Sinter Plant

JNIL

What is sinter
Sinter word comes from the Greek word sint which means dust. The process which utilizes dust to convert it into lumps is called sinter.

Sintering is an agglomeration process which involve heating raw material to incipient temp (below its melting point) to convert it into hard lumpy and porous mass.

Basic Raw Material

Iron ore fines Coke fines Limestone Dolomite

Iron ore specification

Chemical Analysis Fe(T) = 58- 65% SiO2 = 2.0 3.5% Al2O3 = 1.5 2.5% Alkali =

Physical Analysis

Limestone specification

Chemical Analysis CaO = 45 50% Min MgO = 2 4% Max SiO2 = 4 8% Max Al2O3 = 1 2% Max Alkali = 0.20% Max

Physical Analysis Sieve 10 30 +5.0%

Dolomite specification
Chemical Analysis

CaO = 30 25% Min MgO = 20 15% Min SiO2 = 4 8% Max Al2O3 = 0.5 1% Max Alkali = 0.20% Max

Physical Analysis Sieve 10 50 +5.0%

Conveying system of raw material

Reclaiming
The following belt used during operation C3 1.3 1.5 1.6 1.7 3.1 2.1

Ground hopper
The following belt used during operation 1.3 1.5 1.6 1.7 3.1 2.1

Crushing section
As the sinter process required limestone,
dolomite and coke fines (-3mm) around 90%. So there is a need to crush the above material to get the required size for process. For crushing, there is a hammer mill installed for limestone and dolomite. The four roll crusher for coke crushing.

Flux crushing
According to requirement of the mix flux
analysis, pre calculated amount of limestone and dolomite is feed by weigh feeder and crushed in hammer mill followed by the flux screen to separate 3mm size and sent it to storage bunker situated in proportioning building.

Hammer mill

Material = Limestone & Dolomite Bulk density = 1.6T/m3 Moisture = 2 3% (Max.) Feed size = -50mm (97%), 50-75 (3%) Product size = -3mm(50%), 50% recalculation Capacity = 100TPH Type = Reversible swing hammer with open bottom Rotor diameter and width = 1200mm No of hammer = 60 Grinding gib (straight) = 4 Grinding gib (curve) = 12 Grinding jib material = Mn- steel Gr-III Hammer material = Mn- steel gr-II Rotor speed = 645rpm Drive = v belt with fluid coupling Motor = 200Kw, 1485rpm Motor pulley = 375mm, 8 groove, Machine pulley = 864mm, 8 groove Overall dimension = 2250X1950X2300mm Gross weight = 12 Tons

Flux Screen


Material Mixture of L/S and D/M. Bulk Density 1.6 to 1.8T/m3. Moisture 5%. Feed Size = -50mm. Separation Size = -3mm. Capacity 100T/h. No. of Deck 2Deck 10mm, Opening Deck 3.55 Size 1600*5000mm Motor 40HP. 1465rpm.

Coke crushing
There is two bunker in flux building to store the
nut coke size range between 0-15 mm. Material is feed to four roll crusher and sent it to storage bunker situated in proportioning building.

Coke Crusher(New) (Four Roll Crusher)

Material- Coke. Bulk Density- 0.6T/m3. Maximum Feed Size- -30mm,95% Product- -3mm(95%). Capacity- 20T/h. Primary Rolls- 800*1000. Setting- 10mm. Drive- 30HP. 720rpm.(2). Secondary Roll- 600*1000. Setting- 3mm.

Coke Crusher(Old) (Four Roll Crusher) SAYAJI

Material Coke. Feed Size of Coke up to 40mm. Discharge Size of Coke 2.5mm> 93%. Capacity 20T/h. Size of Rolls 900*700mm Long. Top Roll Drive Motor 40/23Kw,-1500/750rpm,3.440V. Bottom Roll Drive Motor 45kw, 1500rpm,3.440V. Speed of Top Roll = 119rpm. Gear Box Speed Reduction Ratio =12.64 Belt Drive Speed Ratio 1.54. V.Belt Type Section D, Pitch= 4473 No. Of Belt =5. Speed of Bottom Rolls 182rpm. Gear Box Speed Ratio- 1.54 V.Belt Type Section D, Pitch 4473, No. of Belt=5 Bearing for Top and Bottom Roll = Babbitt Lined. Lubrication Centralized Grease Lubrication System with Filter & Auto Electric Timer. Gear Boxes with Splash Oil.

Proportioning building
There are 13 bunker in the proportioning
building. The bunker material are as follows Iron ore fines = 4 Flux fines = 2 Coke fines = 2 Return fines = 3 Mill scale = 1 Calcined lime = 1 allotted to different

Base mix charge

According to the chemical requirement in
product sinter by the Blast Furnace, precalculated amount of raw material taken by weigh feeder. This is called base mix and conveyed by 3.7 belt to the MND(Mixing & Nodulizing drum) hopper.

Mixing drum
Mixing drum is 9m long and 3m in
diameter. It rotates 5-7 rpm according to the requirement. Base mix material is fed to the drum by weigh feeder. The purpose of this drum is to make complete mixing of all charged material. After mixing all the material sent to balling drum.

Technical specification (MD)

Capacity = 200 250t/h Material density = 1.6 t/m3 Slope of shell = 2o Speed of shell = 7m/min Fill rate = 12.7% Material temp = <70oC Motor power = 160Kw, voltage 440V Reduce type transmission (Three column reducer) Speed ratio = 25

Balling drum
Balling drum is 12 m long and 3m in diameter. It
rotates around 5 to 7 rpm according to the requirement.In this drum 7 to 8% (by Wt.) water is added to base mix material through water spray nozzle. This helps to ball formation by sticking and adhering fine particle and consequently increase the permeability of the material. The output material from it is called green mix which is sent to storage hopper situated above the sinter machine.

Technical specification (BD)

Size = 3000X1200mm Product ability = 200 250t/h Material density = 1.7+- 0.1 ton/m3 Slop of shell = 1.5o Speed of shell = 7rpm Fill rate = 12.96% normal, 13.9% Max. Finished product = 143.5sec. Motor power 200Kw. 440V, 50Hz Rotation rate = 490 990rpm

Importance of moisture
Addition of moisture in base mix charge results
the overall performance of sinter plant performance in terms of quality and quantity. Moisture addition plays a key role in ball formation inside the balling drum. If moisture is low in base mix then ball formation will not take place and material will be charged on pallet as fines, resulting in low permeability on sinter bed. Similarly if moisture is high in base mix then formation of slurry will take place and once again it will reduce the sinter bed permeability.

Sinter Machine
Sinter machine consist of 76 pallet of which each
one 1m long, 1.5 m wide and 0.55m in height. The green mix material is charged in it through a charging mechanism which consist of a roll feeder and feeding chute. Prior to this hearth layer (size 10 20 mm) is first charged around 40 50 mm over the pallet car to protect the grate bar from overheating and sticking of the material.

S/M Technical specification

1. Sinter M/C = 2

2. Capacity = 1200 MT/Day/machine 3. Effective sintering area = 36m2 4. Effective sintering length = 24m 5. Center distance between sprocket at feeding end and discharge end = 34.3m 6. Pitch circle diameter of sprocket = 2453mm 7. Pallet dimension = SM-01 (1500X1000X550mm) SM-02 (1500X1000X570mm) 8.Pallet speed = 0.56 1.68 m/min. 9. Pallet quantity = 76 piece. 10. Main drive system: Motor 15Kw Speed 750 rpm Voltage 440V 11. Volume of hearth layer hopper = 28m3 12. Feeding roller dimension = 800X1440mm

Ignition & Pre-heater furnace

There are total 14 nozzle burner manually
operated installed over the roof of ignition furnace which heats up the furnace around 950 to 1250 oC by using blast furnace gas as a fuel. Pre-heater furnace has 9 burner manually operated which also using blast furnace gas as a fuel maintaining the furnace temp around 700 to 800 oC to preheat the blast furnace gas and combustion air which finally sent to ignition furnace. It helps to get quick heat in ignition furnace and also drop the heat loss.

Sinter process
As the material charges over the pallet car and
sent into the ignition furnace. Top layer of the charge ignited and sintering process initiate. Sinter machine moves forward direction and as the pallet passes each suction chamber sintering moves downward direction and completed just before the predefined position by maintaining BTP. Atmospheric air is sucked through the sinter bed by induced draft via a ID fan. There is a wind main situated just below the sinter machine. All the 12 bellow connected to this wind main and it is finally connected to ID fan.

BTP
Burn through point, it is the indication that sinter
process is complete as the combustion zone or fusion zone reaches near grate bar and it must be happen before the end of the machine. Sinter machine speed is regulated taking the BTP point as a reference. It is the predefined suction chamber thats temp is highest comparing to other suction chamber and followed one or two suction chamber of lower temp around 30 to 60oC

Machine speed regulation

The vertical speed of the burning zone and the horizontal pallet speed
determines the position of the burn through point. It is the point where the burning zone touches the bottom layer of bed material. The burn thought point can be kept near a predefined position by adjusting the sinter machine speed. For the low sinter bed permeability, airflow through raw sinter mix decreases. As a result machine speed has to be reduced to keep the burn through point at predefined position. Decrease of machine speed means less production, increase in energy consumption (Gas and electricity) and also increase of dust and carbon monoxides & carbon dioxide discharge, results in air pollution. If speed is not decreased accordingly then proper sintering will not take place and un-burnt material will be discharged to cooler. This in results will decrease the sinter strength and increase sinter return generation, in turn decrease in quality and productivity of the sinter plant. Also if BTP moves towards last wind box, then there is possibility that sintering may take place on the cooler and temp of the final sinter may go up and it may damage transportation conveyor belt and sinter cooler accessory. Hence running the sinter machine at an optimal and constant speed is possible only if optimum moisture level is maintained in the sinter raw mix.

Sinter Breaker
Sintering process convert all the material
into solid cake and it is discharged over the breaker to break it to get below 40mm material as this size range is required for the blast furnace.

Breaker Technical specification

Diameter = 1100mm Width = 1860mm Motor power = 22Kw Speed = 5.83rpm No of teeth = 4X6 rows Feed temp = 800oC Feed size = 1500X1000X570mm Three stage gear box.

Sinter Cooler
After breaker, all the material goes to
sinter cooler where it is cooled by air to get the final product temp below 60 oC. Cooling is done by using FD fan (Forced draught). It is necessary to protect the conveyor belt from overheating and burning.

Sinter cooler Technical specification

Effective cooling area = 51m2 Speed of pallet car = 0.573 1.15m/min Center distance of sprocket = 3960mm Inclination of cooler = 7.074o Feeding material temp = 750oC Pallet quantity = 142 Pallet car width 1500mm, length 600mm, height 900mm. Motor power = 15Kw, 440V, 50Hz. Capacity = 75 130 TPH Cooling time = 40 70 min

Sinter Screen
Sinter screen consist of three deck of
different size to get different size range of sinter. Screen size of 5mm used to get return fines for recycling. Screen size of 10 to 20 mm used to get hearth layer of size range 10 to 20mm. Rest of all the material is sent to blast furnace stock house.

Compressor specification

No of compressor = 02 Make = Altas capco Design pressure = 14.5 bar Min design temp= 10oC Max design temp = 120oC Volume air side = 9.971 Volume oil side = 10 Test pressure = 21bar Max working pressure = 10bar Motor = 55Kw, 95A, 2975rpm Relay range = 50 63A Set relay = 63A Fan motor = relay 4 6.3A , Set = 5A

BLOCK DIAGRAM
R/M FROM RMHS
I/O FINES L/S,D/M,COKE

FLUX BUILDING

PROPOTIONING BUILDING

MND BALING DRUM BASE M H

S/MACHINE

BREAKER
S/COOLER

S/SCREEN

C-15.1&15.2

B/F STOCK H

THANK YOU

Miss u yaar
I KNOW UR MY BEST FRIEND . BUT . I AM UR CLOSED FRIEND. I ALWAYS WITH U I ALWAYS NEED U I ALWAYS MISS U.