PM Trophy 2012-13

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JSW Dolvi Works
Steel Limited
Steel ltd.
Sinter Plant
Dolvi
Introduction of Sinter Plant
Commissioning Details
Raw materials for Sintering Process
Product Sinter Quality
Specific Consumptions
Major Equipments
Sinter Plant Layout
a) Flux Crushing & Screening
b) Fuel Crushing
c) Raw material proportioning
d) Material charging to Sinter machine
e) Ignition of Raw mix
f) Sinter Cooling
g) Product Screening & Dispatch
Photograph of Product Sinter
Contact Numbers of department Personnel
Contents:
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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.

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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



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Raw Materials for Sintering Process
Iron Ore : 1. Fines Purchased from various sources
2. Fines from SIP
Coke : 1. Under size (<15mm) generated at BF is crushed to
<3 mm
2. <10mm coke fines is purchased and crushed to
<3mm
Lime Stone : 1. Purchased from outside sources and crushed to
<3mm
2. Limestone fines (<40mm) return from LCP
Dolomite : 1. Purchased from outside sources and crushed to
<3mm
Calcined Lime : Purchased from outside as 0 3 mm in crushed
form.

Plant Secondary Materials:
SIP Sludge
Mill Scale
GCP Dust
EAF Slag
Flue Dust

Furnace Fuel: BF Gas enriched with RLNG
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RAW MATERIAL CHEMICAL ANALYSIS
SL.
No
.
Raw Material
Fe
(%)
Silica
(%)
Alumina
(%)
CaO
(%)
MgO
(%)
Fixed
Carbon
(%)
Moisture
(%)
Ash
(%)
1 Iron Ore Fines 62.05 3.95 3.15 0.25 0.05 7
2
Sinter Fines
(BF + Sinter)
56.23 4.7 3.73 9.81 1.69
3 Limestone 1.63 1.39 0.37 49.98 3.61 1.1
4 Quicklime 0.22 1.87 0.42 92.24 1.79
5 Dolomite 0.67 1.04 0.47 33.4 18.43 0.38
6 Coke Breeze 86.74 8 - 10 9.66
7 Mill Scale 70.48 1.62 0.62 0.73 0.08 4.16
8 SIP sludge 62.59 3.9 1.9 3.58 1.02 1.5 15.42
9 GCP Dust 56.22 1.91 2.14 9.45 2.81 1.13
10 Flue Dust 27.7 12.49 3.87 8.8 0.85 26.85 10.53
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Product Quality

Chemical Analysis: Physical Analysis:
Total Fe : 56 % min Product Size: 5 50 mm
FeO : 10.5 11.5% +50 mm : 5% max
SiO2 : 5.0% max 0 - 5 mm : 5% max
Al2O3 : < 3.3 % T. I :>72
CaO : 9.0 10.0 %
Basicity : 2.0 2.4


Product Sinter Quality :
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Specific Consumptions
IBRM : 995 kg / Ton of Sinter
Lime Stone : 35 kg / Ton of Sinter
Dolomite : 80 kg / Ton of Sinter
Coke Breeze : 65 kg / Ton of Sinter
Quick Lime : 26 kg / Ton of Sinter
Electric Power : 36 kwhr / Ton of Sinter
Water : 0.15 m3 /Ton of Sinter
RLNG gas : 1.5 Sm3 / Ton of Sinter
BF Gas : 10.0 Nm3 / Ton of Sinter
Oxygen : 2.0 Nm3 / Ton of Sinter

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Major Equipments:
Main Suction Fan :18500 Cu mt per min
Sinter Machine : 198 Sq. mt
Ignition Furnace : 2Row vertical Burners (12+11)
Hot Sinter Crusher : 3500 LongX 1700 Dia
Circular Cooler : 228 Sq. mt
Primary Mixing Drum : 3.2mt Dia x12mt Long
Nodulizing Drum : 3.8mt Dia x117.5mt Long
Primary Sinter Screen : 480TPH (2500X8000)
Secondary Sinter Screen : 300TPH (2500X8000)
Conveyor System : 48 Nos ( Belt Length 2.5 KM)
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SINTER PLANT LAYOUT
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SUB-PROCESS FLUX CRUSHING & SCREENING
1) 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.

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Surge bunkers for
primary storage
Hammer Crusher 112B
Hammer
Crusher
112A
F-5 conveyor
F-6 conveyor
F-7 conveyor
F-8 conveyor F-9 conveyor
Flux screen B Flux screen A
F-10
Surge bunkers for
secondary storage
Dolomite Lime stone
Lime stone
Dolomite
Lime stone Dolomite
To Proportional building
PROCESS FLOW- FLUX CRUSHING
AND SCREENING
F-4 conveyor
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SUB-PROCESS FUEL CRUSHING
1) 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.
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4 Roller crusher A,B &C
Double roller crusher
Coke bins
Conveyor C-2
Coke bunkers
Plough
Magnetic iron separator
C-4 conveyor
C-8 conveyor
Conveyor C-7
C-6 C-5
Magnetic iron separator
Conveyor C-3
To proportioning building
14
PROCESS FLOW - FUEL CRUSHING
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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
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GROUND HOPPER
WBC-2
WRSC-1
WF-1 WF-2 WF-3 WF-4
WB-1 WB-2 WB-3
WB-4
WASTE RECYCLING BUILDING
GH-1 GH-2
SECONDARY MATERIAL RECYCLING
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M-1
B 19 B 20 B 18 B 17 B 16 B 15 B 14 B 13 B 12 B 11 B 10 B 9 B 8 B 7 B 6 B 5 B 4 B 3 B 2 B 1
R-3 I-1 C-11
F-13
BC-55
ROUND DISC
FEEDER
D-1
C-10 WBC-3
PNEUMATIC
CONVEYOR
F-12 WEIGH FEEDER
PROPORTIONING BUILDING
17
PROCESS FLOW : RAW MATERIAL PROPORTIONING
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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


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M4
Shuttle Conveyor
Raw Mix Hopper
Drum Feeder
Sinter Machine
Segregation Plate
B1
B2
B3
M3
Hearth
Layer Hopper

M2
Mixer-2
Mixer-1
From
Proportioning
M-1
MIXING and MATERIAL CHARGING TO SINETR MACHINE
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20
MATERIAL CHARGING & IGNITION
SUBGATE
Leveler
Unclean Air from Cooler
Clean Air
from Cooler
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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
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Ignition of Raw mix
Sinter Machine
Burners
BF Gas Line
Ignition Air Line
22
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Zones in sintering

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RAW MIX IGNITION
1) 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

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SINTERING contd
Reduction of Hematite:

3Fe2 O3 + CO 2Fe3 O4 + CO2
Hematite Magnetite

Fe3O4 + CO 3 FeO + CO2

Dissociation of Carbonates:

CaCO3 CaO + CO2
MgCO3 MgO + CO2
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SINTER COOLING
1) 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

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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
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P-1
P-2
P-3
P-4 B-1
B-2
B-3
P-7
P-5
P-6
P-8
P-9
R-1
P-10
BC-56
SCREEN
512
SCREEN
513
SCREEN
522
SCREEN
523

S
SCREEN
515
SCREEN
525
BASE
MATERIAL
BIN
HOPPER
28
PRODUCT SCREENING LAYOUT
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Product Sinter
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