Sinter PlantSinter PlantJNILJNIL

WhatWhat is sinter 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 MaterialBasic Raw Material

• Iron ore fines Iron ore fines

• Coke finesCoke fines

• LimestoneLimestone

• DolomiteDolomite

Iron ore specificationIron ore specification• Chemical AnalysisChemical Analysis

• Fe(T) = 58- 65%Fe(T) = 58- 65%

• SiO2 = 2.0 – 3.5%SiO2 = 2.0 – 3.5%

• Al2O3 = 1.5 – 2.5%Al2O3 = 1.5 – 2.5%

• Alkali = Alkali =

• Physical AnalysisPhysical Analysis

Limestone specificationLimestone specification

• Chemical AnalysisChemical Analysis

• CaO = 45 – 50% CaO = 45 – 50% MinMin

• MgO = 2 – 4% MaxMgO = 2 – 4% Max

• SiO2 = 4 – 8% MaxSiO2 = 4 – 8% Max

• Al2O3 = 1 – 2% Al2O3 = 1 – 2% MaxMax

• Alkali = 0.20% MaxAlkali = 0.20% Max

• Physical AnalysisPhysical Analysis

• Sieve 10 – 30 +- Sieve 10 – 30 +- 5.0%5.0%

Dolomite specificationDolomite specification• Chemical AnalysisChemical Analysis• CaO = 30 – 25% MinCaO = 30 – 25% Min

• MgO = 20 – 15% MinMgO = 20 – 15% Min

• SiO2 = 4 – 8% MaxSiO2 = 4 – 8% Max

• Al2O3 = 0.5 – 1% MaxAl2O3 = 0.5 – 1% Max

• Alkali = 0.20% MaxAlkali = 0.20% Max

• Physical AnalysisPhysical Analysis

• Sieve 10 – 50 +- Sieve 10 – 50 +- 5.0%5.0%

Conveying system of raw Conveying system of raw materialmaterial• ReclaimingReclaiming

The following belt used during The following belt used during operationoperation

C3C3

1.31.3

1.51.5

1.61.6

1.71.7

3.13.1

2.12.1

• Ground hopperGround hopperThe following belt used during The following belt used during

operationoperation

1.31.3

1.51.5

1.61.6

1.71.7

3.13.1

2.12.1

Crushing sectionCrushing section

• As the sinter process required As the sinter process required limestone, dolomite and coke fines (-limestone, dolomite and coke fines (-3mm) around 90%. So there is a need 3mm) around 90%. So there is a need to crush the above material to get the to crush the above material to get the required size for process.required size for process.

• For crushing, there is a hammer mill For crushing, there is a hammer mill installed for limestone and dolomite. installed for limestone and dolomite. The four roll crusher for coke crushing.The four roll crusher for coke crushing.

Flux crushingFlux crushing

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

Hammer millHammer mill

• Material = Limestone & DolomiteMaterial = Limestone & Dolomite• Bulk density = 1.6T/m3Bulk density = 1.6T/m3• Moisture = 2 – 3% (Max.)Moisture = 2 – 3% (Max.)• Feed size = -50mm (97%), 50-75 (3%)Feed size = -50mm (97%), 50-75 (3%)• Product size = -3mm(50%), 50% recalculationProduct size = -3mm(50%), 50% recalculation• Capacity = 100TPHCapacity = 100TPH• Type = Reversible swing hammer with open bottomType = Reversible swing hammer with open bottom• Rotor diameter and width = 1200mmRotor diameter and width = 1200mm• No of hammer = 60No of hammer = 60• Grinding gib (straight) = 4Grinding gib (straight) = 4• Grinding gib (curve) = 12Grinding gib (curve) = 12• Grinding jib material = Mn- steel Gr-IIIGrinding jib material = Mn- steel Gr-III• Hammer material = Mn- steel gr-IIHammer material = Mn- steel gr-II• Rotor speed = 645rpmRotor speed = 645rpm• Drive = v belt with fluid couplingDrive = v belt with fluid coupling• Motor = 200Kw, 1485rpmMotor = 200Kw, 1485rpm• Motor pulley = 375mm, 8 groove, Motor pulley = 375mm, 8 groove, • Machine pulley = 864mm, 8 grooveMachine pulley = 864mm, 8 groove• Overall dimension = 2250X1950X2300mmOverall dimension = 2250X1950X2300mm• Gross weight = 12 TonsGross weight = 12 Tons

Flux ScreenFlux Screen

• Material – Mixture of L/S and D/M.Material – Mixture of L/S and D/M.• Bulk Density – 1.6 to 1.8T/m3.Bulk Density – 1.6 to 1.8T/m3.• Moisture – 5%.Moisture – 5%.• Feed Size = -50mm.Feed Size = -50mm.• Separation Size = -3mm.Separation Size = -3mm.• Capacity – 100T/h.Capacity – 100T/h.• No. of Deck – 2Deck 10mm, Opening Deck 3.55 No. of Deck – 2Deck 10mm, Opening Deck 3.55 • Size – 1600*5000mmSize – 1600*5000mm• Motor – 40HP. 1465rpm.Motor – 40HP. 1465rpm.• Frame Size – 200.Frame Size – 200.• Total Vibrating Weight – 5500KgsTotal Vibrating Weight – 5500Kgs• Total Static Weight – 8200KgsTotal Static Weight – 8200Kgs• Inclination of Screen – 30Inclination of Screen – 30

Coke crushingCoke crushing

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

Coke Crusher(New) Coke Crusher(New) (Four Roll Crusher) (Four Roll Crusher)• Material- Coke.Material- Coke.• Bulk Density- 0.6T/m3.Bulk Density- 0.6T/m3.• Maximum Feed Size- -30mm,95%Maximum Feed Size- -30mm,95%• Product- -3mm(95%).Product- -3mm(95%).• Capacity- 20T/h.Capacity- 20T/h.• Primary Rolls- 800*1000.Primary Rolls- 800*1000.• Setting- 10mm.Setting- 10mm.• Drive- 30HP. 720rpm.(2).Drive- 30HP. 720rpm.(2).• Secondary Roll- 600*1000.Secondary Roll- 600*1000.• Setting- 3mm.Setting- 3mm.• Drive- 60HP,720rpm.(2).Drive- 60HP,720rpm.(2).

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

Proportioning buildingProportioning building

• There are 13 bunker in the proportioning There are 13 bunker in the proportioning building. The bunker allotted to different building. The bunker allotted to different material are as followsmaterial are as follows

• Iron ore fines = 4Iron ore fines = 4

• Flux fines = 2Flux fines = 2

• Coke fines = 2Coke fines = 2

• Return fines = 3Return fines = 3

• Mill scale = 1Mill scale = 1

• Calcined lime = 1Calcined lime = 1

Base mix chargeBase mix charge

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

Mixing drumMixing drum

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

Technical specification (MD)Technical specification (MD)

• Capacity = 200 – 250t/hCapacity = 200 – 250t/h• Material density = 1.6 t/m3Material density = 1.6 t/m3• Slope of shell = 2Slope of shell = 2oo

• Speed of shell = 7m/minSpeed of shell = 7m/min• Fill rate = 12.7%Fill rate = 12.7%• Material temp = <70Material temp = <70ooCC• Motor power = 160Kw, voltage – 440VMotor power = 160Kw, voltage – 440V• Reduce type transmission (Three column reducer)Reduce type transmission (Three column reducer)• Speed ratio = 25Speed ratio = 25• Rotate speed = 1400m/min.Rotate speed = 1400m/min.

Balling drumBalling drum

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

Technical specification (BD)Technical specification (BD)

• Size = 3000X1200mmSize = 3000X1200mm• Product ability = 200 – 250t/hProduct ability = 200 – 250t/h• Material density = 1.7+- 0.1 ton/m3Material density = 1.7+- 0.1 ton/m3• Slop of shell = 1.5Slop of shell = 1.5oo

• Speed of shell = 7rpmSpeed of shell = 7rpm• Fill rate = 12.96% normal, 13.9% Max.Fill rate = 12.96% normal, 13.9% Max.• Finished product = 143.5sec.Finished product = 143.5sec.• Motor power – 200Kw. 440V, 50HzMotor power – 200Kw. 440V, 50Hz• Rotation rate = 490 – 990rpmRotation rate = 490 – 990rpm

Importance of moistureImportance of moisture

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

Sinter MachineSinter Machine

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

S/M Technical specificationS/M Technical specification

• 11.. Sinter M/C = 2 Sinter M/C = 2• 2. Capacity = 1200 MT/Day/machine2. Capacity = 1200 MT/Day/machine• 3. Effective sintering area = 36m23. Effective sintering area = 36m2• 4. Effective sintering length = 24m4. Effective sintering length = 24m• 5. Center distance between sprocket at feeding end and discharge end = 5. Center distance between sprocket at feeding end and discharge end =

34.3m34.3m• 6. Pitch circle diameter of sprocket = 2453mm6. Pitch circle diameter of sprocket = 2453mm• 7. Pallet dimension = SM-01 (1500X1000X550mm) SM-02 7. Pallet dimension = SM-01 (1500X1000X550mm) SM-02

(1500X1000X570mm)(1500X1000X570mm)• 8.Pallet speed = 0.56 – 1.68 m/min.8.Pallet speed = 0.56 – 1.68 m/min.• 9. Pallet quantity = 76 piece.9. Pallet quantity = 76 piece.• 10. Main drive system: Motor – 15Kw10. Main drive system: Motor – 15Kw

Speed – 750 rpmSpeed – 750 rpmVoltage – 440V Voltage – 440V

• 11. Volume of hearth layer hopper = 28m311. Volume of hearth layer hopper = 28m3• 12. Feeding roller dimension = 800X1440mm12. Feeding roller dimension = 800X1440mm

Ignition & Pre-heater Ignition & Pre-heater furnacefurnace• There are total 14 nozzle burner manually There are total 14 nozzle burner manually

operated installed over the roof of ignition operated installed over the roof of ignition furnace which heats up the furnace around furnace which heats up the furnace around 950 to 1250 950 to 1250 ooC by using blast furnace gas as a C by using blast furnace gas as a fuel. fuel.

• Pre-heater furnace has 9 burner manually Pre-heater furnace has 9 burner manually operated which also using blast furnace gas as operated which also using blast furnace gas as a fuel maintaining the furnace temp around a fuel maintaining the furnace temp around 700 to 800 700 to 800 ooC to preheat the blast furnace gas C to preheat the blast furnace gas and combustion air which finally sent to and combustion air which finally sent to ignition furnace. It helps to get quick heat in ignition furnace. It helps to get quick heat in ignition furnace and also drop the heat loss.ignition furnace and also drop the heat loss.

Sinter processSinter process

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

BTPBTP

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

Machine speed regulationMachine speed regulation

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

Sinter BreakerSinter Breaker

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

Breaker Technical Breaker Technical specificationspecification• Diameter = 1100mmDiameter = 1100mm

• Width = 1860mmWidth = 1860mm

• Motor power = 22KwMotor power = 22Kw

• Speed = 5.83rpmSpeed = 5.83rpm

• No of teeth = 4X6 rowsNo of teeth = 4X6 rows

• Feed temp = 800Feed temp = 800ooCC

• Feed size = 1500X1000X570mmFeed size = 1500X1000X570mm

• Three stage gear box.Three stage gear box.

Sinter CoolerSinter Cooler

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

Sinter cooler Technical Sinter cooler Technical specificationspecification• Effective cooling area = 51m2Effective cooling area = 51m2• Speed of pallet car = 0.573 – 1.15m/minSpeed of pallet car = 0.573 – 1.15m/min• Center distance of sprocket = 3960mmCenter distance of sprocket = 3960mm• Inclination of cooler = 7.074Inclination of cooler = 7.074oo

• Feeding material temp = 750Feeding material temp = 750ooCC• Pallet quantity = 142Pallet quantity = 142• Pallet car width – 1500mm, length – 600mm, Pallet car width – 1500mm, length – 600mm,

height – 900mm. height – 900mm. • Motor power = 15Kw, 440V, 50Hz.Motor power = 15Kw, 440V, 50Hz.• Capacity = 75 – 130 TPHCapacity = 75 – 130 TPH• Cooling time = 40 – 70 minCooling time = 40 – 70 min

Sinter ScreenSinter Screen

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

Compressor specificationCompressor specification

• No of compressor = 02No of compressor = 02• Make = Altas capcoMake = Altas capco• Design pressure = 14.5 barDesign pressure = 14.5 bar• Min design temp= 10oCMin design temp= 10oC• Max design temp = 120oCMax design temp = 120oC• Volume air side = 9.971Volume air side = 9.971• Volume oil side = 10Volume oil side = 10• Test pressure = 21barTest pressure = 21bar• Max working pressure = 10barMax working pressure = 10bar• Motor = 55Kw, 95A, 2975rpmMotor = 55Kw, 95A, 2975rpm• Relay range = 50 – 63ARelay range = 50 – 63A• Set relay = 63ASet relay = 63A• Fan motor = relay 4 – 6.3A , Set = 5AFan motor = relay 4 – 6.3A , Set = 5A

BLOCK DIAGRAMBLOCK DIAGRAM

R/M FROM RMHS

L/S,D/M,COKE I/O FINES

PROPOTIONING BUILDING

FLUX BUILDING

MND

BALING DRUM

BASE M H

S/MACHINE

S/COOLER

BREAKER

S/SCREEN

C-15.1&15.2

B/F STOCK H

THANK YOUTHANK YOU

Miss u yaarMiss u yaar

I KNOW UR MY BEST FRIEND ……….I KNOW UR MY BEST FRIEND ………. BUT . I AM UR CLOSED FRIEND….BUT . I AM UR CLOSED FRIEND…. I ALWAYS WITH U ………I ALWAYS WITH U ……… I ALWAYS NEED U……I ALWAYS NEED U…… I ALWAYS MISS U……….I ALWAYS MISS U……….