Reward: 3,00,000 INR to 10,00,000 INR
Tata innoverse was started by Tata industries, to provide open innovation platform to solve challenges for various problems. By this initiative the industry is targeting to solve many real world problems by reaching out to skilled solvers internationally and also to provide them a best platform to demonstrate their ideas, skills and creativity to develop unique and best solutions to solve real world industry challenges. The best problem solvers get rewarded, and also they become trusted technology partner with Tata industries.
1. Silt Removal from open-cast chromite mine
(Closing Date: 14/Apr/2019)
In open pit mines, surface runoff from the mine carries solid particles and deposits them as silt at the bottom of the bank. As a result, the ores are covered with silt, which eventually affects the mining operations. The problem persists throughout the rainy season and the following months and applies to all of Chrome Ore's extractive industries. It is necessary to eliminate the suspension at about 100 TPH (weight of solid particles) up to about 120 m in height. Sludge pumps were not appropriate due to blocks> 3 mm in size. The current combination dumper shovel is capable of treating such a silt with an efficiency of only 30%.
2. Alternate Mining Technology - Steep Gradient Mining
(Closing Date: 14/Apr/2019)
The combination dumper with shovel is currently used for the excavation of ores. The lowest level of excavation is limited by the allowable slope angle and the ultimate pit boundary. Our goal is to carry out a new excavation up to 20 m beyond the pit limit. The problem with this is the stabilization of the pit wall which will collapse beyond 6 m of excavation. As a result, it is impossible to extract ore below the ultimate pit level by open casting.
The cost of excavation in the current method increases with depth due to the greater excavation of Over Burden (mine waste) to extract the same amount of ore. The current ratio of ore to overburden is 1: 5. If only the ore could be excavated or the amount of overburden could be reduced, the cost of mining would drop significantly.
3. Chimney Inspection And Maintenance
(Closing Date: 15/Apr/2019)
Chimney inspection is a standard problem in the iron and steel industry because the chimney is hot and difficult to inspect if it is not closed. In addition, the chimneys are very high (> 150 feet and over) and difficult to deploy at these heights, even during the shutdown period. The main purpose is to measure the wall thickness of the chimneys and to ensure that the structure is not weak. Maintenance is then started to reinforce the weakest parts of the chimneys.
Inspection and maintenance of the chimney pose problems due to temperature and heights. This requires the preparation of scaffolding to climb to the places where to inspect these chimneys. It is also very difficult to reach all areas of the chimney because the ladder or scaffold only gives access to limited parts of the chimney. The high temperature and the height do not facilitate the inspection of these structures.
A non-invasive method for the quantitative inspection of chimneys - wall thickness as well as location information must be provided. This method should not ideally require a shutdown of the zone / equipment.
No manual intervention is desired.
A maintenance plan with detailed information on the wall thickness and the location of the corrosion must also be generated.
4. Flame Ignition In Flare Stacks
(Closing Date: 15/Apr/2019)
The by-products of BF and LD are burned before being released into the atmosphere by the chimneys (known as "flares"). It consists of three chimney heads to release the main gas, each with four igniters (and pilot burners) at the top of the chimney. The night light is used to ignite these gases which are located at the top of these flares. A detection system (based on the flame temperature) is used to detect if the pilot flame is on. It becomes difficult to detect the presence or absence of the flame for various reasons.
5. Residual Stress Measurement Of Steel Strips
(Closing Date: 21/Apr/2019)
Steel strips (width 400-1800mm and thickness 1-8mm) produced by a hot or cold rolling mill will exhibit inherent defects due to unbalanced residual stresses in the web. Residual stresses occur in the form of warp, arc, twisting, or curvature when the web is cut into small pieces using laser, plasma, or oxycutting cutting. Industrial users of hot-rolled steel strip prefer flat and level sheets. Defects such as coil set, camber, side wave, twist or loop are also not acceptable for these users / industries. Curvature and warping in the sheet and other defects should be kept to a minimum.
Steel service centers use a roller leveler to flatten the sheet by reducing or balancing residual stresses. Proper knowledge and mapping of residual stresses along the length and width of the web can be an important contribution to the leveler in order to obtain a correct adjustment of the rollers in order to improve the flatness desired by the end users.
In light of the above requirements, we are looking for a non-destructive method to accurately determine or measure the residual stress inherent in the surface of a steel strip, prior to its treatment by the leveler. The residual stress measured will therefore allow the leveler to flatten the sheet properly. The stress measurement unit can be mounted on a machine cut to the length just before the leveler (as shown in Figure 1) and its output would be transmitted to the leveler control system so that the leveler rollers are adjusted automatically and band without stress. The speed of the line is approximately 60 meters per minute for the HSM line (Hot Strip line) and 100 meters per minute for the CR line (cold rolled line). The apparatus shall be capable of measuring the stress on the rolling line prior to the shearing and leveling operation. It is also necessary to measure the residual stresses after the leveling operation to see the stresses after leveling.
2. Please share your solution
3. What other solutions have you seen in the market for this problem? What have been the flaws in those solutions?
4. Please define the problem statement as understood by you
5. What positive and unique results do we expect to see from your solution?
6. What is the estimated investment required to implement your solution at our end?
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Contest link: www.tatainnoverse.com
Category of contest: Hardware contest, Industry contest
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