend materials for use in mineral dressing

processes, paints, pyrotechnics, ceramics and selective laser sintering.

Principle:- A ball mill works on the principle of impact: size reduction is done by impact

as the balls drop from near the top of the shell.

Construction:- A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shell may be either horizontal or at a small angle to the horizontal. It is partially filled with balls. The grinding media is the balls, which may be made of steel (chrome steel), stainless steel or rubber. The inner surface of the cylindrical shell is usually lined with an abrasion-resistant material such as manganese steel or rubber. Less wear takes place in rubber lined mills, such as the Sepro tyre drive Grinding Mill. The length of the mill is approximately equal to its diameter.

Working:- In case of continuously operated ball mill, the material to be ground is fed from the left through 60° cone and the product is discharged through a 30° cone to the right. As the shell rotates, the balls are lifted up on the rising side of the shell and then they cascade down (or drop down on to the feed), from near the top of the shell

6. In doing so, the solid particles in between the balls are ground and reduced in size by impact.

ROD MILL:- A rotating drum causes friction and attrition between steel rods and ore particles. But note that the term 'rod mill' is also used as a synonym for a slitting mill, which makes rods of iron or other metal. Rod mills are less common than ball mills for grinding minerals.

The rods used in the mill, usually high-carbon steel, can vary in both the length and the diameter. However, the smaller the rods, the larger is the total surface area and hence, the greater the grinding efficiency.

CELLS

OTHER

In sequenger cell - 14 motor In Rubber cell - 18 motor In cliner cell - 4 motor In recliner cell - 2 motor

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SEQUENGER CELL

RUBBER CELL CLINER CELL

Pinole oil used for flotation. Zinthode & Sodium silicate used for Absorbing Cu. Ore used in KCC cufes2. Mixing of Zinthode is 2200cc/m. Mixing of Pinole is 50cc/m. Store Storage capacity is 10000 tons ore and 2000 tons slag.

FILTRATION:-

Filtration is commonly the mechanical or physical operation which is used for the separation of solids from fluids (liquids or gases) by interposing a medium through which only the fluid can pass. The fluid that passes through is called the filtrate. Oversize solids in the fluid are retained, but the separation is not complete; solids will be contaminated with some fluid and filtrate will contain fine particles (depending on the pore size and filter thickness). Filtration is also used to describe some biological processes, especially in water treatment and sewage treatment in which undesirable constituents are removed by absorption into a biological film grown on or in the filter medium as in slow sand filtration.

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Applications:-

Filtration is used to separate particles and fluid in a suspension, where the fluid can be a liquid, a gas or a supercritical fluid. Depending on the application, either one or both of the components may be isolated.

Filtration, as a physical operation is very important in chemistry for the separation of materials of different chemical composition. A solvent is chosen which dissolves one component, while not dissolving the other. By dissolving the mixture in the chosen solvent, one component will go into the solution and pass through the filter, while the other will be retained. This is one of the most important techniques used by chemists to purify compounds.

Filtration is also important and widely used as one of the unit operations of chemical engineering. It may be simultaneously combined with other unit operations to process the feed stream, as in the biofilter, which is a combined filter and biological digestion device.

Filtration differs from sieving, where separation occurs at a single perforated layer (a sieve). In sieving, particles that are too big to pass through the holes of the sieve are retained (see particle size distribution). In filtration, a multilayer lattice retains those particles that are unable to follow the tortuous channels of the filter. Oversize particles may form a cake layer on top of the filter and may also block the filter lattice, preventing the fluid phase from crossing the filter (blinding). Commercially, the term filter is applied to membranes where the separation lattice is so thin that the surface becomes the main zone of particle separation, even though these products might be described as sieves.

Filtration differs from adsorption, where it is not the physical size of particles that causes separation but the effects of surface charge. Some adsorption devices containing activated charcoal and ion exchange resin are commercially called filters, although filtration is not their principal function.

Filtration differs from removal of magnetic contaminants from fluids with magnets (typically lubrication oil, coolants and fuel oils), because there is no filter medium. Commercial devices called "magnetic filters" are sold, but the name reflects their use, not their mode of operation.

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MINING MECHANICAL SHOP

Mining is the extraction of valuable minerals or other geological materials from the earth

from an ore body, lode, vein, seam, or reef, which forms the mineralized package of

economic interest to the miner.

MRR SHOP(MINES MACHINARY REPAIR SHOP)

AIR MOTOR:- A pneumatic motor (Air motor) or compressed air engine is a type of

motor which does mechanical work by expanding compressed air. Pneumatic motors

generally convert the compressed air energy to mechanical work through either linear or

rotary motion. Linear motion can come from either a diaphragm or piston actuator, while

rotary motion is supplied by either a vane type air motor, piston air motor, air turbine or gear

type motor.

Pneumatic motors have existed in many forms over the past two centuries, ranging in size

from hand-held motors to engines of up to several hundred horsepower.

10Some types rely on pistons and cylinders; others on slotted rotors with vanes (vane motors)

and other uses turbines.

Many compressed air engines improve their performance by heating the incoming air or the

engine itself. Pneumatic motors have found widespread success in Pneumatic motors have

found widespread success in the hand-held tool industry but are also used stationary in a

wide range of industrial applications. Continual attempts are being made to expand their

use to the transportation industry. However, pneumatic motors must overcome

inefficiencies before being seen as a viable option in the transportation industry.

Application:- A widespread application of pneumatic motors is in hand-held tools, impact

wrenches, pulse tools, screwdrivers, nut runners, drills, grinders, sanders and so on.

Pneumatic motors are also used stationary in a wide range of industrial applications.

Though overall energy efficiency of pneumatics tools is low and they require access to a

compressed-air source, there are several advantages over electric tools. They offer greater

power density (a smaller pneumatic motor can provide the same amount of power as a

larger electric motor), do not require an auxiliary speed controller (adding to its

compactness), generate less heat, and can be used in more volatile atmospheres as they

do not require electric power and do not create sparks. They can be loaded to stop with full

torque without damages.

LHD (Load, Haul, Dump machine):- LHD loaders are similar to conventional Front end loader but developed for the toughest of Underground mining (hard rock) applications, with overall production economy, safety and reliability in mind. They are extremely rugged, highly maneuverable and exceptionally productive. highly maneuverable and exceptionally productive More than 75% of world's underground metal mines use LHD for handling the muck of their excavations.

Capacity:-

Their tramming capacity varies from 1 to 17-25 metric tons. Their bucket size

varies from 0.8 meter cube to 10 meter cube. Bucket height range from 1.8 meter to 2.5

meter.

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WINDERAIR 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 (i.e., 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 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.

According to the design and principle of operation

Rotary screw compressor

Turbo compressor

Positive Displacement:-

Positive-displacement compressors work by forcing air into a chamber whose volume is decreased to compress the air. Common types of positive displacement compressors are

Piston-type air compressors use this principle by pumping air into an air chamber through the use of the constant motion of pistons. They use one-way valves to guide air into a cylinder chamber, where the air is compressed.

Rotary screw compressors use positive-displacement compression by matching two helical screws that, when turned, guide air into a chamber, whose volume is decreased as the screws turn.

Vane compressors use a slotted rotor with varied blade placement to guide air into a chamber and compress the volume. A type of compressor that delivers a fixed volume of air at high pressures.

Rotary screw compressors use positive-displacement compression by matching two helical screws that, when turned, guide air into a chamber, whose volume is decreased as the screws turn

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Negative displacement

Negative-displacement:- air compressors include centrifugal compressors. These use centrifugal force generated by a spinning impeller to accelerate and then decelerate captured air, which pressurizes it.

Applications:- To supply high-pressure clean air to fill gas cylinders To supply moderate-pressure clean air to a submerged surface supplied

diver To supply moderate-pressure clean air for driving some office and

school building pneumatic HVAC control system valves To supply a large amount of moderate-pressure air to power pneumatic

tools, such as jackhammers For filling tires To produce large volumes of moderate-pressure air for large-scale

industrial processes (such as oxidation for petroleum coking or cement plant bag house purge systems).

To supply moderate-pressure clean air for driving some office and school building pneumatic HVAC control system valves

For filling tires To supply moderate-pressure clean air to a submerged surface supplied

diver To supply moderate-pressure clean air to a submerged surface supplied

diver Piston-type air compressors use this principle by pumping air into an air

chamber through the use of the constant motion of pistons. They use one-way valves to guide air into a cylinder chamber, where the air is compressed

Vane compressors use a slotted rotor with varied blade placement to guide air into a chamber and compress the volume. A type of compressor that delivers a fixed volume of air at high pressures

Vane compressors use a slotted rotor with varied blade placement to guide air into a chamber and compress the volume. A type of compressor that delivers a fixed volume of air at high pressures

To supply moderate-pressure clean air for driving some office and school building pneumatic HVAC control system valves

13MB&R A&R AND FOUNDRY SHOP

AC REPAIRING SHOP:-

Air conditioning (often referred to as A/C, AC, or aircon) is the process of altering the properties of air (primarily temperature and humidity) to more comfortable conditions, typically with the aim of distributing the conditioned air to an occupied space to improve thermal comfort and indoor air quality. The 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

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Operating Principles:- In the refrigeration cycle, heat is transported from a colder location to a hotter area. As heat would naturally flow in the opposite direction, work is required to achieve this. A refrigerator is an example of such a system, as it transports the heat out of the interior and into its environment (i.e., the room). The refrigerant is used as the medium which absorbs and removes heat from the space to be cooled and subsequently rejects that heat elsewhere.

Circulating refrigerant vapor enters the compressor and is compressed to a higher pressure, resulting in a higher temperature as well. The hot, compressed refrigerant vapor is now at a temperature and pressure at which it can be condensed and is routed through a condenser. Here it is cooled by air flowing across the condenser coils and condensed into a liquid. Thus, the circulating refrigerant moves heat from the system and the heat are carried away by the air.

The condensed and pressurized liquid refrigerant is next routed through an expansion valve where it undergoes an abrupt reduction in pressure. That pressure reduction results in flash evaporation of a part of the liquid refrigerant, lowering its temperature. The cold refrigerant is then routed through the evaporator. A fan blows the warm air (which is to be cooled) across the evaporator, causing the liquid part of the cold refrigerant mixture to evaporate as well, further lowering the temperature. The warm air is therefore cooled.

To complete the refrigeration cycle, the refrigerant vapor is routed back into the compressor.

By placing the condenser inside a compartment, and the evaporator in the ambient environment (such as outside), or by merely running an air conditioners refrigerant in the opposite direction, the overall effect is the opposite, and the compartment is heated instead of cooled. See also heat pump.

16The engineering of physical and thermodynamic properties of gas–vapor mixtures is called psychometrics.

Heat Pump:-A heat pump is an air conditioner in which the refrigeration cycle can be reversed, producing heating instead of cooling in the indoor environment. They are also commonly referred to as a "reverse cycle air conditioner". The heat pump is significantly more energy efficient than electric resistance heating.

Some homeowners elect to have a heat pump system installed as a feature of a central air conditioner. When the heat pump is in heating mode, the indoor evaporator coil switches roles and becomes the condenser coil, producing heat. The outdoor condenser unit also switches roles to serve as the evaporator, and discharges cold air (colder than the ambient outdoor air).

FOUNDRY:-A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.

Process:-In metalworking, casting involves pouring liquid metal into a mold, which contains a hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods.

Melting:-Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying elements are used to charge the furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy.

Alloying elements are either pure forms of an alloying element, like electrolytic nickel, or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching, forging, or machining. Internal scrap consists of gates, risers, defective castings, and other extraneous metal oddments produced within the facility.

The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove deleterious gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards.

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Certain fluxes may be used to separate the metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve certain gasses. During the tap, final chemistry adjustments are made.

Furnace:-Several specialized furnaces are used to melt the metal. Furnaces are refractory lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include electric arc furnaces (EAF), induction furnaces, cupolas, reverberatory, and crucible furnaces.

Furnace choice is dependent on the alloy system quantities produced. For ferrous materials EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminum, bronze, and brass castings.

Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from small ones used to melt precious metals to furnaces weighing several tons, designed to melt hundreds of pounds of scrap at one time. They are designed according to the type of metals that are to be melted.

Certain fluxes may be used to separate the metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve certain gasses. During the tap, final chemistry adjustments are made

Furnaces must also be designed based on the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 500° C. Electricity, propane, or natural gas is usually used to achieve these temperatures.

For high melting point alloys such as steel or nickel based alloys, the furnace must be designed for temperatures over 1600° C. The fuel used to reach these high temperatures can be electricity (as employed in electric arc furnaces) or coke.

Furnace choice is dependent on the alloy system quantities produced. For ferrous materials EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminum, bronze, and brass castings.

The majorities of foundries specialize in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (for cast iron) may use a cupola, induction furnace, or EAF, while a steel foundry will use an EAF or induction furnace. 

Bronze or brass foundries use crucible furnaces or induction furnaces. Most aluminum foundries use either electric resistance or gas heated crucible furnaces or reverberatory furnaces.

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GARAGE

An automobile repair shop (also known as a garage) is a repair shop where automobiles are repaired by auto mechanics and electricians.

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REFERENCES Training material provided by the Hindustan Copper limited.

en.wikipedia.org

google.com

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