Sinter Plant Presentation (Sinter Operation)

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  • PM Trophy 2012-13

    < department >

    JSW Dolvi WorksSteel LimitedSteel ltd.Sinter Plant

  • Introduction of Sinter PlantCommissioning DetailsRaw materials for Sintering ProcessProduct Sinter QualitySpecific ConsumptionsMajor EquipmentsSinter Plant Layouta) Flux Crushing & Screeningb) Fuel Crushingc) Raw material proportioningd) Material charging to Sinter machinee) Ignition of Raw mixf) Sinter Coolingg) Product Screening & DispatchPhotograph of Product SinterContact Numbers of department PersonnelContents:

  • Introduction to Sinter Plant Integrated steel plants generate a lot of waste from the various units which are rich in metallurgical content. For Example : BF - Iron ore fines, Sinter fines, Pellet fines, Coke fines & Flue Dust SMS - Slag, Gas cleaning plant dust Sponge Iron Plant SIP Sludge, Iron Ore fines Rolling Mill - Mill scale Iron Ore mines Iron Ore fines

    Sintering process caught attention of steel plant managers around the world to take care of waste generated in the steel plant and the fines generated in the mines.

  • Plant Commissioning Details Plant Capacity : 2.24 Million tons Per Annum @ 6653 tpd with 337 working days

    Date Of Commissioning : 15th December 2005

    Plant & Equipment Design: C M I, China

    Equipment Supply : MECC, China Area Of Plant : 465 mt X 220 mt

  • Raw Materials for Sintering ProcessIron Ore: 1. Fines Purchased from various sources 2. Fines from SIPCoke: 1. Under size (
  • RAW MATERIAL CHEMICAL ANALYSIS

    SL. No.Raw Material Fe (%)Silica (%)Alumina (%)CaO (%)MgO (%)Fixed Carbon (%)Moisture (%)Ash (%)1Iron Ore Fines62.053.953.150.250.0572Sinter Fines (BF + Sinter)56.234.73.739.811.693Limestone1.631.390.3749.983.611.14Quicklime0.221.870.4292.241.795Dolomite0.671.040.4733.418.430.386Coke Breeze86.748 - 109.667Mill Scale70.481.620.620.730.084.168SIP sludge62.593.91.93.581.021.515.429GCP Dust56.221.912.149.452.811.1310Flue Dust27.712.493.878.80.8526.8510.53

  • Product Quality Chemical Analysis:Physical Analysis:Total Fe :56 % minProduct Size: 5 50 mmFeO :10.5 11.5%+50 mm :5% maxSiO2 :5.0% max0 - 5 mm : 5% maxAl2O3 :< 3.3 % T. I :>72CaO :9.0 10.0 % Basicity :2.0 2.4

    Product Sinter Quality :

  • Specific ConsumptionsIBRM:995 kg / Ton of SinterLime Stone:35 kg / Ton of SinterDolomite:80 kg / Ton of SinterCoke Breeze:65 kg / Ton of SinterQuick Lime:26 kg / Ton of SinterElectric Power:36 kwhr / Ton of SinterWater:0.15 m3 /Ton of SinterRLNG gas:1.5 Sm3 / Ton of SinterBF Gas:10.0 Nm3 / Ton of SinterOxygen :2.0 Nm3 / Ton of Sinter

  • Major Equipments:Main Suction Fan :18500 Cu mt per minSinter Machine : 198 Sq. mtIgnition Furnace : 2Row vertical Burners (12+11)Hot Sinter Crusher : 3500 LongX 1700 DiaCircular Cooler : 228 Sq. mtPrimary Mixing Drum : 3.2mt Dia x12mt LongNodulizing Drum : 3.8mt Dia x117.5mt LongPrimary Sinter Screen : 480TPH (2500X8000)Secondary Sinter Screen : 300TPH (2500X8000)Conveyor System : 48 Nos ( Belt Length 2.5 KM)

  • SINTER PLANT LAYOUT

  • SUB-PROCESS FLUX CRUSHING & SCREENING1) Flux Crushing and Screening is a Closed Loop Process.

    1.1 )Flux (0-50mm) received from conveyor F-4 will be unloaded into 2 surge bunkers, each holding effective volume of 85 m3 for storage of 270 metric tons.

    1.2 )Hammer crusher is used to crush materials having size 0-50mm into 0-3mm (85%). The incoming flux materials are Limestone and Dolomite coming from conveyors F5 &F6 is crushed in to required size and falling to conveyor F7 through discharge chute. When rotor rotates feed comes in contact between hammers and great carrier liners causing crushing of flux

    1.3 ) After Hammer Crusher material is further screened to 0-3mm and sent to proportioning building and Oversize material sent to hammer Crusher for further crushing.

  • Surge bunkers forprimary storageHammer Crusher 112BHammer Crusher112AF-5 conveyorF-6 conveyorF-7 conveyorF-8 conveyorF-9 conveyorFlux screen BFlux screen AF-10Surge bunkers for secondary storageDolomiteLime stoneLime stoneDolomiteLime stoneDolomiteTo Proportional buildingPROCESS FLOW- FLUX CRUSHING AND SCREENINGF-4 conveyor

  • SUB-PROCESS FUEL CRUSHING1) The process involves Crushing of Fuel (coke breeze) and Flux which includes:

    A) Primary Crushing of Coke breeze B) Secondary crushing of Coke breeze

    2) Fuel (coke breeze) crushing is done for obtaining required crushing index (90%) and can be used in sintering process.

    3) To meet the production and process requirement, coke discharged from Double Roll Crusher 900 Dia. X 900mm is fed to 3 nos. of Four Roll Crusher to ensure that minimum 85% of 3 0 mm fraction in crushed coke breeze will be supplied to Raw material Proportioning building.

  • 4 Roller crusher A,B &CDouble roller crusherCoke binsConveyor C-2Coke bunkersPloughMagnetic iron separatorC-4 conveyorC-8 conveyorConveyor C-7C-6C-5Magnetic iron separatorConveyor C-3To proportioning building*PROCESS FLOW - FUEL CRUSHING

  • RAW MATERIAL PROPORTIONING The raw materials are stored in the bunkers. Description : Bunkers 1 to 20 Bunker 1&2 Quicklime Bunker 3 - ESP Dust Bunker 4 - Limestone fines Bunker 5&6 - Dolomite fines Bunker 7&8 - Coke breeze Bunker 9 to 18- Iron ore fines Bunker 19&20 - Return fines WMRS Bunkers (1-4) : Secondary Materials ( SIP Sludge, Mill Scale, Flue dust, GCP Dust, EAF Slag)

    Materials are proportioned in a ratio to obtain desired Sinter Chemistry and extracted with the help of Weigh Feeders/Round disc feeders and fed on to main gathering conveyor (M-1) and then discharged into Primary Mixer

  • GROUND HOPPERWBC-1WBC-2WRSC-1WF-1WF-2WF-3WF-4WB-1WB-2WB-3WB-4WASTE RECYCLING BUILDINGGH-1GH-2SECONDARY MATERIAL RECYCLING

  • M-1B 19B 20B 18B 17B 16B 15B 14B 13B 12B 11B 10B 9B 8B 7B 6B 5B 4B 3B 2B 1R-3I-1C-11F-13PROPORTIONING BUILDING*PROCESS FLOW : RAW MATERIAL PROPORTIONING

    BC-55ROUND DISC FEEDERD-1C-10WBC-3PNEUMATIC CONVEYORF-12WEIGH FEEDER

  • MIXING and MATERIAL CHARGING TO SINETR MACHINE

    1 The process involves Dry mixing inside Primary mixing drum (Mixer-1) and Nodulizing inside Secondary mixing drum (Mixer-2) and finally charging it onto Sinter Machine.

    2 Water is sprayed inside Secondary mixer to maintain Moisture content of Raw mix to 7.5+/-0.5 as per process requirement as it helps in nodulizing

    3 Steam is also added in Secondary mixer for preheating of Raw mix

    4 Raw mix is then discharged in Raw mix bin via Belt conveyors

    5 Raw mix is charged onto Sinter machine with the help of Drum Feeder and Segregation Plate

  • M4Shuttle ConveyorRaw Mix HopperDrum FeederSinter MachineSegregation PlateB1B2B3M3 HearthLayer Hopper

    M2Mixer-2Mixer-1From ProportioningM-1MIXING and MATERIAL CHARGING TO SINETR MACHINE

  • *MATERIAL CHARGING & IGNITIONSUBGATELevelerUnclean Air from CoolerClean Air from Cooler

  • The process involves Ignition of raw mix after material charging to sinter machine

    Ignition is done for, a) To Dry top layer of sinter bed and initiate combustion of Carbon.

    Ignition furnace consists of:: a) Two rows of total 23 Nos. burners are installed on the roof of the ignition furnace. The first row consists of 11 nos. burners and the second row has 12 nos. Two numbers of opening are provided on roof for installation of temperature measurement, 4 nos. inspection openings on side wall of furnace hearth and two inspection openings on side wall of annealing hood. Gaseous Fuels used are BF Gas and RLNG gas to maintain Furnace temperature 1150 +/- 50 Deg. C:

    RAW MIX IGNITION

  • Ignition of Raw mixSinter MachineBurnersBF Gas LineIgnition Air Line*

  • Zones in sintering

  • RAW MIX IGNITION1) The Raw mix is deposited in a layer of 600-700mm height in the Sinter strand.

    2) The hearth layer is deposited in a layer of 40 mm height below raw mix

    3) The Sintering Process starts with ignition of top layer with Fan sucking the heated air down through the sinter bed. The fuels in the bed generate the heat to melt and fuse the Ore particles together.

    4) At the end of sinter strand the flame front has passed all the way through the raw mix to the bottom.

    5) The sinter cake then drops off at the end of strand on Single roll crusher and charged on Circle cooler

  • SINTERING contdReduction of Hematite: 3Fe2 O3 + CO 2Fe3 O4 + CO2 Hematite Magnetite Fe3O4 + CO 3 FeO + CO2 Dissociation of Carbonates: CaCO3 CaO + CO2 MgCO3 MgO + CO2

  • SINTER COOLING1) The process involves Cooling of sinter inside circle cooler.

    2) The sinter cake discharged from the hot sinter breaker, 120 ~ 0 mm, at temperature of 750 ~ 850 deg. C in average is charged into circular sinter cooler.

    3) Product Sinter temperature should be reduced down to < 100deg. C for easy handling by belt conveyor and down stream equipment.

    4) To achieve this performance a circular sinter cooler with effective area of 228 m2 is provided along with 4 nos. of cooling blowers to supply sufficient cooling air to the cooler.

    5) The heat from Cooler is utilized in two ways: a) Steam is generated via waste heat recovery Boiler and added in Mixer-2 to preheat raw mix b) Unclean Hot air is provided in Annealing hood after Ignition

  • 1) The process involves Screening of Product Sinter i.e. +5 mm for BF , -5 mm as return sinter and 12 mm to 20 mm as hearth layer.

    2) Size of product sinter plays utmost importance in productivity of hot metal (BF). Also a product sinter size of 12 mm-20 mm is required as hearth layer for better suction and protection from grate bar damage.

    3) Sinter product screening is done via two route P2 & P3 each equipped with three vibrating screens of different mesh size.

    4) The two route is divided from P1 discharge through Y chute. Each route is equipped with three different vibrating screens of size 12 mm,20 mm & 5 mm respectively.

    PRODUCT SCREENING

  • *PRODUCT SCREENING LAYOUT

  • Product Sinter