Fertilizers and chemicals Ltd, popularly known as FACT, is the first large scale fertilizer manufacturer in India. The bulk movement of raw materials ships to their storage areas and reclamation of these materials to their different plants at various sites is a tedious and expensive task, for which different material handling systems and equipments are being made use of. Based upon the principles of Material Handling Institute (MHI) of U.S a detailed study of the material handling systems and its analysis was done for the belt conveyor system of FACT.
Fertilizers and Chemicals Travancore Ltd have their own Raw Material Handling systems at Q10 berth and Ammonia berth of Wellington Island, Kochi. The material handling systems at Q10 berth comprises a complex system of belt conveyors and pipe conveyors. The belt conveyors are used for the bulk movement of imported raw materials like Sulphur, Rock phosphate, etc, while pipe conveyors are used for the moment of Sulphuric acid, Phosphoric acid etc. Material handling involves the movement, protection, storage and the control of materials throughout the manufacturing and distribution process including their consumption and disposal. The handling of material must be performed safely and efficiently at low cost in a timely manner accurately, without any damage. Conveyors are one of major economical means of bulk material handling. The cost of material handling is a significant portion of total production cost is estimating about 20 to 25% of total manufacturing labor cost. In this analysis of the material handling system, a detailed study of logistics management and belt conveyor system has been done. A special attention has been given for the enhancement analysis of belt conveyor system and possible solutions are recommended to the company.
2. INDUSTRY PROFILE
Agriculture which accounts for the 1/5 of gross domestic products provides sustenance to 2/3 of our population, besides it provides crucial background, and forward linkages to the economy. Successive five years plan have laid stress on self-sufficiency, and self reliance in food grains production and concerted efforts in this direction have resulted in substantial increase in agriculture production and productivity is clear from the fact that from a very modest level of 52 million MT in 1952 food grain rose to about 230.78 million MT in 2008. In India's success in agriculture sector, not only in terms of meeting total requirements of food grains but also generating exportable surplus, the role played by chemical fertilizers, is well recognized and established.
Keeping in view, the vital role played by chemical fertilizers in the success of India's green revolution and consequent self-reliance in food-grain production, the government of India has been consistently pursuing policies conductive to increased availability and consumption of fertilizers in nutrient terms has increased from 0.7 lakhs MT in 1951-1952 to 225.70 lakhs MT in 2007-2008, when the first manufacturing unit of single super phosphates (SSP) was set up in Ranipet in Chennai with an annual capacity of 6000 MT. The Fertilizers and Chemical Travancore Limited (FACT) and the Fertilizer Corporation of India (FCI) in Sindri in Bihar were the first large sized fertilizer plants set up in the forties and fifties with a view to establish an industrial base to achieve self-sufficiency in food grains. Subsequently, green revolution in sixties gave an impetus to the growth of fertilizer industry in India and in 70s and 80s then witnessed a significant addition to the fertilizer production capacity. Out of the three main nutrients, namely Nitrogen, phosphate and potash required for various crops, indigenous raw materials are available mainly for nitrogenous fertilizers. The government policy was aimed at achieving the maximum possible degree of self-sufficiency in the production of nitrogenous fertilizers. The subsidy on fertilizers is...