Chapter 1 Company Profile
Hindustan Zinc Limited (HZL) is an integrated mining and resources producer of zinc, lead, silver and cadmium. It is a subsidiary of Vedanta Resources PLC. HZL is the world's second largest zinc producer. Its FY2011 revenues were Rs. 108.91 billion. Zawar Mines , is a unit of Hindustan Zinc Limited. It was started in 1968. In this plant, zinc along with its products viz. Silver, Cadmium, Sulphuric acid etc. are produced from Zawar Mines and other mines of the company. Initially this Smelter started with 18,000 tonnes per annum capacity, but at present the capacity of plant is 49,000 tonnes per annum, the recovery of Zinc in this plant is 99.52%. In HZL Various Departments (Plants) as under: Roaster plant Acid plant Leaching and purification plant Zinc Electrolysis and melting plant Zinc Dust plant Electrical department Instrumentation plant Finance Department Project Department
1.1 ROASTER PLANT
At Zawar, Zinc Smelter two roasters are used for roasting i.e. Roaster1 & Roaster2. Roasters are mainly furnaces which are maintained at 9500C. These furnaces are fluidized type in which fluidized bed is made and air is passed from bottom for oxidation. The furnaces are autogenously, so only to start the reaction or to obtain required temperature of fuel is required. Roaster Specification-
Roaster1
Roaster2
Capacity Heath area Air flow Feed No. of nozzles Diameter Acid
140 tonnes/day 18.5sqm 9500 5tonnes/hr 1848 4.18m 100m
240 tonnes/day 35sqm 9500 10tonnes/hr 3500 6.69m 200m
The raw materials used for production of zinc is named blend which is prepared by the concentrate with comes from various mines. The main constitute present in the blend is ZnS. For the leaching of ZnS it is necessary to first convert it into oxide i.e. roasting of ZnS is done here at roaster.
1.2 ACID PLANT
Gases coming out of hot gas precipitator have 7-8% SO2 & at 3300C. In this section SO2 Gas at temp 3300C is passed through scrubbing tower, which has sedimentation tank & SO2 stripper & wet gases precipitator is obtained at temp 550C. SO2 gas has moisture. This SO2 gas is first dried in a drying tower with H2SO4 to remove the moisture content. Parameters that are maintained in neutral leaching:Total Iron Initial P Fe++ Temperature Reaction time
H
2.5 3.5gpl 2.8 3.2gpl 4.5 4.6 5 Mg Pl 65-700 150 180 minutes
Final PH
1.3 LEACHING AND PURIFICATION:Leaching is a selective dissolution of ore minerals /oxide minerals in acid or solution of other reagents according to the condition adjusted in a manner to leave maximum gangue in the insoluble residue. Calcine comes into the hopper from roaster with the help of bucket elevators. From the hopper the calcite is coming to a redder conveyor through a rotatory value. By adjusting the speed of the rotatory value calcine directly into puchuua. The calcine if expand in stored in sizes The average rates of calcine consumption is 11MT/hr, whereas the rate of solution supply is 90 m3/hr . this corresponds to 140-150MT of Zinc ingots per day. Total calcite storage capacity in the leaching plant:Total Capacity Old Silo [Nos.1, 2, 3] New Silo [Nos.4, 5, 6] 3930 Mts 680 Mts each 680 Mts each
According to the reaction Fe (SO4)3 +3ZnO 3H2O 2Fe(OH)3+3ZnSO4
1.4 ELECTROLYSIS AND MELTING:Electrolysis of zinc sulphate solution take place in electrolysis cell with aluminum sheet as cathode and silver lead alloy as anode .The reaction can be represented as: As cathode (reduction) Zn2+ +2eAt anode (oxidation) So42 +H2O Over all reaction 2ZnSO4 + 2H2O 2Zn + 2H2SO4 + O2 H2So4 + 2e Zn
The zinc gets deposited on the Al cathode and is stripped after 24 hours of deposition whereas oxygen is given OFF at the anode.As SO42- ions have strong affinity for hydrogen ions this results in formation of sulphuric acid. The oxygen
which is liberated oxidizes the MnSO4 in solution to MnO2 which deposits as anode mud which is cleaned out periodically.
Solution cooling and storage: Neutral electrolyte from purification shall be available at 60-70% as hot purification process has been adopted for expansion. The neutral solution is fed directly to atmospheric coolers where solution is cooled to 35oC, coolers have been provided for this circulating spent solution cooled in separate 5nos. coolers out of which normally three are in services and two are standby. Here temperature drop is from 42oC to 35o. Gypsum deposit take place in these coolers.
1.5 ZINC DUST PLANT
Zinc dust is produced in the Zinc dust plant. Zinc dust is produced & then used in Leaching & purification plant.In the production of Zn dust following types steps is followed. First of all Zinc maggots are melted in an oil furnace, from which melted Zinc is taken into Electro Furnace to vapourise the Zinc. For this purpose coke is used between two graphite electrodes. This Vapour is allowed to pass through a condenser or where it is cooled by Nitrogen Gas. After cooling the Vapour is changed in the form of dust Known as ZINC DUST.
1.6 ELECTRICAL DEPARTMENT:Power situation in any industry is alarming. The gap between demand and supply keeps widening day by day. The energy SBU thus determines how each business unit or process consumes power. This helps to promote accountability, increase efficiency and productivity. Electrical energy acts as a raw material for industry. It implies energy saving through various ways after all energy saved is energy generated.
1.7 INSTRUMENTATION DEPARTMENT
Different instruments used in the plant are:1. Line Measuring instruments : i. Differential pressure transmitter
ii. iii.
Bip Tube Ultra sonic
2.
Pressure measuring instruments Pressure Gauge
3. Temperature Measuring Instruments I. K-type thermocouple These are made up of Cr Al. II. T- type thermocouple These are made up of Fe & Constantan.
4. Flow Measuring Instrument I. II. III. IV. Orifice Magnetic Flow Rota meter Venturimeter
5. RTD
1.8 FINANCE DEPARTMENT
If the estimated amount is less than 5 Lacks than quotations are invited from vendors and no open tenders is issued. A period of month is given to the contractors for sending their bids. The vendors and the contractors who offer the minimum bid are awarded with the order or contract. When any new materials arrived in factory an R.I.S.R. (receive some inspection report) prepared by the concerned engineer. It is found unsatisfactorily. The material is sent back to the vendor from where it has been finance and purchased.
1.9 PERFORMANCE:Zawar Mines has achieved an impressive growth pattern and condition and endeavors are being made to improve the production, as productivity. Emphasis is given for energy
conservation, improvement in recovery efficiency and reduction in process chemical consumption which is prime factor in controlling the cost of production. In order to sustain above achievement, TQM and workman participation through suggestion scheme are in Zinc smelter Zawar, now is a 9002 certified unit for quality management system from 05-11-1998.
Chapter 2 PROJECT PROFILE
The aim Our project entitled Electricity Billing System aims is to generate electricity bill with all the charges and penalty. Manual system that is employed is extremely laborious and quite inadequate. It only makes the process more difficult and hard.
The aim of our project is to develop a system that is meant to partially computerize the work performed in the Electricity Board like generating monthly electricity bill, record of consuming unit of energy, store record of the customer and previous unpaid record.
The overall project report is divided into some parts. These parts are further divided into their subparts. In the parts we have described the purpose, scope of the project, objective of the project i.e. approach which used for developing this software. It includes the topics like the problems with the existing system and the functionality of the organization. Introduction to tools, design, coding, testing and debugging of the system are discussed in very detail. We have also provided the names of the books from which we have taken guidance to complete the work. Last section contains the matter about the overall work performed and the efforts taken to complete the project.
2.1 SYSTEM STUDY: 2.1.1 Scope:
Our project aims at Business process automation, i.e. we have tried to computerize various processes of Electricity Billing System. In the sector of electricity board we have computerizes their department and stock maintenance. Scope of any software depends upon the following things: 1. It satisfy the user requirement 2. Be easy to understand by the user and operator 3. Be easy to operate 4. Have a good user interface 5. Be expandable 6. Delivered on schedule within the budget.
We have tried to make such type of software, which satisfy the above given requirement.
2.1.2 Objectives Of The System:
The firm handles all of the work manually, which is very tedious and mismanaged. The objective of our project is as follows: a. To keep the information of Customer. b. To keep the information of consuming unit of energy of current month. c. To keep the information of consuming unit of energy of previous month. d. To keep the information of employee working in the department. e. To maintain the record of the department.
2.2 SYSTEM ANALYSIS: 2.2.1 Identification Of Problem:
The old manual system was suffering from a series of drawbacks. Since whole of the system was to be maintained with hands the process of keeping, maintaining and retrieving the information was very tedious and lengthy. The records were never used to be in a systematic order. there used to be lots of difficulties in associating any particular transaction with a particular context. If any information was to be found it was required to go through the different registers, documents there would never exist anything like report generation. There would always be unnecessary consumption of time while entering records and retrieving records. One more problem was that it was very difficult to find errors while entering the records. Once the records were entered it was very difficult to update these records. In present, work done in the electricity board is performed manually which is a great headache for the department .The reason behind it is that there is lot of information to be maintained and have to be kept in mind while running the business .For this reason we have provided features Present system is partially automated (computerized), actually existing system is quite laborious as one has to enter same information at three different places.
Following points should be well considered-: Documents and reports that must be provided by the new system: there can also be few reports, which can help management in decision-making and cost controlling, but since
these reports do not get required attention, such kind of reports and information were also identified and given required attention. Details of the information needed for each document and report. The required frequency and distribution for each document. Probable sources of information for each document and report. With the implementation of computerized system, the task of keeping records in an organized manner will be solved. The greatest of all is the retrieval of information, which will be at the click of the mouse. So the proposed system helps in saving the time in different operations and making information flow easy giving valuable reports.
2.2.2 Feasibility Study:
Feasibility study is the phase in which the analyst checks that the candidate system is feasible for the organization or not. This entails identification, description & evaluation of the system. Feasibility study is done to select the best system that meets the performance requirement. If the feasibility study is to serve as a decision document, it must answer key questions. 1. Is there a new and better way to do the job that will benefit the user? 2. What are the costs and savings of the alternatives? 3. What is recommended? The most successful system projects are not necessarily the biggest or most visible in the business but rather those truly meet users expectations.
Feasibility considerations Three key considerations are involved in the feasibility study. They are as follows:-
Economic Feasibility: Economic analysis is the most frequently used method for evaluating the effectiveness of the candidate system. We analyze the candidate system (computerized system) is feasible as than the manual system because it saves the money, time and manpower. It also feasible according to cost benefits analysis.
Technical Feasibility: Technical feasibility centers around the technology used. It means the candidate system is technically feasible i.e. it dont have any technical fault and work properly in the given environment. Our system is technically feasible; it is providing us required output.
Behavioral Feasibility: Behavioral feasibility is the analysis of behavior of the candidate system. In this we analyze that the candidate system is working properly or not. If working than it communicating proper with the environment or not. All this matters are analyzed and a good candidate system is prepared. Due to the change of system what is the change in behavior of the users, this factors are also analyzed.
2.3 SYSTEM DEVELOPMENT ENVIRONMENT:
System development environment shows the hardware and software requirement, which is necessary for developing the software. Necessary software and hardware requirement, which are necessary for making this software are as follows:
2.3.1 Software Requirement:
OPERATING SYSTEM COMPILER : DOS, Windows 98/XP/7 : TURBO C
2.3.2 Hardware Requirement:
PROCESSOR RAM HARD DISK OUTPUT DEVICE INPUT DEVICE : : : : : Pentium i 133 MHz or Higher 16 MB or Higher 2.1 GB or Higher Color Monitor Keyboard & Mouse
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2.4 FLOW DIAGRAM The Data Flow Diagram takes an input-process-output view of a system. That is, data objects flow into the software, are transformed by processing elements, and resulting data objects flow out of the software. Data objects are represented by labeled arrows and transformations are represented by circles. DFD provide an additional insight into system requirements and flow.
Keyboard IV.
V.
III.
User commands and data
Electricit y Billing Software
VI.
Display information
Monitor
Context level DFD for Electricity billing software
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2.5 USE CASE DIAGRAM
Use case diagram illustrates the manner in which an actor (in this case, the data entry operator) interacts with the system.
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2.5 TOOLS DESCRIPTION 2.5.1 Introduction of Turbo C:
Turbo C++ was a C++ compiler and integrated development environment and computer language originally from Borland. Most recently it was distributed by Embarcadero Technologies, which acquired all of Borland's compiler tools with the purchase of its CodeGear division in 2008. The original Turbo C++ product line was put on hold after 1994, and was revived in 2006 as an introductory-level IDE, essentially a stripped-down version of their flagship C++Builder. Turbo C++ 2006 was released on September 5, 2006 and was available in 'Explorer' and 'Professional' editions. The first release of Turbo C++ was made available during the MS-DOS era on personal computers. Version 1.0, running on MS-DOS, was released in May 1990. An OS/2 version was produced as well. Version 1.01 was released on February 28, 1991[1], running on MS-DOS. The latter was able to generate both COM and EXE programs, and was shipped with Borland's Turbo Assembler compiler for Intel x86 processors. The initial version of the Turbo C++ compiler was based on a front end developed by TauMetric (TauMetric was later acquired by Sun Microsystems and their front end was incorporated in Sun C++ 4.0, which shipped in 1994).This compiler supported the AT&T 2.0 release of C++.
2.5.2 Characteristics Of C Language/Main Features
1. Modularity. 2. Portability. 3. Extendability. 4. Speed. 5. Flexibility. Modularity: Ability to breakdown a large module into manageable sub modules called as modularity, that is an important feature of structured programming languages.
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Advantages: 1.Projects can be completed in time. 2. Debugging will be easier and faster. Portability: The ability to port i.e. to install the software in different platform is called portability. Highest degree of portability: C language offers highest degree of portability i.e., percentage of changes to be made to the sources code are at minimum when the software is to be loaded in another platform. Percentage of changes to the source code is minimum. The software that is 100% portable is also called as platform independent software or architecture neutral software. Eg: Java. Extendability: Ability to extend the existing software by adding new features is called as extendability. SPEED: C is also called as middle level language because programs written in c language run at the speeds matching to that of the same programs written in assembly language so c language has both the merits of high level and middle level language and because if this feature it is mainly used in developing system software. Flexibility: Key words or reverse words ANSIC has 32 reverse words C language has right number of reverse words which allows the programmers to have complete control on the language. C is also called as programmers language since it allows programmers to induce creativeness into the programmers.
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2.5.3 Structure In C:
A struct in C programming language is a structured (record) type that aggregates a fixed set of labelled objects, possibly of different types, into a single object. A struct declaration consists of a list of fields, each of which can have any type. The total storage required for a struct object is the sum of the storage requirements of all the fields, plus any internal padding. For example: struct account { int account_number; char *first_name; char *last_name; float balance; }; Defines a type, referred to as struct account. To create a new variable of this type, we can write struct account s; which has an integer component, accessed by s.account_number, and a floating-point component, accessed by s.balance, as well as the first_name and last_name components. The structure s contains all four values, and all four fields may be changed independently. The primary use of a struct is for the construction of complex datatypes, but in practice they are sometimes used to circumvent standard C conventions to create a kind of primitive subtyping.
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2.5.4 File system in C
The C programming language provides many standard library functions for file input and output. These functions make up the bulk of the C standard library header <stdio.h>. The functionality descends from a "portable I/O package" written by Mike Lesk at Bell Labs in the early 1970s. The I/O functionality of C is fairly low-level by modern standards; C abstracts all file operations into operations on streams of bytes, which may be "input streams" or "output streams". Unlike some earlier programming languages, C has no direct support for random-access data files; to read from a record in the middle of a file, the programmer must create a stream, seek to the middle of the file, and then read bytes in sequence from the stream. The stream model of file I/O was popularized by the Unix operating system, which was developed concurrently with the C programming language itself. The vast majority of modern operating systems have inherited streams from Unix, and many languages in the C programming language family have inherited C's file I/O interface with few if any changes (for example, PHP). The C++ standard library reflects the "stream" concept in its syntax; see iostream.
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2.6 HOW TO USE THIS APPLICATION
Execute the C file and press enter to continue. Enter your choice as 1,2,3 from keyboard .
Menu is as follows :
1.ADD 2.EDIT 3.VIEW 4.VIEW ALL 5.DELETE 6.EXIT
The above options have following effects : ADD - It will add new Customer details. EDIT - It will edit the Customer details. VIEW - It will display payment list of a customer. VIEW ALL It will display whole list. DELETE - It will delete the customer details. EXIT Exits the program
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CHAPTER 3 FILE STRUCTURE
When user will write on console to insert the data, it will be saved on one binary file in our PROJECT. We have used one file, BILL.DAT, to store information of customer bill details. The structure of these file are shown below.
The structure of this file is shown below. BILLS
code name present previous bill char[5] char[35] int int float
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CHAPTER 4 SAMPLE OUTPUTS
WELCOME SCREEN:
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MAIN MENU:
The main menu displays processes that can be accessed through the project. Various operations are listed as follows:
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ADD RECORD:
This allow to add New Customer Detail.
EDIT RECORD:
By Pressing key 2, you can edit the current record of customer.
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DELETE RECORD:
By Pressing Key 3, You can delete the customer record.
VIEW RECORD:
By Pressing key 4, you can view a particular record.
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VIEW ALL: By Pressing Key 5, You can see all the records.
EXIT:
By pressing Key 6, you can exit.
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Chapter 4 REFERENCES
Software Engineering - A Practitioners Approach, Roger S. Pressman. Sixth Edition. Tata McGraw Hill. Let us C, Yashwant Kanethkar. Technical references provided by company . www.wikipedia.com
www.hzlindia.com
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