1.

0 ACKNOWLEDGEMENT

In the name of Allah the Beneficent, the Merciful,

I would like to express my deepest appreciation to all those who provided me the possibility to complete this
industrial training programme. I would to thank all Schaefer Kalk Sdn Bhd staffs for your help and guidance
throughout these 10 weeks of my internship programme. I am grateful to my supervisor, Mr Fairuoze Roslin
whose expertise, understanding, generous guidance and support made is possible for me to have a
meaningful internship throughout the process. I am hugely indebted to Mr Muzakkir Aziz for finding out time
to give me some guidance and advice about the process.
I also would like to express my deepest appreciation to all those who provided me the possibility to complete
this industrial training programme. Special thanks go to Mr Mohd Yusof, Business Technical Support
Manager for his advices. Mrs Farah Wahida and Miss Nurul Huda, also not forget to Mr Syukri, the
Production Engineer of Schaefer Kalk that give me a lot of new knowledge and to al Technical Staff. The
conducive working environment and the good working culture in the company are difficult to come by.
Also I would like to extend my sincere thanks to lecturers from Faculty of Chemical Engineering, University
Technology Mara especially Miss Habsah for coordinating this internship programme to gain some
knowledge and working experience, for her willingness to spend her time visiting me during my internship
period. Also to our Dean, Prof Dr Norazah Abd Rahman and others who encourage and motivate us, share,
knowledge and experience.
Last but not the least, special thanks to my mother, Mrs Mariam Jantan and my sibling for their support,
encouragement and endless prays given to me. Finally, I would like to thank to my friends and to who have
contributed directly or indirectly to me until my industrial training have been completed

2.0 TABLE OF CONTENT

1

PAGE
1
2

1.0 ACKNOWLEDGEMENT
2.0 TABLE OF CONTENT
3.0 INTRODUCTION
3.1 INDUSTRIAL TRAINING

3.2 TRAINING SCHEDULE

4.0 COMPANY BACKGROUND

4
5

4.1 COMPANY ORGANIZATION CHART

5.0 TASK 1 : REACTOR PERFORMANCE
6.0 TASK 2: FUNCTION OF PHOSPHATE
7.0 TASK 4: DESIGN PROJECT ON KILN DUST SILO 5
8.0 TASK 5: QUICK LIME RECYCLE PROJECT ON SILO 5
9.0 EFFECT OF SIZE PARTICLE ON DRUM FILTER
10.0 SUGGESTION ON IMPROVEMENT
11.0 CONCLUSION

7
8

13
16
23
26
27
29

3.0

INTRODUCTION
3.1

INDUSTRIAL TRAINING

Industrial Training program is one of the important components in the degree syllabus offered by Bachelor of
Chemical Engineering, Universiti Technology Mara (UiTM Shah Alam). The industrial training program is
compulsory to all engineering students as they will be trained at any selected engineering company, covering
a wide range engineering fields and industries. The training at Schaefer Kalk Sdn Bhd was commenced from
23rd Jun until 5th September 2014. The duration was 11 weeks. The main reason for this industrial training
program is to help students to achieve objectives stated below:

1)To provide early exposure to students in order to adapt to the working environment.
2)To create a special bond or relationship between the employment sector and universities.
3)To introduce future graduates with the quality of the field and themselves to prospective
employers.
4)To give students opportunity to put into practice the theories they have learned in the real job
situation.
5)To improve students skills and increase the efficiency of communication with employers and
working colleagues.
6)To increase self-confidence to act as a professional engineer in the working environment.

3.2

TRAINING SCHEDULE
3

WEEK
1

DATE
18/07/201622/07/2016

25/07/201629/07/2016

01/08/201603/08/2016

Briefing on PCC and waste water treatment

plant (WWTP)
PCC and waste water treatment plant analysis
Draw and understand process flow

04/08/16

Briefing on hydration and PCC packing plant

Draw and understand process flow

05/08/16

Briefing on warehouse system (hydration and

PCC)
Draw and understand process flow

SUMMARY ACTIVITIES
Briefing about safety and the company
Visit around the plant (limestone storage, kiln,
hydration, PCC, packing plant and warehouse)
Briefing on kiln and hydration plant
Kiln and Hydration plant analysis
Draw and understand process flow

08/08/201610/08/2016

Briefing on maintenance plant operation and

engineering warehouse system
Briefing on engineering plant and internal
plant project
Briefing on laboratory
Briefing on plant quality control
Briefing on plant quality control
Briefing on plant technical Kiln and hydration,
PCC and waste water treatment plant.

11/08/201612/08/2016
15/08/2016
16/08/201619/08/2016

22/08/201626/08/2016

Attachment to PCC and WWTP

Attachment to kiln and hydration plant
Attachment to packing plant

29/08/201602/09/2016

Attachment to PCC and WWTP

Attachment to kiln and hydration plant
Attachment to packing plant

05/09/201609/09/2016

Attachment to PCC and WWTP

Attachment to kiln and hydration plant
Attachment to packing plant

12/09/201616/09/2016

Attachment to PCC and WWTP

Attachment to kiln and hydration plant
Attachment to packing plant
Presentation preparation

10

19/09/201623/09/2016

Presentation preparation
Presentation to SKM

4.0

COMPANY BACKGROUND

Established in 1995, Schaefer Kalk (M) Sdn Bhd is 100% owned by Schaefer Kalk GmbH & Co. KG,
Germany. Based on Diez, 70 kilometres northwest of Frankfurt, Schaefer Kalk has been involved in
producing calcium products since 1860. The German company employs 700 staff and produces a wide
range of high-quality calcium-based products. The research and development department based in
Henstatten develops many products to match specific demands from costumers, as does Schaefer Kalk
(Malaysia)s research and development facilities in Kuala Ketil, Kedah. Schaefer Kalk has established a fully
automatic production process to produce high quality calcium products. Capacity is 50 000 tons annually of
precipitated calcium carbonate (PCC), 80 000 tons per year of calcium hydroxide with purity above 98 %.
Producing High Quality Precipitated Calcium Carbonate and highly reactive Calcium Hydroxide using the
highest technology, with customers being worldwide leaders in various ranges of applications from paper,
toothpaste, paint and plastics to pharmaceuticals, oil refinery processes and waste treatment. This company
runs 3 plant in producing high quality precipitate calcium carbonate and highly reactive calcium hydroxide.
The process involve are:

REACTION IN KILN:

CaCO3

CaO + CO2

(Quicklime)

REACTION IN HYDRATED LIME PROCESS:

CaO + H2O

Ca(OH)2

(Hydrated Lime)

REACTION IN PCC PLANT:

Ca (OH) 2 + CO2

CaCO3 + H2O

(PCC)

SCHAEFER KALK has been producing precipitated calcium carbonates since 1954. They are marketed
under the brand name SCHAEFER PRECARB.
In our modern production plants we are able to manufacture a range of qualities that meet the exacting
requirements of our customers.
We always focus on our customers and their individual needs. We develop specific solutions to products and
processes in close cooperation with them.
Crystal Design
Precipitated calcium carbonate (PCC) can be produced as various crystal modifications and granule forms.
The physical parameters for each of these precipitation products are optimized according to desired

application, e.g.
particle size and granule size distribution
single particles or agglomerations of primary crystals
specific surface, pore volume, absorptive capacity (oil number)

4.1

COMPANY ORGANIZATION CHART

5.0 TASK 1: REACTOR PERFORMANCE

Objective:

AND 2:
To find how many PCC produced from each reactor and power used forMILL
each 1reactor
To reduce size of the grits to
<45m
To find whether amount of PCC produced is in range amount

Above are the sample images of reactor. Reactors are only used in PCC plant. There are 6 reactor available
in the plant. There are small reactors and large reactors. Reactor 1, 3 and 5 are labelled as small reactor
which only consist of feed pump and agitator which uses power. Reactor 2, 4 and 6 are labelled as large
reactor which uses blower and agitator as source of power.

Every sample from each reactor needs to be taken and then those samples are used to find how many solid
contents are available in those samples. Three trials were taken for each sample and thus average was
obtained.

PCC PRODUCED FOR EACH REACTOR

8

TRIAL 1

REACT

UNIT

R1

R2

R3

R4

R5

R6

OR
Ca(OH)2

TOTA
L

g/L

200.2

215.52

192.09

173.27

186.49

164.66

m3/batch

16.5

36.19

12.5

40.57

14

31.47

L/batch

16500

36190

12500

40570

14000

31470

Total

(min/batc

195

199

158

224

173

181

Batchin

h)

16940

39194.3

15196.

31381.

15091.

28629.

99

98

68

01

24.40

56.44

21.88

45.19

21.73

41.23

210.87

1.02

2.35

0.91

1.88

0.91

1.72

8.79

R1

R2

R3

R4

R5

R6

TOTA

Solid
Content,
Volume
per
batch,

g Time
Rate of

g/min

Producti
on

ton/day

Average

146434

TRIAL 2

REACT

UNIT

OR
Ca(OH)2

L
g/L

226.23

197.8

220.12

192.69

190.19

204.8

m3/batch

16.4

35.84

13.67

34.35

13.89

27.02

L/batch

16400

35840

13670

34350

13890

27020

Total

(min/batc

175

203

165

182

138

170

Batchin

h)

21200.

34921.

18236.

36367.

19143.

32551.

Solid
Content,
Volume
per
batch,

g Time
Rate of

g/min

162421

Producti
on

ton/day

Average

98

93

61

59

04

15

50.29

26.26

52.37

27.57

46.88

233.89

50.29

1.23

2.10

1.10

2.18

1.15

1.95

9.75

R1

R2

R3

R4

R5

R6

TOTA

TRIAL 3

REACT

UNIT

OR
Ca(OH)2

L
g/L

Solid

220.7

226.73

226.53

220.22

221.02

211.51

35.9

13.6

34.57

21.06

30.7

Content,
Volume

m3/batch

per

16.88
6

batch,

L/batch

16886

35900

13600

34570

21060

30700

Total

(min/batc

196

210

152

233

195

232

Batchin

h)

19015

38760.0

20268.

32673.

23870.

27988.

162576.

.7

47

84

16

61

27.38

55.81

29.199

47.05

34.37

40.30

234.11

1.14

2.32

1.21

1.96

1.43

1.67

9.75

g Time
Rate of

g/min

Producti
on
Average

ton/day

All these three trial were taken at different time and date. It is to ensure that these reactors are applicable
and can be investigate. Then, the average was calculated from these trials. From there the value of Ton PCC
can be obtained. For a day, range of PCC obtained from PCC plant are 200 ton PCC. Thus, the objectives in
this experiment are to obtain the value of ton PCC must above 200.

10

AVERA

UNIT

R1

R2

R3

R4

R5

R6

TOTA

GE

L
Ton/day

27.44

54.18

25,77

48.20

27.89

42.80

226.29

Ton/hr

1.14

2.26

1.07

2.01

1.16

1.78

9.43

Ton PCC

3.6

7.7

2.8

7.1

3.3

5.7

30.20

In conclusion from this performance, it shows that total of Ton PCC per day exceeds 200 which are 226.29
Ton PCC. Next we going to discuss on the power used for each reactor.

AMOUNT OF POWER USED BY EACH REACTOR

Reactor 1,3 and 5 is small reactor thus it only used feed pump and agitator as the power source while
reactor 2, 4 and 6 used blower and agitator as its power source due to its largeness.

TRIAL

R1
FEED

R3

AGITATOR

PUMP

FEED

R5

AGITATOR

PUMP

FEED

AGITATOR

PUMP

16

832

19

448

28

643

17

642

10

511

25

592

20

724

11

455

32

702

AVERAG

17

733

10

472

28

646

304

196

12

268

E
KWHR
TOTAL

311

200

280

TRIAL

R2

R4

R6

FEED

AGITATOR

PUMP

FEED

AGITATOR

PUMP

FEED

AGITATOR

PUMP

228

367

203

169

149

299

300

504

183

409

146

262

247

378

211

482

210

214

AVERAG

258

416

199

420

168

259

11

E
KWHR

300

TOTAL

504

183

311

409

146

619

262
427

TOTAL AVERAGE FOR POWER USED

REACTO

R1

R2

R3

R4

R5

R6

86.9

87.9

70,7

87.3

84.6

74.4

R
kWhr/ton
PCC

The above data shows that the most efficient reactor between those 6 reactor is R3 because it used less
power to produce PCC and to conserve energy.

6.0 TASK 2: FUNCTION OF PHOSPHATE

Objective:

MILL
AND 2: to be
Phosphate is one of the agent or catalyst which are added in PCC to control
the 1structure
To reduce size of the grits to
much more refined.
<45m

12

To investigate whether phosphate can reduce pH of PCC or not.

Above is the flowchart where phosphate are added

At first, the pH was directly taken from PCC tank and Receiving tank. PC tank is where before phosphate
added and Receiving tank is where phosphate was been added. Below are the data that shows the result.

TRIAL

pH VALUE
PCC TANK

RECEIVING TANK
10.10
13

10.14

9.53

9.96

9.76

9.19

The data shows that even after phosphate added, the data still shows an increasing pH value although it
should shows decreasing value. Thus another experiment was conducted which include Buchner funnel

EXPERIMENT USING BUCHNER FUNNEL

Procedure
Shake the sample vigorously and pour the solution through the Buchner funnel onto the filter paper
Filter the solution with the aid of vacuum pump or water pump jet until the water is filtered out
Then dry those sample in oven about 1 hour
Mix the powder with distilled water and pH value was measured.

NUMBER OF TRIAL

pH VALUE
14

PCC TANK

RECEIVING TANK

9.48

9.67

9.42

9.86

9.25

9.46

The data still shows no decreasing sign thus in conclusion phosphate cannot reduce the pH value.
Phosphate only acted as buffer solution to control viscosity.

7.0 TASK 3: KILN DUST SILO 5

Objective:

To loading kiln dust silo 5 in bulk truck

To increase the expenditure of kiln dust in silo 5

15

MILL 1 AND 2:
To reduce size of the grits to
<45m

OVERVIEW OF PFD KILN DUST

16

FLOWCHART FOR KILN DUST

17

PROPOSAL 1: ATTACHED SCREW BELT CONVEYOR TOWARDS SILO 4

Silo 4 was unused due to construction of kiln 3 in one year. By attaching screw belt conveyor connected to
silo 4 area, bulk truck can be pass underneath silo 4. These are the most approvable design between other
two proposal which include less costly and can use recycle screw belt conveyor ,

PROPOSAL 2: SCREW BELT CONVEYOR

18

Silo 5 area needs to be enlarged thus screw belt conveyor can be attached. The screw belt conveyor
transports the kiln dust directly to rotary feeder. The bulk truck can pass through underneath silo 5 and the
loading of kiln dust can be achieved. Actually these proposals are the most rejected due to area of silo 5
cannot fir screw belt conveyor.

PROPOSAL 3: USE HOPPER AND BLOWER

19

A new hopper 30 meter cube is attached at hydration plant with purpose loading kiln dust into bulk tank.
Blower from pendulum mill section is alternately used to transport kiln dust from silo 5 to the hopper.

20

These are the additional PFD in terms of proposal 3. In conclusion, between all these three proposal, the
most effective proposal will be proposal will be Proposal 1 due to less costly, less renovation and less work
compare to other two proposal.

HAZOP
GUIDEWORDS

FLOW

PROCESS

POSSIBLE

POSSIBLE

EXISTING

RECOMMENDED

DEVIATION

CAUSES OF

CONSEQUENCES

SAFEGUARDS

ACTION

DEVIATION
Power

Loss

Make

outage

production

NO

of

backup
power

LESS

HIGH

Monitor the alarm

silo
Monitor

the

Do regular check-

operator

current

and

ups

Loss of production

alarm
Preventive

chute
Monthly check-ups

maintenances

on ROF

Operator

Install pneumatic air

checklist

knocker
Always check and

Loss of kiln dust

in silo
Transfer chute

Injuries

blockage
ROF less flow

to

the

due to flight

blockage
chute
Manual
gate fails

Injuries
in
slide

has

prepared
Level alarm in

No production

worn out
Partially

sure

to

the

operator
Overfeed

of

kiln

Operator

dust
Injuries

to

the

training
Stop

21

the

on

transfer

monitor slide gate

Do
maintenances

operator

production

in

procedure

silo

GUIDEWORDS

PROCESS

POSSIBLE

POSSIBLE

EXISTING

RECOMMENDED

DEVIATION

CAUSES OF

CONSEQUENCES

SAFEGUARDS

ACTION

DEVIATION

PRESSURE

HIGH

Too

much Injuries to the Wear PPE

Stops

the

air released operator

loading of kiln

at

dust

transfer

chute

8.0 TASK 4: QUICK LIME RECYLCE PROJECT SILO 5

Objective:

22

MILL 1 AND 2:
To reduce size of the grits to
<45m

To recycle waste from big bag into silo 5

To save and increase the profit of kiln dust by using unused vibrating screen in warehouse

PROPOSAL DESIGN

HYDRATION
PLANT

This design is based on proposal 3. This idea is to collect all the waste from big bag back into silo
5. It will be mixed with kiln dust and can be selling. This design will be using unused screening
which obtained from warehouse to reduce cost of renovation.

23

Above is the image of unused screening that can be recycle to use for kiln dust silo 5. Besides
these equipment, the hopper that we gonna use in this design are also recycle so that the cost can
be reduced. This project will be hold until the renovation of kiln 3 that will be added next year.

HAZOP
GUIDEWORDS

PROCESS

POSSIBLE

POSSIBLE

EXISTING

RECOMMENDED

DEVIATION

CAUSES OF

CONSEQUENCES

SAFEGUARDS

ACTION

Hopper

Spill to the

Any split can

overfills

building floor

be swept and

There are

Potential to

reprocessed
Steep sided

No further action

clumps in

damage the

hopper

required

hopper

hopper and

minimises the

causes blockages

risk of

DEVIATION

FLOW

HIGH

LOW

material holdup on the

hopper walls.

24

NO

Hopper

No production

empty

Process

No further action

controls come

required

into effect to
trip
downstream
fired
Feeder fails

Hopper full of

appliances
Routine

Preventive

material.

checks on belt

maintenance

Confined space

feeder during

procedures

entry to unblock

shutdowns,

25

9.0 TASK 5: EFFECT ON SIZE PARTICLE ON DRUM FILTER

Objective: To study the effect of size and moisture content in drum filter
Schaefer Kalk (M) Sdn Bhd runs 5 products of PCC. But in our task, we use only 2 products which different
is size for study purpose. P110 is one of the PCC products where the size is small and P230 is the products
that have larger size. These 2 products are from reactor where Ca (OH) 2 is converted to CaCO3. Then the
products from reactor are transfer to drum filter to absorb water before it will enter a dryer.
This study is based on effect of size on moisture content in a cake sample taken from drum filter.

Products

P230

Take

P110
Moisture content (%)

46.33

50.79

45.51

52.25

46.32

50.27

46.47

52.92

P110 has small in size, thus moisture content is high around 50-55%. While, P230 has bigger size, thus
moisture content is low around 45-48%. Thus, P230 has higher productivity than P110 per day.
Bigger size will give lower moisture content because the water trapped inside together with the products
easily suck in into central duct. Bigger size gives larger void space. Therefore, water molecules easily diffuse
out through the filter cloth while water is hardly pass through the small size particles.
By using mass balance, the water removal from dryer is high for high moisture content (small size particle).
Thus, larger amount of product are produced from the dryer as less water contain in the cake.

10.0 SUGGESTION ON IMPROVEMENT

1. Reverse parking procedure is to avoid accident at parking space

26

Accuracy To successfully park in a bay within the lines and not too close to a car on either side.

Control By keeping the cars speed under control by use of clutch control and by use of effective
steering.

Observation Constant all-round observation throughout the bay parking manoeuvre.

1. Purchase more land area

Due to the company becomes more demand, the company needed to enlarge the company by purchasing
more land area so that more process and more products can be produced. The company needs to extend
stockyard, storage and improve material transportation
2. Install sensor that indicates IPU
Regarding dust pollution incident, i propose that SKM install sensor that indicates dust pollution index or IPU
(indeks pencemaran udara) on top of each building from time to time. This dust pollution index or IPU (indeks
pencemaran udara) need to be monitored from time to time.
3. Using stacker and reclaimer system
It is to enhance material transportation system and homogenizing the chemical content of limestone. These
processes were worldwide used in other large companies and can make the limestone more high quality

27

Image example of stack and reclaimer system

28

11.0 CONCLUSION
These 11 weeks of internship programme starting from 18 nd July 2016 to 23rd Sept 2016 had ended with a
success. I have gained a lot of technical and non-technical skills which will help me to prepare for working
environment. I have learned much unit operation, wastewater treatment and to verify the specification that
we need in lab. Actually, the industrial training program has strengthened my soft skills include adaptability
and flexibility, time management, priority management and problem solving skill.
As conclusion, I would like to say that Schaefer Kalk (M) Sdn Bhd is one of the best places for University
Technology Mara student especially those who pursue chemical engineering to do their internship
programme. I strongly believe the experience gained will prepare me as a better engineer in the future.

29

APPENDICES

30