Rmhs

RMHS & Logistics Department,
Technical Reference Manual

FOREWORD
It gives me immense pleasure to present to you the Technical Reference Manual for Tata Steel
Orissa Project’s RMHS & Logistics Department. This manual is the perfect amalgamation of
departmental overview and technical insights for novices and experts alike and gives a holistic
view of the various processes involved.
The various sections in the manual are richly illustrated with relevant drawings, process flow
diagrams, data tables and graphs to enable a deep understanding of the department.
I believe that whether you are a seasoned professional or a person just joining the
department, you will find this immensely helpful in understanding the functions and
objectives of our department.
(C L Karn)
Chief RMHS & Logistics
Tata Steel Ltd, Orissa Project India
PREFACE
With so many independent units in the department, there was a need to collect the
information about the various process units and the theoretical background behind the
processes and major equipment involved in each process, so that a complete one stop manual
could be created which can be referred by any person to get a holistic understanding of RMHS
& Logistics.
The Training Manual is the result of combined efforts of many officers of our department who
painstakingly collected all the information and organised it in an easy to understand manner.
Special thanks to Mr B C Kedia for his guidance.
(Arindam Das) (Anshul Maheshwari)

Manager, RMHS & Logistics Senior Manager, RMHS & Logistics
Tata Steel Limited, Orissa Project India Tata Steel Limited, Orissa Project India
Tata Steel Limited - Overview
Tata Steel Limited has operations in 26 countries, commercial presence in over 50 countries
and 80,000 employees across five continents. What sets the company apart is not just extent
or magnitude of its operations - it is the excellence of its people, innovative approach, and
overall conduct. Established in 1907 as Asia's first integrated private sector steel company,
Tata Steel Group is among the top-ten global steel companies with an annual crude steel
capacity of nearly 30 million tonnes per annum. It is now the world's second-most
geographically-diversified steel producer. The Group recorded a turnover of US$ 24.81bn in
FY 14.
Over the years Tata Steel has enriched the glorious legacy handed over by its Founder J.N.
Tata, by placing equal emphasis on stakeholder value creation and corporate citizenship.
Underpinning this vision is a performance culture committed to aspiration targets, safety and
social responsibility, continuous improvement, openness and transparency. What binds
together every member of the global Tata Steel family today is a shared corporate culture,
shaped by value-based guiding principles and the lineage of some of the world’s most
pioneering and respected entities - the Tata group itself, British Steel, Koninklijke Hoogovens
and NatSteel.
Tata Steel Limited, Orissa Project India
Conforming to Tata Steel’s vision of Value Creation and Corporate Citizenship and its
commitment to nation building and strengthening its partnership with the State of Odisha,
the Company is setting up a 6 million tonnes per annum capacity integrated steel plant in
Kalinganagar Industrial Complex in Jajpur district of Odisha. Subsequent to the signing of the
MOU, 3470 acres of land was allotted to the Steel Company for setting up the steel plant. The
proposed plant site happens to be a part of six revenue villages - Gobaraghati, Chandia,
Gadapur, Nuagaon, Khurunti and Baragadia - of the Sukinda Tehsil in Jajpur District.
While the plant site at Kalinganagar Industrial Complex is beside the National Highway 200,
the all-weather ports at Paradip and Dhamra are at a distance of about 100 to 110 km by rail
route. Similarly, the iron ore mines are located at a distance of about 200 km from the project
site.
Kalinganagar – Project Highlights
 MoU for the steel project was signed between the Government of Odisha and Tata Steel
on November 17, 2004.
 As per the MoU, Odisha Government agreed to provide 3,471.808 acres of land,
earlier acquired through the Industrial Development Corporation of Orissa.
 MoU was also signed with the Nippon Steel Corporation on August 28, 2005 for offering
technical assistance for the project.
 As per the terms of the MoU, Government of Odisha would be allocating an iron
ore mine to the Company on completion of 25% of the project work.
The state-of-the-art, Kalinganagar Project is being established in two modules of three million
tonnes each. The plant, which boasts of the Blast Furnace of 4330 cum capacity, will roll out
high-end flat products.
During the first phase, the Blast Furnace will have a capacity of 3.3 Million Tonnes Per Annum
(MTPA) of hot metal and the Coke Plant will have a capacity of 1.65 MTPA (recovery type
oven). While the Sinter plant will have a capacity of 4.91 MTPA, the Steel Melting Shop (SMS)
and the Hot Strip Mill (HSM) will have capacity of 4.1 MTPA and 3.5 MTPA, respectively.
The project will have a 3X67.5 MW gas-based Captive Power Plant. New technologies like
Granshot Systems & CAS OB will be introduced in the plant for steelmaking. The plant is also
designed for Zero Liquid Discharge, Waste Recycling Plant and Central Effluent Treatment
Plant. High-end flat products will be rolled out from Kalinganagar plant.
Layout of Kalinganagar Project Odisha
RMHS & Logistics Department – Overview
The department aims at an uninterrupted supply of raw materials to its customer

departments like Coke Plant, Sinter Plant, Blast Furnace, Lime Calcining Plant and Steel
Melting Shop as per their demand without any adverse impact on the Environment and
Society.
Inward Traffic:
Iron ore, the basic raw material consisting of size ore and fine ore aggregating to 5.50 Mtpa
will be received from Tata Steel’s captive mines of Joda/Khonbond. The pelletization plant
will be set up at the plant end for conversion of fine ore into pellets.
Besides, the plant will need 3.0 million tonnes of coking coal annually. The requirement of
coal will comprise of indigenous and imported coal. The imported coal will be received
through Dhamra port.
CPP (Captive Power Plant) which will be set up along with the steel plant will require 2.1
Million ton of Thermal which will be mainly imported through Dhamra port. The rest of the
coal will be met from coal-meddlings generated in the Tata Steel’s captive coal mines in
Barkakana area. If any more coal is required then the same will be procured commercially
from domestic mines in Talcher Coalfields, etc.
The lime stone requirement consisting of BF and SMS grades, will be imported through
Dhamra port only.
Outward Traffic:
The plant will finally produce 6.0 MTPA of steel annually after Phase I and Phase II, out of
which Tata Steel proposes to dispatch 4.0million tonnes of steel by rail annually and the
balance will move via road. Of the assessed rail borne traffic, about 1.0 MTPA will be exported
through Dhamra port while 3.0 mtpa will be dispatched to major consuming centres situated
all over India. About 2 million tonnes of granulated slag will move to the cement plants
located in Central India or consumed in Orissa.
The material flow within KPO is majorly handled by the conveyors that connect every
department together; starting from the RMHS and Logistics department. However, the
inbound and outbound materials solely depend on the means and support provided by the
logistics railway network that connects the plant to the outside world via Jakhapura station.
Once inside the plant boundary, the inbound wagons unload at the Wagon Tippler Complex
(from where the materials are distributed throughout the plant via the rich network of
conveyors). The outbound wagons carry the finished product from the dispatch yards. A
certain level of intra-plant logistics is present in certain special cases like that in case of Hot
Metal Logistics; where hot metal is carried from Blast Furnace to SMS using Torpedoes.
A layout of the entire rail network in KPO is presented below.
Process Flow Circuits in RMHS
The circuits shown above highlight the major material flow within the plant. However, to
understand the circuits in detail it is necessary to segregate them into functional components
and look at them separately. For this reason the entire material flow has been divided into 7
separate circuits as given below. These circuits together make up the entire flow of materials
to and from various departments within the plant and looking at them individually lets us
know more about the major equipments and process involved.
Circuits:
1. Coke Oven Input Circuits

1.1. Coal from Wagon Tippler to Coal Yard
1.2. Coal from Coal Yard to Coal Tower
1.3. Coke spillage from Coke Oven Battery to Coal Tower via Secondary Crusher House
2. Coke Oven Output Circuits
2.1. Coke from Coke Oven to Coke Storage Yard
2.2. Coke from CPSH to CSBB
3. Sinter Plant Input Circuits
3.1. Ore & Flux from Wagon Tippler to Ore & Flux Yard
3.2. Iron Ore Fines from Ore & Flux Yard to PBB
3.3. Fuel from Coke Stock Bin to PBB
3.4. Base Mix from PBB to Sinter Plant via Base Mix Yard
4. Sinter Plant Output Circuits
4.1. Sinter from Sinter Plant to Sinter Stock House
4.2. Sinter from Sinter Plant to BF Stock House
5. BF Input Circuits
5.1. Ore & Flux from Ore & Flux Yard to BF
5.2. PCI coal from WT to Coal Injection Plant
5.3. Coke from Coke Storage Yard to BF
5.4. Coke from Coke Breeze Shed to BF
6. BF Output Circuits
6.1. Slag to corresponding Loading Stations
6.2. BF Sludge to CSBB and fines to PBB
7. SMS Input Circuits
7.1. Limestone from Ore & Flux Yard to LCP
7.2. Lime from LCP to SMS
7.3. SMS grade ore from Ore & Flux Yard to SMS
1. Coke Oven Input Circuits
The above circuit shows the movement of coal from the Wagon Tippler to the Coal Tower.
1.1 Coal from Wagon Tippler to Coal Yard

The circuit begins at the Twin Wagon Tippler 1 in the Wagon Tippler complex where the
incoming rakes of coal are unloaded. The coal falls through the hoppers (beneath the twin
tippler) onto the apron feeders below. From there, coal is conveyed via conveyors CC-1, CC-
2, CC-3, CC-4 and CC-5, via Junction Houses JH-1, CJH-1, CJH-2 and CJH-3, until it reaches the
Stacker cum Reclaimers (SRC-1, SRC-2 and SRC-3 in future) in the Coal Yard. There the coal is
first stacked and later reclaimed (by CC-6, 7 and 8) as per demand.
Twin Wagon Tippler 1
Twin Wagon Tippler-1
Introduction:-
There are total four wagon tipplers in KPO out of which first two are twin and the other two
are single tipplers. The wagon tippler which is used in circuit 1 is twin wagon tippler 1 (TWT
1) and this tippler is entirely dedicated for handling coal. The twin tippler machine consists of
three major components – indexer, sidearm charger and wagon tippler. The indexer is used
for pulling the rake while the sidearm charger is used for placing the two wagons
simultaneously at the tippling area over the two hoppers and the wagon tippler is used for
unloading the material into the hoppers. In twin wagon tippler-1, coal falls through hoppers
over two apron feeders and from there it is guided to CC-1 and with the help of further
conveyors it is stacked in coal yard. Two dribble conveyors are placed below two apron
feeders to avoid spillage.
The Wagon Tippler Unit mainly consists of:
 Wagon Tippler drives with brakes, lubrication systems and position control.
 Side Arm Charger with position control.
 Indexer with position control
 Hydraulic system for wagon holding on the Wagon dumper, gripper on tippler table &
grippers at inhaul and outhaul
 Hydraulic system on the Indexer for luffing arm & de-coupler cylinder
 Hydraulic system on the SAC for luffing arm & de-coupler cylinder
 Environmental measures (Pre-wetting and water spraying during tippling)
The twin tipplers are capable of handling two wagons at a time unlike single wagon in the present
tipplers. This means that de-coupling for a whole rake consisting of 59 wagons will require 30
cuts instead of present 59. Handling capacity of twin tipplers is 8 rakes and that of single tippler
is 5 rakes per day respectively. Each tippler is designed to have minimum 25 tips per hour. This
has been arrived on the basis of following calculation.
TIPPLER TIME ASSESSMENT

SL NO ACTIVITY
SINGLE TWIN
1 No. of tips/wagons per hour 25 25
No. of wagons handled per

2 25 50
hour
Time required for tippling a 59
3 142 minutes 71 minutes
wagon rake.
Placement and release time in
4 30 min 30 min
pre tippling line
Grouping, engine attaching,
creation of air pressure and
5 60 min 60 min
evacuation from post tippler
line
232 min = 3 hours 52
Total time for unloading of 161 min = 2 hours 41 min.
6 min.
one rake Say 3 hours
say 4 hours
7 Cushion time to EOL time limit 1 hour 2 hours

Time allowed under EOL
concept by railway for
8 4 hours
unloading of one rake with 59
BOXN wagons.
Number of rakes that can be 1260 ÷ 232 1260 ÷ 161
9 handled in 21 hours leaving 3 = 5.43 or say = 7.826 or say

hours for tippler maintenance. 5 rakes. 8 rakes
Operation:
 Depending upon the Wagon Type the rake is Pulled or Pushed on to the Wagon Tippler table.
 For placing of Loaded Wagon rake at inhaul position, we have Indexer machine. Placement
by Indexer is achieved with the help of 5 No’s of Electromechanical (VFD Driven) drives.
 For placing of Loaded Wagons to be tippled on Tippler Platform, we have Side Arm Charger
machine (SAC) Placement of loaded wagon on platform will be achieved by SAC with the help
of 3 No’s of Electromechanical (VFD Driven) drives.
 Wagons shall be gripped at Inhaul Side (WG-1&2) & Outhaul Side (WG-3) during placement
of wagons on rail track.
 Wagons will be clamped on table with Horizontal Side Wall clamping (Unloading side) &
Vertical Top clamping (Unloading side & Opposite to Unloading side) on Tippler table.
 Programmable Logic Controller (PLC S7-4H) is of Siemens make.


Operation modes:
The wagon tippler system is equipped with control devices which allow the following operating
modes:
 Manual mode - Operation initiated from Control Desk by operator in predetermined

operational sequence.
 Auto Mode - Operation initiated from Control Desk by operator with all sequential operation
carried out from PLC.
 Local Mode - Operation initiated from Local Control Stations by Local operator for respective
equipment.
Technical Detail of Twin Wagon Tippler -1 :
Wagon Tippler is provided with Electro-mechanical drive driven through VVVF Drive with
regenerative braking with active front end for tippling motion. WT serves the purpose of
unloading two wagons placed on the table by SAC into the hopper. Tippling angle of the table
shall be from 0 Degree to 180 Degree. For equal load & speed sharing each motor is supplied
with Tacho generator in close loop operation with VVVF Drive.
All the VVVF motor drive units are run in Master-Master configuration.
1 Material To Be Unloaded Coal
Boxn, Boy-25, Boxnha, Boxnhs,

2 Type Of Wagon To Be Unloaded
Boxnlw, Boxnhl, Wagons
Operating At Dfc & Feeder Route.
3 Track Gauge & Rail Size 1676 Rail Gauge & Rail Uic 60
4 Wagon Unloading Capacity 2*25 Wagons/Hr (Max.)
5 Rotating Speed Of Tippler Approx 1.5 M/S
6 Design Base As Per RDSO G-33(Rev-A) May

2010
7 Design Load 280 Ton
8 Tippling Angle 180 °
9 Top & Side Clamping Through Hydraulic Cylinder With

Power Pack
10 Type Of Tippler Rotary ’ C ’
11 Positioning Device Indexer & Side Arm Charger
12 Installed Power 250 K.W * 2 Nos.
13 Quantity 2 Nos.
14 Total Weight Per Machine Approx 380 Tons.

Technical Detail of SAC of Twin Wagon Tippler-1:
SAC is provided with Electro-mechanical drive driven through VVVF Drive with
regenerative braking with active front end for travel motion. SAC serves the purpose of
placing the two loaded wagons on table & pushing empty wagons / rake out of the table.
SAC also serves the purpose of pulling/pushing locomotive. Operating zone of SAC will
be from wheel gripper W2 to wheel gripper W3.
In order to push or pull, the SAC arm is lowered to zero degree position & coupled with the
wagon either at inhaul or outhaul side as required. For equal load & speed sharing each motor
is supplied with Tacho generator in close loop operation with VVVF Drive. All the VVVF motor
drive units are run in Master-Master configuration.
SAC Arm luffing is achieved with the help of Hydraulic system driven by Sq. cage Electric motor.
2 Loaded Wagons To Be Pulled & 58

1 Max. No. Of Wagons To Be Pulled / Pushed Nos. Empty Wagons To Be Pushed
On Straight & Levelled Track
2 Type Of Luffing System Hydraulics Cylinder

3 Rail (Track) Crs 1600mm
Forward With Wagons 0.7m/s (Max.)

4 Operational Speed
Return 1.4 m/s (Max.)
5 Type Of Power Supply Energy Drag Chain
6 No. Of Running Wheels – 630 Dia. 4
7 No Of Guide Wheels- 800 Dia. 4
8 Travel Drive Arrangement Rack & Pinion Type
Drive Type Electro-Mechanical With VVF Drive
9 Electric Motor Kw 110
Qty. 3 Nos.
Disc Brake On Gear Box Input Shaft
10 Brake
Of Each Drive
Technical Detail of Indexer of Twin Wagon Tippler-1:
Indexer is provided with Electro-mechanical drive driven through VVVF Drive with regenerative
braking with active front end for travel motion. Indexer serves the purpose of pulling the
complete rake upto handing over zone of SAC. In order to pull & push the rake/ wagon &
locomotive respectively, Indexer arm is lowered to zero degree position & coupled with wagon
either at inhaul side as required. For equal load & speed sharing each motor is supplied with
Tacho generator in close loop operation with VVVF Drive. All the VVVF motor drive units are run
in Master-Master configuration. Indexer Arm raise/lowering is achieved with help of Hydraulic
system driven by Sq. cage Electric motor.
Max. No Of Wagon To Be 60 Loaded Wagons + 2 Locomotives On

1
Pulled Straight And Levelled Track
2 Type Of Luffing System Hydraulics Cylinder
3 Rail (Track) Crs 1600mm
Forward With Wagons 0.6 M/S (Max.)

4 Operational Speed
Return 1.2 M/S (Max.)
5 Type Of Power Supply Energy Drag Chain
No. Of Running Wheels – 630

6 4
Dia.
7 No Of Guide Wheels- 800 Dia. 4
8 Travel Drive Arrangement Rack & Pinion Type
9 Drive Type Electro-Mechanical With VVF Drive
10 Electric Motor Kw 110
11 Quantity 5 Nos.
Disc Brake On Gear Box Input Shaft Of

10 Brake
Each Drive
Technical Detail of Apron Feeder for Twin Wagon Tippler 1:

Apron Feeder system is provided with common Hydraulic Power pack with dedicated Electric
motor & pump system for Feeder-1 & Feeder-2. AF system serves the purpose of receiving
material dumped by Wagon tippler into the hopper & further feeding to preceding conveyor. AF
hydraulic system is provided with Spider controller for close loop controlling of feeder.
Sl No. Equipment Specification

1 Width of pan 2130mm
2 Length of apron feeder 11000 mm (head shaft to tail shaft CSR)
3 Design Capacity 1750 TPH
4 Lump size (-) 50 mm
5 Chain speed (range) 0 – 13.2 m/min
6 Drive Hydraulic drive
Technical Detail of Dribble Conveyor for TWT 1:
Two dribble conveyors are placed below the two apron feeders of TWT-1 to convey the
spilled material of apron feeder towards the CC-1 conveyor.
Sl No. Equipment Specification

1 Belt width 2000 mm
2 Length (pulley centre) 11900 mm
3 Capacity 100 TPH
4 Pulley dia (drive & non drive) 500mm
5 Belt speed 0.26 M/sec
6 Belt type Fire resistant nylon 400/4
7 Belt cover thickness(top/bottom) 5mm & 3mm
8 Drive Electro mechanical
Wagon Tippler lubrication system:

Centralized Automatic Lubrication Systems is provided at strategic locations of the Wagon
Tippler. Manual lubrication is provided for SAC & Indexer.
Lubrication Systems for Wagon tippler provided are:

a) Motorised Lubrication system for Horizontal & Vertical Holding Devices – 1 No.
b) Motorised Lubrication System for Drive Pinions – Inhaul & Outhaul Side – 1 No. each
c) Motorised Lubrication System for Drive pinion bearings, Runner wheels, Guide wheels – Inhaul
& Outhaul Side – 1 No
.
Safety Measures :
 Operate the wagon tippler system only on condition that all safety devices, in particular the
limit switches and sequential interlocks are complete and ready for operation.
 In case of power failure, WT machine will come to standstill. The clamping System will hold
the wagon in clamped position & all the actions such as tippling of table & SAC/Indexer travel
will be stopped.
 Prior to commencing the shift, inspect the wagon tippler system for externally visible
damages and faults.
 In the event of malfunctions stop the wagon tippler system immediately and lock it. Have any
defects rectified immediately.
Conveyors:
In circuit 1, conveyor line starts from CC-1 which connects Twin Wagon tippler-1 (TWT-1) to
JH-1. And from JH-1, coal transfers to CC-2 which is underground up to Pent House-2 (PH-2)
and there after above ground up to CJH-1. There is a separate circuit for pulverized coal from
CJH-1 to PCI Building which will be explained later. Between JH-1 and PH-2, there is one
Metal Detector (CMD-1) to detect the metallic impurities and one Magnetic Separator to
remove the metallic impurities. CJH-1 connects CC-2 and CC-3, CJH-2 connects CC-3 and CC-
4 and similarly CJH-3 connects CC-4 and CC-5. Between PH-2 and CJH-1, there is Belt Scale
(CBS-1) to weigh the coal and just before CJH-2, there is Coal Sampler (CS-1) to collect the
sample of coal. CC-5 has a tripper conveyor which can move to and fro to supply material to
CC-6, CC-7 or CC-8 as per requirement. CC-6 is used for stacking as well as reclaiming coal
from Stacker Reclaimer-1 (SRC-1), CC-7 and CC-8 does the same for Stacker Reclaimer-2 and
Stacker Reclaimer-3 respectively. In phase I, we have only Stacker Reclaimer-1&2 and
Stacker Reclaimer-3 will be coming in phase II.
Technical description of conveyors
Belt
Length Width Capacity Motor Coupling
Conveyor Speed
(meters) (mm) (tph) capacity(KW) type
(m/s)
CC-1 150 2000 3500 3.8 300 Scoop
CC-2 474 2000 3500 3.8 740 DFC
CC-3 746 2000 3500 3.8 580 DFC
CC-4 453 2000 3500 3.8 400 DFC
CC-5 (Tripper Conveyor)

CC-5 has a travelling tripper (with two ways discharge chute) which can move to and fro to
discharge coking coal in the conveyors CC-6, CC-7 & CC-8 (one at a time) that are associated
with Stacker cum Reclaimers - SRC-1, SRC-2 & SRC-3 respectively of Coal Yard. SRC-3 will be
coming in Phase II.
Tripper Data Table (CC-5)

SL No. Parameters Equipment Description
1 Type Motorised self-propelled
2 Conveyor No. CC-5
3 Location Coal tripper building
4 Belt Width 2000 mm
5 Belt Speed 3.8 m/s
6 Rated/Designed Capacity 3500 TPH / 3850 TPH
7 Material Coking coal
8 Bulk Density 0.8 T/m3
9 Max. Lump Size -25 mm
10 Moisture Content 10 % (max)
11 Travel Speed 0.25 m/s
12 Travel Length 200 m (Approx.)
13 Track Rail Size 52 kg/m
14 Estimated Weight of Tripper 40 Tonnes (Approx.)
15 Power Feeding Arrangement Through cable reeling drum
16 Type of CRD Motorised composite CRD unit
17 Type of Power Feeding Centre feed
18 Supply Voltage 415 V. ±10 %. 50 Hz ± 5 % 3 phase. AC.
19 Troughing Angle 45 degree
20 Pulley Diameter 800 mm
21 Chute Profile Two ways
Technical Data of Tripper Conveyor (CC-5)
Discharge Pulley
SL. No. Description Specification

1 Pulley Dia. * Face Width * BRG. Dia. 800 * 2200 * 240
2 BRG. Dia / Type 240 mm / SPH. Roller
3 Lagging 10 mm THK. Plain Lagging
Hot Lagged With Vulcanised Natural Rubber
Bend Pulley

Drive Wheel & Axle
1 Wheel Tread Dia. 400 mm ( Double Flange)

2 Wheel / Axle Material Forged Steel
Non Drive Wheel & Axle

Travel Drive
1 Electric Motor AC SQ. Cage 2 * 5.5 KW @ 1500 RPM With 60 Start/ Stop
Bevel Helical Hollow Shaft With Shrink Disc,
2 Gear Box ( 2 No.’s)
Ratio 130:1, Rating - 12.40 KW
3 H.S Coupling Resilient Type
4 Brake ( 2 No.’s) D.C Electro Magnetic Brake
5 Braking Torque ( Min) 5.35 Kg.m. Each
Yard Machines- SRC-1, 2 & 3
RMHS’ Coal Yard has three Stacker Reclaimers out of which Stacker reclaimer-1 (SRC-1) and
Stacker racliamer-2 (SRC-2) are being commissioned in phase I and Stacker Reclaimer-3 (SRC-
3) will be commissioned in phase II. Conveyor associated with SRC-1, SRC-2 and SRC-3 is CC-
6, CC-7 and CC-8 respectively. Storage capacity of the entire Coal Yard is 400000 T.
Stacker cum Reclaimer
General Description
The rail mounted stacker cum reclaimer is suitable for building stockpiles on either side of the
track rails and subsequently reclaiming these materials from the piles and feeding them for
onward usage. The machine is designed for working with a unidirectional yard conveyor with
additional provision for direct feeding with the machine by-passed.
The machine is designed and built to incorporate the lates t technological progress in the
engineering of large bulk material handling equipment.
Technical Specifications of Stacker Reclaimers (Coal Yard)
Material Handled
Material Bulk density Angle of repose Moisture

Size (mm)
Handled (t/cu.m) (degree) content (%)
Coal 0.9 to 0.8 +1 to -25 36-38 9-10
Stockpile
Total Nos. 2
Pattern Chevron
Section Linear triangular and conical
Maximum base width 40 metres
Maximum height above ground level 15 metres
Depth below rail level 0.80 metres
Capacity
Capacity (tph) Coal

Reclaiming 800(rated)/960(design)
Stacking 3500(rated)/3850(design)
Luffing range
Luffing range ( degree ) Coal

Max down -8.1
Max up +13.5
Parking -4
Operating speeds
Bucket wheel 48 discharges/min

Boom conveyor 3.8 m/s
Luffing 4.5 m/min
Slewing 7 – 35 m/min
Travel 7.5 – 30 m/min
Yard conveyors (CC-6, CC-7 & CC-8)
Conveyors CC-6, CC-7 & CC-8

Length 698 meters
Belt width 2000 mm
Troughing angle 45 degree
Speed 2 m/s
Type of Belt Steel cord
Wind loads
Operating 80 km/hr
Non-operating 180 km/hr
Track rails
Size 60 kg/m
Gauge 8.2 m
Other specifications
Boom length 41 metres

Slewing range +110 to -110 degree
Total travel of machine 460 metres
Ambient temperature 50 degree centigrade
Duty of machine Continuous, 24 hours
ISO 5049/1 – Mobile continuous bulk
Design standard
handling equipment
6.6 kv,450 MVA, 3 Ph (HT), 50 Hz, 415 V,
Power supply
3 Ph (LT)
Principles of operation
The rail mounted stacker cum reclaimer is suitable for serving two parallel stockpiles, one on
either side of the track rails.
The machine is designed to operate with a yard conveyor with provision for feeding at one
end for stacking and discharging at the other end during reclaiming, i.e. a non-reversible one.
The following modes of operation are possible:
 Stacking mode
 Reclaiming mode
 Direct feeding mode
 50% stacking & 50% direct feeding
Emergency Stop
The mushroom head, press to stop lockable, rotate to release type emergency Stop (E-Stop)
stations are strategically located at different parts of the machine. Pressing this button gets
the topmost priority of operation and stops the machine irrespective of the mode of
operation.
Technical Detail of Critical Parts of Stacker Reclaimer of Coal Yard:

Boom Conveyor
Drive name Boom conveyor
Driven by LT cage motor through fluid coupling
Type of control Reversible DOL
Rating 180 KW,4p(160KW,4p for ore)
Location of L/R sel sw. MCC feeder
Controlling hardware location
MCCB, contactor and MPR in MCC
Of operation
•Local from LCS/individual feeder at MCC

Mode and location of operation •Remote(manual/auto) from HMI
Hydraulic Power Pack for Bucket Wheel

Drive name Hydraulic power pack for bucket wheel
Driven by Hydraulic motor power pack and pump
Type of control DOL(for pump);SPIDER control system for hydraulic
Rating 75 KW 4p(for pump) 132 kw 4p (for ore)
For pump
•Local from LCS / individual feeder at MCC
Mode and location of operation •Remote(manual/auto) from HMI for hydraulic power pack
•Local from SPIDER control panel
•Remote from HMI
PLC control interfaces with MCC (for pump) and SPIDER for hydraulic power pack
Hydraulic Power Pack for Bucket Wheel & Stacking Skirt
Hydraulic power pack for bucket wheel & stacking
Drive name
skirt
Driven by Hydraulic motor ,power pack
DOL (for pump) solenoid valves for flap gate chute,
Type of control
stacking skirt and bucket wheel chute
Rating 3.7kw, DOL for pump
MPCB, contactor & EOCR in MCC
Of operation
For pump
Mode and location of operation •local from LCS
•REMOTE ( manual /auto)from HMI
Hydraulic Power Pack for Boom Luff and cabin Cylinder

Hydraulic power pack for boom luff & cabin
Drive name
levelling
Driven by Hydraulic motor ,power pack & hydraulic pump
Type of control DOL (for pump)
Rating 30kw,4p
MCCB,contactor & EOCR in MCC for the pump
Of operation
For pump
Mode and location of operation •local from LCS/individual feeder at MCC
Long Travel
Drive name Long travel
Driven by LT AC sq. cage motor ( total 14 motors)
VVVF drive (single drive for 14 motors) reversible , with
Type of control
bypass facility
Rating 5.5 kw every motors , 4p
Location of L/R sel sw. Drive panel
MCCB, contactor & master drive in the VVVF drive panel
Of operation
•local from LCS
Mode and location of operation
Hydraulic Power Pack for Slew
Drive name Hydraulic power pack for Slew
Driven by Hydraulic motor, power pack & hydraulic pump
Rating 30 KW, 4p (for pump)
Location of L/R Sel sw. MCC feeder
MPCB, contactor & EOCR in MCC &control for
hydraulics in SPIDER control panel (common with
Of operation
bucket wheel
For pump
•local from LCS/Individual Feeder at MCC
Mode and location of operation
•REMOTE ( manual /auto)from HMI for hydraulic
power pack
Power Cable Reeling Drum

Drive name Power Cable Reeling Drum
Driven by Slip ring stall torque AC motors
Type of control Torque control by variable resistance method
Rating 5.5 KW
Location of L/R Sel sw. Not applicable
Controlling hardware location MPCB, contactor & variable resistance controls in
Of operation the MCC panel
Mode and location of operation Not applicable
Rail Clamp
Drive name Rail Clamps
Driven by Hydraulic pump & its power pack

Rating 3.7 KW, 4p (for pump)
Location of L/R Sel sw. LCS, MCC feeder
For pump
Mode and location of operation •local from LCS
1.2 Coal from Coal Yard to Coal Tower
Coal from coal yard is reclaimed by the stacker reclaimers - SRC-1,2 & 3 (SRC-3 will come in
phase II) at the reclaiming rate of 800tph to the conveyors- CC-6, 7& 8 respectively. There is
a common conveyor CC-9 which receives coal from CC-6, 7& 8 through junction houses CJH-
4, 5& 6 respectively. Between CJH-6 and CJH-7, there is one Belt Scale (CBS-2) to weight the
coal. Thereafter, CJH-7 connects CC-9 and CC-10 and the coal gets transferred from CC-9 to
CC-10, a tripper conveyor. Coal from CC-10 is discharged to the 10 bins in Coal Blending
Bunker Building (CSBB). Each bin has a storage capacity of 1500 T.
CC-11 carries coal from CSBB to Primary Coal Crusher House. In between CSBB and primary
crusher, there is coal sampler (CS-2) to collect the sample and then Magnetic Separator (CMS-
1) to remove the metallic impurities from the coal. Thereafter, there is Metal Detector (CMD-
1) to detect any metal and stop the flow of the circuit to prevent damage to the primary
crusher. In CC-11 conveyor after CMD-1, there is Belt Scale (CBS-5) to weigh the coal.
The crushed coal from the primary crusher is discharged to the CC-15, which in turn discharges
the coal into the hopper above secondary coal crusher house. Between the two houses, there
is one Magnetic Separator (CMS-5) to remove the metallic impurities from the coal.
Thereafter, there is Metal Detector (CMD-3) to detect any metal and stop the flow of the
circuit to prevent damage to the secondary crusher. After CMD-3, there is Microwave Type
Moisture Gauge (MMG-1) and Moisture Addition Facility to regulate the moisture content as
per requirement (Generally 5 %). After this, there is Coal Sampler (CS-4) to collect the sample
and Belt Scale (CBS-7) to weigh the coal.
The crushed coal from the secondary crusher is discharged to the CC -19; where a Microwave
Type Moisture Gauge (MMG-4) and Moisture Addition Facility is used to regulate the moisture
content if further required. The coal from CC-19 is then conveyed to Coal Junction House (CJH-
8). CJH-8 connects CC-19 and CC-21, CJH-9 connects CC-21 and CC-23 and similarly CJH-10
connects CC-23 and CC-24.
CC-24 is a reversible conveyor that can feed both CC-25 (via CJH-11) and CC-26 which will lead
to Coal Tower 1 and Coal Tower 2 respectively.
CC-10 (Tripper Conveyor)
CC-10 has a travelling tripper (with two ways discharge chute) which can move to and fro to
discharge coking coal in all the 10 bins (one at a time) of Coal Blending Bunker Building.
Tripper Data Table (CC-10)

2 Conveyor No. CC-10
3 Location Blending bunker
5 Belt Speed 3 m/s
7 Material Coking coal
Technical Data of Tripper Conveyor (CC-10)
Discharge Pulley

Bend Pulley

Drive Wheel & Axle


Travel Drive
Coal blending bunker building (CSBB):
Coal Blending Bunker Building
CSBB is for storage of 15000 T (1500 x 10) coal; received through travelling tripper (CTT-3).
Each blending bunker is provided with one radar type level indicator and transmitter for
getting the level of the bunker in the CHP PLC system. Each bunker has been provided with
two discharge facilities at the bottom, one for the Phase I and other for the Phase II.
Flow diagram of CBB Building
Different types of coal (by composition & source) will be available at the coal blending bunker
bins and the blending is carried out at predetermined rate through weigh feeders.
Similarly for the Phase II same discharge and blending facility will be provided.
Number of Coal Blending Bins 10
Capacity of each bin 1500 T
Number of Coal Rod Gate (CRG) 10
Number of Coal Rack & Pinion Gate (CRPG) 10
Number of Coal Way Feeder (CWF) 10
Capacity of output conveyor (CC-11) 400 TPH
Belt Speed of output conveyor (CC-11) 2.8m/s
Size of Input Coal -80 mm
Primary Coal Crusher House:

There are two surge bins each 140T used to receive the incoming blend coal from the bunkers
before conveying to the crusher (each 400TPH capacity). 2 No’s level indicators are located
on the bins to measure the level of the material heap.
Primary Coal Crusher House (Outside View)
The blended coal from bins will be crushed as per battery requirements (generally -3mm)
through primary & secondary crushers. There is a moisture adjustment system after the
primary crusher. The primary crusher is equipped with surge bunker of capacity of 140T. The
crusher is operating with 900KW HT motors and operating with one standby.
Primary Crusher House (Inner View)
Hammers Inside Primary Coal Crusher

Flow diagram of Primary Coal Crusher House
Number of Surge bins 2

Number of Coal Rack & pinion gate (CRPG) 2
Number of Retractable Coal Belt Feeder (RTCBF) 2
Capacity of Retractable Coal Belt Feeder (RTCBF) 40 – 400 TPH
Number of Coal Crusher (CCR) 2
Number of hammers per crusher 96
RPM of Rotor 600
Output Coal Size -3mm
Secondary Coal Crusher House:
There are two surge bins each 140T used to receive the incoming blend coal from the primary
crushers before further pulverising at the secondary crushers, (each 400TPH capacity). 2 Nos
level indicators are located on the bins to measure the level of the material heap.
Secondary Coal Crusher House (Outside View)
There is also a moisture adjustment system after the secondary crusher. There is also an
arrangement to by-pass the Secondary Coal Crusher house if the required crushing is achieved
through Primary Coal Crusher House.
Secondary Coal Crusher House (Inside View)
Hammers Inside Secondary Coal crusher

Flow Diagram of Secondary Coal Crusher House
Number of Coal Blending Bins 3

Number of Coal Rack & pinion gate (CRPG) 3
Number of Retractable Coal Belt Feeder (RTCBF) 2

Capacity of Retractable Coal Belt Feeder (RTCBF) 40 – 400 TPH
Number of Coal Way feeder ( for spillage coal ) 1
Number of Coal Crusher (CCR) 2
Number of hammers per crusher 96

RPM of Rotor 600

Output Coal Size -3mm
1.3 Coke spillage from Coke Oven Battery to Coal Tower via
Secondary Crusher House
There is another bunker, having 150 T capacity, used to receive the excess / spillage coal from
the coke oven batteries via junction houses SPJ – 1 and 2. These are then fed back into the
system as input via Coal Towers.
This bunker has a level indicator to measure the level of the material heap.
Motor
Length Capacity Belt Speed Coupling
Conveyor Width (mm) Capacity
(meters) (tph) (m/s) Type
(KW)
CC-6 705 2000 3500 3.8
CC-7 705 2000 3500 3.8
CC-9 363 1600 1800 3
CC-10 236 1600 1800 3
CC-11 333.85 1000 400 2.8
CC-13 (RS) 16.625 1200 400 1.55
CC-15 247 1000 400 2.8
CC-17 (RS) 20.4 1200 400 1.55
CC-19 209 1000 400 2.8
CC-21 62 1000 400 2.8
CC-23 275 1000 400 2.8
CC-24 (R) 80 1200 400 2.8
CC-25 76 1000 400 2.8
CC-26 76 1000 400 2.8
SPC-1 183.886 1000 600 2.8
SPC-2 70 1000 600 2.8

2. Coke Oven Output Circuits
This circuit begins at the coke warf of the battery from where the coke is conveyed to the
Coke Screening House (CPSH). The coke from CPSH is sent to the coke stock bins, to be sent
to fuel crushing later, and to the coke storage yard to create the buffer stock to be sent to the
blast furnace tripper as per operation requirements.
Coke reaches the Coke Stock Bins by conveyors CK- 11, 12, 15 and 16 via junction houses KJ –
1 and 1A. It is diverted towards the Coke Storage Yard by the conveyors CK – 18, 28, 29 and
30 via junction houses KJ – 2, 6 and 7, and it is stacked in the yard by the Coke Stacker.
2.1 Coke From Coke Oven to Coke Storage Yard
Coke Screen House
Coke Screen House
Flow Diagram of Coke Screen House

Side View of Coke Screen House
Top View of one of the Screens of Coke Crusher House

Coke from the Coke Oven Battery is brought to the Screen House by the conveyors CK-3 and
4 (future), where it is received by the 400T Coke Surge Bin. The Surge Bin distributes incoming
coke into 5 Vibrating Screens (2 of which are to be commissioned in the future) each having
a capacity of 200TPH.
The screens separate incoming coke into three sizes: -10 (Coke Breeze), 10-34 (Nut Coke) and
+34 (Coke Breeze).
These are then distributed on to three separate conveyors CK – 15, 11 and 18 which carry
screened coke of sizes -10, 10-34 and +34 respectively. Another conveyor CK – 19 will be
commissioned in the future to carry screened coke of size +34.
+34 (BF Coke) screened coke is taken by CK – 18 (and 19 in future) to junction house KJ – 2
from where a reversible conveyor directs it on to CK – 22 for BF Stock House or to CK-28 for
conveying to Single Boom Stacker for ground stock, in case BF Stock House is not ready to
receive the coke.
10-34 (Nut Coke) screened coke is taken by CK-11 to junction house KJ-1A from where it leads
to Coke Stock Bin Building by series of conveyors.
-10 (Coke Breeze) screened coke is taken by CK-15 to junction house KJ-1 from where it leads
to Coke Stock Bin Building by series of conveyors.
Equipment Details of Coke Screen House:
Coke Surge Bin (KSB) 1 No.
Rod Gate (KRG) 5
Rack & Pinion Gate (KRPG) 5
Vibrating Feeder (KVF) 5
Capacity of Vibrating Feeder 20-200 tph
Vibrating Screen (KVS) 5
Capacity of Vibrating Screen 200 tph
Flap Gate (future) (KFG) 5

Coke Storage
CK-18 takes the BF Coke (+34) towards KJ-2 where it falls on CK-20(R), a reversible conveyor
which can take the coke towards the BF Stock House by series of conveyors ( CK-22, CK-24,
CK-24A, CK-26) or towards the Single Boom Stacker for coke storage by series of conveyors
(CK-28, Ck-29, Ck-30) where it is stacked by the Coke Single Boom Stacker (KSBS-1).
Coke Single Boom Stacker
Coke Single Boom Stacker
Coke Single Boom Non Slewable Luffing Stacker will create a stock pile of BF Coke using
Chevron Method. The Stock Yard is located on the west side of the Sinter Plant adjoining NS-
30 Road. The coke will be reclaimed using pay-loaders on to the return conveyor CK-31 and
will subsequently be transferred to the Blast Furnace. The Stacker is of FL Smidth make with
a capacity of 500 TPH and will create a stock pile of approximately 200 layers to a height of
11m and length 260m. Storage capacity of the BF Coke Yard is 19000T.
Technical Specification of Coke Luffing Stacker
General Equipment Specification

Name Non slewable single boom luffing stacker
In/Outdoor Outdoor
Stacking Capacity (tph) 500
Design Capacity (tph) 550
Type of Support Three point corner

Stacking Boom Length (m) 21.38
Stacking Method Chevron method
Max Wind Velocity (operation) 80 km/h

Max Wind Velocity (non-operation) 180 km/h
Boom Luffing Mechanism

Type of Drive Hydraulic operated system
Luffing Speed 2 m/min at boom discharge pulley
Type of Mounting Clevis mounted with spherical bearing
Luffing Range Luff up: +12 degree; Luff Down: -14 degree
No. of Cylinders 1
Make Rexroth
Hydraulic Unit 1 Hydraulic power pack
Motor Power 3.7 kW
Make Rexroth
2.2 Coke from CPSH to CSBB
Coke Breeze (-10mm) after getting screened from CPSH is conveyed by the conveyor CK-15.
KJ-1 connects CK-15 to Ck-16 which takes Coke Breeze to Coke Stock Bin Building. Similarly,
Nut Coke (10-34mm) after getting screened from CPSH is conveyed by the conveyor CK-11.
KJ-1A connects CK-11 and CK-12 which takes Nut Coke to Coke Stock Bin Building.
Coke Stock Bin Building
Coke Stock Bin Building

Flow Diagram of Coke Stock Bin Building
There are 5 surge bins in Coke Stock Bin Building, out of which 2 No.’s are for Nut Coke, 2
No.’s are for Coke Breeze and 1 No. is for Anthracite. Each bin has a storage capacity of 100
T. The coke is then transferred to the common conveyor CK – 41 by various reversible
conveyors, and then CK -41 takes both the coke breeze and the nut coke to the Coke Breeze
Shed, where they are stacked by using a travelling tripper KTT -1. The coke from CK-41 is
conveyed to KTT-1 by series of conveyors (CK-42, CK-46, CK-47, CK-48 & CK-49).
The coke can also be sent towards the Fuel Crushing System through conveyor CF -1 and other
downstream conveyors.
The Nut coke, Coke Breeze and Anthracite from Coke Breeze Shed is reclaimed by Pay- Loader
and unloaded on Hoppers on CK-51 conveyor and then the same is transferred to Coke Stock
Bin Building through series of conveyors (CK-51, 52, 53& 54).
There is also a provision of sending Nut Coke (10-34) from Coke Stock Bin Building to BF-I
Stock House through series of conveyors (CK-41, CK-42 and CK-43) using flap gate located at
KJ-10.
KTT-1 (Tripper Conveyor)
KTT-1 has a travelling tripper (with one way discharge chute) which can move to and fro to
discharge material in the Coke Breeze Shed.
Tripper Data Table (KTT-1)

2 Conveyor No. KTT-1
3 Location Coke breeze shed
4 Belt Width 800 mm
7 Material Coke
8 Bulk Density 0.5 to 0.6 T/m3
10 Moisture Content 3.5 % (max)
11 Travel Length 350.5 m (Approx.)
16 Supply Voltage 415 V. ±10–15 %. 50 Hz ± 6 % 3 phase. AC.
19 Chute Profile One way
Technical Data of Tripper Conveyor (KTT-1)
Discharge Pulley

3 Lagging Drive/Non Drive 12 mm Ceramic Embedded Rubber Lagging/
10 mm Plain Rubber Lagging
Bend Pulley

3 Lagging Drive/Non Drive 12 mm Ceramic Embedded Rubber Lagging/
10 mm Plain Rubber Lagging
Drive Wheel & Axle

1 Wheel Tread Dia. (Tail) 500 mm ( Double Flange)

Travel Drive
1 Electric Motor AC SQ. Cage 30 KW @ 1475 RPM

Helical, Ratio 31.5:1, Rating -40 KW
(Mechanical)
Tyre Type (High Speed) & Geared (Low
3 H.S Coupling
Speed)
Coke Return Fines from Blast Furnace is also conveyed to the Coke stock Bin Building through
series of conveyors (Ck-56A, 56, 57).
Details of Coke Stock Bin Building:
No. of Stock Bins (KSB) 5
No. of Continuous Level Indicator (KCLI) 5
Capacity of each Stock Bin 100 T
5
No. of Rod Gate (KRG)
No. of Rack & Pinion Gate (KRPG) 5
No. of Vibrating Feeder (KVF) 5
Capacity of Vibrating Feeder 100 tph
Motor
Width (mm) Capacity Coupling
Conveyor Length (m) Belt Speed (m/s) Capacity
(tph) Type
(KW)
CK-3 7 1400 400 1.6
CK-11 336.3 1000 200 1.6
CK-12 34 1000 200 1.6
CK-15 339.33 1000 200 1.6
CK-16 32.15 1000 200 1.6
CK-18 313 1400 400 1.6
CK-28 209.35 1400 400 1.6
CK-29 82.1 1400 400 1.6
CK-30 372 1600 400 1.45
CK-41 268.97 800 100 1.6

3. Sinter Plant Input Circuits
The circuit shows how different raw materials are carried to the Proportionate Bin Building.
3.1 Ore & Flux from Wagon Tippler to Ore & Flux Yard
As shown in the circuit, there are total 3 wagon tipplers (1 twin and 2 single) dedicated for
Ore & Flux Circuit - WT-2 is twin and WT-3, 4 are single tipplers. The circuit is designed in such
a way that each of the three tipplers can be used for iron ore, iron ore fines and flux. CO-1,
C0-2 & CO-3 are the associated conveyors for WT-2, WT-3& WT-4 respectively. The material
gets dumped in respective hoppers by wagons and then respective apron feeders
through hoppers. There is also dribble conveyor below each apron feeder to prevent spillage
of material.
WT-1 and WT-2 are both identical twin tipplers and so their technical specifications and
working principle are also similar to each other. WT-1 is already explained in details in coal
circuit. WT-3 and WT-4 are both identical single tipplers.
There is metal detector in each of the three conveyors (CO-1, CO-2, and CO-3) to detect any
metallic material. Thereafter, JH-1 connects CO-1 to CO-9, CO-2 to CO-8 and CO-3 to CO-7.
CO-7, 8& 9 are underground conveyors till Pent House -1 (PH-1) and aboveground after it and
these conveyors ultimately lead to JH-2.
Between PH-1 and JH-2, we have Magnetic Separator House (MSH) to separate the metallic
material and Belt Scale (BS) to weigh the material.
There is also an additional circuit straight for quartz and pyroxenite from Ground Hopper-1
(GH-1) through Pent House (PH-3), CO-10 connects Ground Hopper (GH-1) to JH-2.
JH-2 also connects CO-7 to CO-11, CO-8 to CO-12, CO-9 to CO-13 and CO-10 to CO-14. CO-11,
12, 13& 14 are all Reversible Shuttle (RS) conveyors which can discharge material in any of
the three conveyors (CO-15, CO-16, and CO-17).
CO-15, 16, 17 each connects with Tripper Gallery which has three tripper conveyors one for
each CO-15, 16, 17. Now each tripper conveyor in tripper gallery can discharge material in any
of the four Stacker-cum-Reclaimers of Ore and Flux yard.
Two Stacker-cum-reclaimers (SR-1 and SR-2) are coming in Phase I while the other two (SR-3
and SR-4) are coming in Phase II. CO-19 and CO-20 are the associated conveyors for SR-1 and
SR-2 respectively which can stack as well as reclaim material as per requirement.
CO-15, CO-16 & 17 (Tripper Conveyors)
CO-15, CO-16 and CO-17 each has a travelling tripper (with single way discharge chute)
which can move to and fro to discharge iron ore fines and fluxes in the conveyors CO-19,
CO-20, CO-21 & CO-22 (one at a time) that are associated with Stacker cum Reclaimers - SR-
1, SR-2, SR-3 & SR-4 respectively of Ore & Flux Yard. SR-3 and SR-4 will be coming in Phase II.
Tripper Data Table (CO-15, CO-16 & CO-17)

2 Conveyor No. CO-15, CO-16 and CO-17
3 Location Tripper gallery
7 Material Iron ore fines and fluxes
21 Chute Profile Single way
Technical Data of Tripper Conveyor (CO-15, 16 & 17)
Discharge Pulley

Bend Pulley

Drive Wheel & Axle


Travel Drive
Stacker Reclaimer (Ore Yard)
Stacker cum Reclaimer – Ore Yard
Part Wise Specification of SCR – 1

Equipment Name Equipment Parts Unit Description
Type Cell-Less
Wheel Dia. Mm 6000
No. of Bucket 8
0.6 max (max fill
Bucket Capacity Cu m.
Bucket Wheel factor 0.85-0.9)
Hydraulic Motor (132
Type kW) [Make –
Drive Hagglands]
Speed r/min 8.5
Length (pulley crs.) Mm 42400
Speed m/sec 2.75
1600 mm all nylon,
Boom Conveyor heavy duty, 630/4
Belt cover grade FR, Top
cover = 6mm, bottom
cover = 3mm
Ore SCR – 1
Process Unit Capacity
Reclaiming T/hr 1800(rated)~2160(designed)
Stacking T/hr 3500(rated)~3850(designed)
Travel (LT) M 459 (max.)
Height of Stockpile M 15 (max.)
Slew Deg. -105 to +105 (max.)
Luffing Deg. -7.71 to +13.5 (max.)
Ore Stacker cum Reclaimer SCR – 1

Equipment Name Equipment Parts Unit Description
630 dia, 1800
face, ceramic
Driving lagging & shell
thickness = 16
mm
Pulleys 630 dia, 1800
face, neoprene
rubber lagged,
Non-Driving
lagging & shell
thickness = 12
mm
Carrying (ø152.4, 3 roll, 45 deg,
Boom conveyor
spacing = 1000 mm, bearing I/D =
35mm
Return (ø152.4, 2 roll, 10 deg, trough
spacing = 3000 mm, bearing I/D = 30
Idlers
mm)
Impact (ø190.3, 3 roll, 45 deg, Trough
spacing = 400 mm, bearing I/D = 35
mm, neoprene rubber thk. = 25 mm,
hardness = 65±5(shoreA)
Screw type take
Take Up type up unit with
hydraulic jack
Speed m/min 7.35 (at BW tip)
-105 to +105
Range Degree
Slew Drive (max.)
Hydraulic motor
Motor
(make – Parker)
Ore Stacker cum Reclaimer SCR - 1
Equipment Name Equipment Parts & Unit Description
Through Hydraulic
Operation
Cylinder
Luffing of Boom &
other components Range Deg -7.7 to +13.5
4.5 (at bucket wheel
Speed m/min
centre)
Cylinder for skirt arrangement at slew centre
Luff cylinder
Cylinder Bucket wheel chute cylinder
Cabin levelling cylinder
Seal kit for above cylinders
Hose for above cylinders
Material Specification
Size Iron
Limestone
d ore Limestone
Property (SMS Quartzite Pyroxenite Anthracite Dolomite
iron and (BF Grade)
grade)
ore fines
Lump size 10-

-10 10-50 10-80 10-40 10-50 -25 30-80
(mm) 40
Bulk
2.2+ 2.2+ 1.5+ 1.5+ 1.4+ 1.5+ 0.9+ 1.5+
Density
-0.1 -0.1 -0.1 -0.1 -0.1 -0.1 -0.1 -0.1
(T/m3)
Max.
Moisture
8-10 8-10 4.5 4.5 4.5 4.5 8.9 4.5
content
(%)
Angle of
36- 36-
repose 34-37 34-37 20-38 34-37 36-38 34-37
40 40
(deg)
OPERATION MODE OF
CONVEYOR CKT.
OPERATING MODES
BASED ON BASED ON PROCESS

EQUIPMENT POINT POINT OF VIEW
OF VIEW
LOCAL MODE REMOTE AUTO MODE

MODE
OPERATION MODE OF STACKER CUM

RECLAIMER
Operating
Modes
Based on Based on
Equipment process point
Point of view of view
Remote Auto Auto

Auto Stacking
Local mode mode Reclaiming Directfeeding
In direct feeding mode we can also do 50-50%

direct feeding & stacking
SAFETY DEVICES-CONVEYOR
Equipment Equipment Safety Person Safety
Zero Speed Switch Pull Chord

Belt Sway Switch Conveyor Safety Guard
Belt Snap Switch Emergency Stop Switch
Guide Roller Hooters
Conveyor Belt Scrapper PA SYSTEM

Fire Hydrant
Metal Detector
Magnetic Separator
Chute Block Sensor
SAFETY DEVICES-SCR
Stacker Cum Reclaimer Equipment Safety Person Safety

Zero Speed Switch Pull Chord
Belt Sway Switch Conveyor Safety Guard
Belt Snap Switch Emergency Stop Switch
Guide Roller Hooters
Boom Conveyor Scrapper Walk Way With Toe Guard
Fire Hydrant
Bucket Wheel Bucket Wheel Guard
Pile Height Sensor Fully Covered With Glass
Speed Sensor Stairs With Hand Rail
Operator Cabin Walk Way With Toe Guard
Wipers
Luff Limit Switch Hooter
Slew Limit Switch Hooter
Storm Lock Hooter
Limit Switch
Long Travel
Buffer
Safety Guard
Drivers Coupling Guard Coupling Guard
Rail Track Track Cleaner Plate Track Guard
Wind Speed Sensors Hooter Hooter
Diverter Gate Limit Switch
Motor
Width Capacity Belt Speed Coupling
Conveyor Length (m) Capacity
(mm) (tph) (m/s) Type
(KW)
CO-1 145.3 1600 3500 2.8
CO-2 109.6 1600 1750 2.8
CO-3 92.2 1600 1750 2.8
CO-7 625 1600 1750 2.8
CO-8 635 1600 1750 2.8
CO-9 639 1600 3500 2.8
CO-15 308 1600 3500 2.8
CO-16 365 1600 3500 2.8
CO-17 308 1600 3500 2.8
CO-19 606.4 1600 3500 2.75
CO-20 606.4 1600 3500 2.75
3.2 Iron ore fines & flux from Ore & Flux Yard to PBB
Iron ore fines and flux is reclaimed from the yard with the help of two stacker-cum-reclaimers
(SR-1 and SR-2). CO-19 and CO-20 are the associated conveyors for SR-1 and SR-2
respectively. While reclaiming CO-19 connects to CO-23 via JH-9 and CO-20 connects to CO-
24 via JH-8. Again, CO-23 and CO-24 are Reversible Shuttle Conveyors which can discharge
material to any of the four conveyors namely FX-1, OF-1, CO-30 and CO-27 out of which CO-
27 is coming in Phase II.CO-23 and CO-24 are reversible conveyors which can discharge the
required material in the required circuit. FX-1 is associated with the fluxes and OF-1 is
associated with the iron ore fines. JH-10 connects FX-1 to FX-2 and OF-1 to OF-2. Iron ore fines
(-3mm) reach to Proportionate Bin Building (PBB) via JH-15 and OF-3.
Flux is first passed thru Flux Crusher House (via FX-3) where it is crushed by hammer mill and
then sent to Flux Screen House (via FX-5). Flux that is crushed to less than -3mm is sent to PBB
building via JH-16, FX-8 and FX-9 and the flux whose size is still greater than +3mm is sent
back to Flux Crusher House via FX-7 and this cycle is repeated till the required size of flux is
attained.
Flux Crusher House

There are five bins each of capacity 480 T each in Flux Crusher House. FX-4 is the reversible
shuttle conveyor of which feeds material to all the five bins. Below the five bins there are five
Reversible Belt feeders (RBF) one for each bin and below each Reversible Belt Feeder there is
a Flux Crusher of capacity 225 TPH. Material after getting crushed from each crusher falls on
FX-5 and from there it is sent to Flux Screen House.
Flux Crusher House
Total number of Stock Bins for Flux (FXSB) 5
No. of bins for Limestone 3
No. of bins for Pyroxenite 1
No. of bins common to Limestone & Pyroxenite 1
Capacity of Stock Bins 460 t
Flux Rod Gate (FXRG) 5
Flux Rack & Pinion Gate (FXRPG) 5
Retractable Belt Feeder for Flux (FXRBF) 5
Capacity of Retractable Belt Feeders 25-225 tph
No. of Flux Crushers (FXCR) 5
Type of Flux Crushers Hammer Mill - Impactor Type
Capacity of Flux Crushers 225 tph
Flux Screen House

Flux Screen House
Flow Diagram of Flux Screen House

Five Screens at Flux Screen House
Top view of one of the screens at Flux Screen House

Like Flux Crusher house, there are five bins of capacity 200 T each in Flux Screen House. FX-6
is the Reversible Shuttle conveyor which feeds material to all the five bins. Below the five bins
there are five Vibrating-Feeders (VF), one for each bin, and below each Vibrating Feeder there
is a Vibrating Screen (VS) of capacity 225 TPH. Material whose size is less than -3 mm falls on
FX-8 and sent to PBB and material whose size is more than +3 mm falls on FX-7 and sent to
Flux Crusher House for re-crushing.
Total number of Stock Bins for Flux (FXSB) 5
No. of bins for Limestone 3
No. of bins for Pyroxenite 1
No. of bins common to Limestone & Pyroxenite 1
Capacity of Stock Bins 200 t
Flux Rod Gate (FXRG) 5
Flux Rack & Pinion Gate (FXRPG) 5
Vibrating Feeder for Flux (FXVF) 5
Capacity of Vibrating Feeders 25-225 tph
No. of Flux Crushers (FXCR) 5

Motor
Capacity Belt Speed Coupling
Conveyor Length (m) Width (mm) Capacity
(tph) (m/s) Type
(KW)
CO-23 (RS) 9 1600 1800 2
CO-24 (RS) 9 1600 1800 2
FX-1 273.5 1400 1800 2
FX-2 519 1400 1800 2
FX-3 30 1600 1800 2
FX-4 (RS) 23.8 1800 2315 2
FX-5 284 1000 675 2
FX-6 (RS) 19.8 1200 675 2
FX-7 280.9 1000 675 2
FX-8 406.9 1000 675 2
FX-9 24.05 1000 675 2
OF-1 277.5 1400 1800 2
OF-2 577 1400 1800 2
OF-3 35.2 1400 1800 2
RF-1 595.56 1200 800 1.35
3.3 Fuel from Coke Stock Bin to PBB
The fuel from coke stock bin passes through Fuel Screen House and a Fuel Crusher House;
where a rod mill operates to crush fuel down to the required size. Thereafter it is conveyed
to the PBB via a network of conveyors and junction houses.
Fuel Screen House

Fuel Screen House
Flow Diagram of Fuel Screen House

Fuel Screen House receives fuel from the Coke Stock Bin by the conveyor CF – 1, which dumps
the incoming fuel into Fuel Stock Bins. The screen house has 5 stock bins, 3 of which will be
commissioned in the future. Each of these stock bins transfer the fuel on to a vibrating feeder
and then on to a vibrating screener which separates the fuel into two size grades: -3 and +3 –
34.
The separated fuel grades then exit the screen house via separate conveyors: CF – 3 and CF –
4 for grades -3 and +3 – 34 respectively.
Fuel Cross Belt Magnetic Separator (FCBMS) 1
Fuel Metal Detector (FMD) 1
Fuel Belt Scale (FBS) 1
No. of Bins in PH I (FSB) 2
Capacity of Bins 100 tph
No. of Load Cells per bin 3
Rod Gate (FRG) 1/ bin
Vibrating Feeder (FVF) 1/ bin
Capacity of Vibrating Feeder 10-100 tph
Vibrating Screen (FVS) 1/ bin
Capacity of Vibrating Screen 100 tph

Fuel Crusher House
Fuel Crusher House
No. of Bins in PH I (FSB) 2
Capacity of Bins 80 tph
No. of Load Cells per bin 3
Rod Gate (FRG) 1/ bin
No. of Retractable Belt Feeder (RTFBF) 1/ bin
Capacity of Belt Feeder 5-50 tph
No. of Rod Mills (FRM) 1/ bin
Capacity of Rod Mill 50 tph

Flow Diagram of Fuel Crusher House
The crusher house receives sized fuel (+3 – 34) from the Fuel Screen House via conveyor CF –
4. The fuel drops into 3 Fuel Stock Bins, from where exiting fuel drops on to Retractable Belt
Feeders. The fuel is then fed to corresponding Fuel Rod Mills for crushing (each has a capacity
of 50tph).
Crushed fuel is taken up by a common conveyor CF – 6 which takes the material to the fuel
junction house: FJ – 5.
Fuel to Proportioning Bin Building
Fuel from the screen house is taken towards the PBB by a conveyor system that consists of CF
– 3, 8, 9, 10, 11, 12 and FX – 9. These conveyors pass through junction houses FJ – 6, 1, 2, 3, 4
and JH – 16.
While fuel of size -3 follows this route directly, the fuel of size +3 – 34 first gets crushed, passes
through FJ – 5 and is then fed to CF – 3 to be carried to PBB.
In future a conveyor CF – 6B will send a part of crushed fuel from FJ – 5 to the Fuel Screen
House for further screening and subsequent crushing as and when required.
Motor
(tph) (m/s) Type
(KW)
CF – 1 229.3 800 100 1.6
CF – 2 (R) 8 1000 100 1.6
CF – 3 388.3 800 100 1.6
CF – 4 281.3 800 80 1.6
CF – 5 (RSC) 15 1000 80 1.6
CF – 6 132.5 800 100 1.6
CF – 6A 12.1 800 100 1.6
CF – 8 19.298 800 100 1.6
CF – 9 428.75 800 100 1.6
CF – 10 77.4 800 100 1.6
CF – 11 14.9 800 100 1.6
CF – 12 22.35 800 100 1.6

3.4 Base Mix from Proportionate Bin Building to Sinter Plant
via Base Mix Storage Yard
First of all, the conveyor BMS – 1 carries out the Base Mix. The contents are then either
directly taken to Sinter Plant or to the Base Mix Yard and the corresponding circuits separate
at the junction house BMJ – 1. From there conveyors BMR – 3,4 and 5 go towards Sinter Plant
via junction houses BMJ – 2, 3 and 4.
In the Base Mix Yard, the Twin Boom Stacker is used to stack the Base Mix whereas the
reclamation is done by a Barrell Reclaimer.
Proportioning Bin Building
Proportionate Bin Building

Flow Diagram of Proportionate Bin Building
As the name suggests, this building is responsible for making the base mix, which goes into
the making of sinter, by carefully mixing all the necessary ingredients in calculated
proportions.
The building houses 12 bins to receive incoming materials from various sources – 2 bins for
return fines via RF – 1, 2 bins for coke fines via CF – 12, 1 bin each for Pyroxenite and
Anthracite and 2 bins for Limestone via FX – 9, and 4 bins for iron ore fines. The capacities of
all the bins are as follows:
Bin number and material Capacity in tonnes
PB – 1 & 2 (Return Fines) 675
PB – 3 & 4 (Coke Fines) 390
PB – 5 (Pyroxenite) 515
PB – 6 (Anthracite) 320
PB – 7 & 8 (Limestone) 1040
PB – 9, 10, 11 & 12 (Iron Ore Fines) 1430

No. of Proportioning Bins (PB) 12
No. of Load Cells (PLC) 3/ bin
No. of Rod Gates (PRG) 1/ bin
No. of Weigh Feeders (PWF) 1/ bin
Type of Weigh Feeders Load cell based
Weigh Feeder number Capacity (tph)

1&2 25-250
3&4 15-150
5&6 10-100
7&8 25-250
9, 10, 11 & 12 180-1800
Once the proportions have been decided the materials are dropped down from the weigh
feeders, situated just below each bin, on to the common conveyor BMS – 1. This conveyor
carries the material out of PBB and transfers it on to BMS – 2 which connects PBB to the first
junction house of the circuit: BMJ - 1
Base Mix to the Base Mix Yard
At the junction house BMJ – 1, the incoming conveyor BMS – 2 meets the reversible conveyor
BMS – 3 which dumps the material on to either BMR – 3 (towards Sinter Plant) or BMS – 4
(towards Base Mix Yard).
BMS – 4 is the conveyor on which the Twin Boom Stacker TBS – 1 operates and the same is
used to stack the Base Mix in the yard.
Twin Boom Stacker
Twin Boom Stacker
The purpose of the stacker is to stack the material in the storage yard by 400layers. The
material is being received from the yard conveyor through tripper. The flow rate of the stacker
is 2500 to/h. The stockpile area consists of 2 piles. The first pile is above of conveyor belt
BMR-1 (Pile I). The second one is below the conveyor belt BMR-2 (Pile II). Stacking of both
piles will be done by the Twin Boom Stacker TBS-1.
The Twin Boom stacker consists of:
 A Boom conveyor - 1 at pile side -1

 A Boom conveyor -2 at pile side - 2
 One flap gate with diverting chute
 A wire rope luffing winch system for Boom conveyor - 1
 A wire rope luffing winch system for Boom conveyor -2
 A travel system on fixed side
 A travel system on pendulum side
 An automatic rail clamp on fixed side
 An automatic rail clamp on pendulum side
 One automatic grease lubrication systems for long travel wheels
 A MV cable reel for 6.6 KV supply with holding brake
 A radio communication system for communication to:
 Barrel Reclaimer BR-1
 Central control station (CCS)
Operation Modes
The mode of operation is to be selected in the operator cabin on the machine itself. The
following operation modes can be selected:
 Remote Automatic Mode

In this operation mode the automatic process can to be started and stopped from central
control room (CCR). All machine interlocks are active.
 Automatic Mode
In this operation mode the automatic process can be started and stopped on the machine
only. A movement of single drives in operation cabin is not possible. All machine interloc ks
are active.
 Manual Mode
In this operation mode each motor can be started and stopped separately from the operator
cabin. All machine interlocks are active.
 Local control mode

In this operation mode the drives can be moved manually. Additionally certain motors can be
started and stopped separately on the local control panel outside of the operator cabin.
Certain interlocks of sensors or with other drives are disabled in this mode.
Technical Details
Boom Conveyor Belt
No. Of Boom conveyor 2

Drive pulley diameter 630 mm
Discharge pulley diameter 500 mm
Length between above pulleys 27.25 m
Belt width 1400 mm
Belt speed 2.8 m/s (Motor 1500 rpm)
Conveyor capacity 2500 t/h
Number of motors for each boom 1
Boom Luffing Winch
Luffing drive system Steel rope winch

Luffing range min -12 deg
Luffing range max +32 deg
Operating range min (Stacking) -12 deg
Operating range max (Stacking) + 15 deg
Shunting position +32 deg
Diameter of drum 648 mm
Diameter of rope 24 mm
Length of rope 100 m
Luffing force (approx.) 50 kN
Rope speed 7 m/min
Number of motors for each system 1
Travel System
Travelling drive system electro mechanical

Number of motors 6
Motors on fixed side 3
Motors on Pendulum side 3
Max. travel distance (approx.) 291m
Rail length stockyard (approx.) 2 x 352 m
Rail span 6m
Pile width 38 m
Max. travel speed 35m/min
Gear ratio 80:1 (Motor 1500 rpm)
Wheel diameter 630 mm
Reclaimation
Barrel Reclaimer
The purpose of the Barrel Reclaimer is to scrape material and deliver it to a yard conveyor
(BMR – 1 or 2). The flow rate of the reclaimer can be regulated between 920 and 2750
tonnes/hour.
The stockpile area consists of 2 piles. The first pile is above of conveyor belt BMR – 1. The
other one is below BMR – 2. The reclaiming of both piles will be done by the Barrel Reclaimer
BR – 1. For changing the stockpile, the Barrel Reclaimer can be moved from one pile to the
other by the transfer car.
The Barrel Reclaimer consists of the following:
 A hydraulic driven drum.

 A separate cooler unit for the hydraulic unit of the drum.
 One automatic oil lubrication system for gear and pinion (drum).
 A reversible cross conveyor belt.
 A harrow luffing winch drive.
 A hydraulic rake travel system.
 A travel system on the fixed side.
 A travel system on the pendulum side.
 An automatic rail clamp on the fixed side.
 An automatic rail clamp on the pendulum side.
 One automatic grease lubrication system for fixed side.
 One automatic grease lubrication system for pendulum side.
 A MV cable reel for 6.6kV supply with holding brake.
 A plug socket for 415V supply on ground level used for power supply at pile change.
 Twin boom stacker
 Transfer car
 Central control station
Operation Modes

 Automatic Mode
only. A movement of single drives in operation cabin is not possible. All machine interlocks
are active.
 Manual Mode
 Pile Change Mode/ Transfer Mode

This mode is similar to manual operation mode, so in this mode certain motors can be started
and stopped separately but not on the operation desk but on the local control panels outside
the operator cabin. Certain interlocks of sensors are disabled in this mode. Some drives are
basically disabled in this mode.

Technical Details
Drum Drive
Length of drum 40000 mm
Drum body diameter 4200 mm
Drum cutting diameter 6200 mm
Number of buckets in middle row 6
Max number of buckets 62

Number of permanent buckets 58
Number of buckets for monsoon period 4
Width of one bucket 2111 mm

Max capacity of one bucket 420 liter
Used capacity of one bucket 150 liter
Bucket discharge angle 70 degrees
Drive design Hydraulic
Cross Conveyor Belt
Drive pulley diameter 630 mm

Discharge pulley diameter 630 mm
Length between above pulleys 44m
Belt width 1400 mm

Belt speed 2.2 m/s
Conveyor capacity 2750 tph

Number of motors 1
Harrow Luffing Winch
Luffing drive system Steel rope winch
Luffing range min +36 degrees
Luffing range max +42 degrees
Luffing distance (top end to ground) 15.98 m at 42 degrees
Operating range min +38 degrees

Operating range max +40 degrees
Diameter of drum 295 mm
Diameter of rope 20 mm
Length of rope 67 m
Harrow weight 30 tonnes
Luffing force 75 kN
Number of motors 1
Rake Travel System
Number of raking device 1
Type of raking device travelling harrow
Number of harrows 1
Width of harrow 30400 mm
Travel length of harrow 2 X 1.0 m
Operation travel speed 96 mm/s
Travel System
Number of motors 10
Motors on pendulum side 5
Max travel distance (including transfer car) 343 m
Rail length stockyard 2 X 323 m

Distance rail fixed side to rail pendulum side 40 m
Pile width 38 m
Max travel speed (under no-load) 10000 mm/min
Travel speed (under load) 36.8 – 110.4 – 220.8 mm/min
Gear Ratio 481:01

Base Mix to Sinter Plant
At the junction house BMJ – 1, the incoming Base Mix from PBB and the reclaimed Base Mix
from the Base Mix Yard are transferred onto BMR – 3. This begins the transfer of the Base Mix
to the Sinter Plant by conveyors BMR -4 & 5 via junction houses BMJ – 2, 3 & 4.
Motor
Length Width Capacity Belt Speed Coupling
Conveyor Capacity
(metres) (mm) (tph) (m/s) Type
(KW)
BMS – 1 57.4 1400 2500 2.8
BMS – 2 66.4 1400 2500 2.8
BMS – 4 413.5 1400 2500 2.8
BMR – 1 403.4 1400 2500 2.6
BMR – 2 403.4 1400 2500 2.6
BMR – 3 47.4 1400 2500 2.8
BMR – 4 124.4 1400 2500 2.8
BMR – 5 71.6 1400 2500 2.8

4. Sinter Plant Output Circuits
The circuit explains the movement of sinter after it exits the sinter plant. The sinter is either
directly sent towards the BF stock house or is sent towards the sinter stock pile, where the
sinter is first stacked and later reclaimed to be sent towards the BF stock houses via a Sinter
Storage Building.
By The sinter that has been sent towards the stockpile can also be allowed to bypass stacking
and go directly to the Sinter Storage Building. So effectively, there are three ways of
transferring sinter from the Sinter Plant to the BF stock house – Direct, Semi-direct and
Indirect.
From Sinter Plant
Sinter is taken up at the exit of Sinter Plant by conveyor SC – 1. Thereafter the sinter travels
to the junction house SJ – 3 by conveyor SC – 2.
At SJ – 3 the sinter can be sent towards BF or towards the Sinter Stockpile by operating a flap-
gate at the tail end of SC – 2. The junction house also has the incoming conveyor, carrying
reclaimed sinter, from the Sinter Storage Building. That conveyor transfers material on to the
conveyor directed towards BF stock house.
4.1 To Sinter Stockpile

At the junction house SJ – 3, once the sinter has been directed towards storage, the sinter is
taken along the conveyors SC – 3, 4 and 5 towards the stockpile via junction houses SJ – 4 and
5.
Conveyor SC – 5 runs over a travelling tripper STT – 1 which is used to trip and stack the
incoming sinter onto the stockpile (capacity 55000 tonnes). The conveyor can also carry the
sinter directly to the junction house SJ – 6 without stacking the sinter. From there the sinter
is taken to the Sinter Storage Bunkers in the Sinter Storage Building by the conveyors SC – 6
and 7 via SJ – 7.
SC-5 (Tripper Conveyor)
SC-5 has a travelling tripper (with three ways discharge chute and a flap gate) which can
move to and fro to discharge sinter in the Sinter Stock Yard
Tripper Data Table (SC-5)
2 Conveyor No. SC-5
3 Location Sinter Stock Yard
7 Material Sinter
9 Max. Lump Size +5 mm to -50 mm
21 Chute Profile Three ways with flap gate

Technical Data of Tripper Conveyor (SC-5)
Discharge Pulley

Bend Pulley

Drive Wheel & Axle


Travel Drive
Ratio 130:1, Rating – 6.73 KW
Sinter Storage Building
This is primarily a storage building where 16 bunkers, adding up to a capacity of 15750 tonnes,
are used to store incoming sinter.
Firstly, the sinter is received from SC – 7 by a reversible conveyor SC – 8. This conveyor is used
to fill the storage bunkers first. Whenever required, the sinter is then taken out of these
bunkers and transferred on to the conveyors SC – 9 and 10 to be carried away from the
storage building. These conveyors also receive sinter from the sinter loading station when
pay-loaders are used to reclaim the stacked sinter from the sinter stockpile.
Finally, the exiting sinter is carried to the junction house SJ – 3 by the conveyors SC – 11 and
12 via junction houses SJ – 5 and 4.
Flow Diagram of Sinter Storage Building
No. of Sinter Storage Bunkers 16
Total Capacity 15750 t
No. of Level Indicators (SBLI) 16
No. of Rod Gates for Sinter (SRG) 2/ bin
No. of Rack & Pinion Gates for Sinter (SRPG) 2/ bin
No. of Vibrating Feeders for Sinter (SVF) 2/ bin
Capacity of Vibrating Feeders 100 tph

4.2 To BF Stock House
As mentioned in the beginning, the sinter from Sinter Plant can be directly sent towards BF
stock house by operating the flap-gate in SJ – 3. Now, we have seen that the sinter directed
towards the Sinter Stockpile or the Sinter Storage Building is also brought to SJ – 3 after
storage and reclaimation.
In SJ – 3, the conveyor SC – 13 collects all the sinter that needs to be sent to the BF stock
house. From there onward the sinter is carried on by the conveyors SC – 14, 15, 16 and 17
(future) to the junction houses SJ – 10 and 11 (future) via SJ – 9, KJ – 3 and 4. The final junction
houses then transfer the sinter to the respective BF stock houses.
Length Width Capacity Belt Speed Motor

Conveyor Coupling Type
(m) (mm) (tph) (m/s) Capacity (KW)
SC – 1 69.8 1400 1200 1.5
SC – 2 71.4 1400 1200 1.5
SC – 3 120.17 1400 1200 1.5
SC – 4 134.7 1400 1200 1.5
SC – 5 315.1 1400 1200 1.5
SC – 6 28.8 1400 1200 1.5
SC – 7 173.8 1400 1200 1.5
SC – 9 224 1400 1400 1.5
SC – 10 224 1400 1400 1.5
SC – 11 158.8 1400 1400 1.5
SC – 12 116.3 1400 1400 1.5
SC – 13 312 1400 1400 1.5
SC – 14 23 1400 1400 1.5
SC – 15 317 1400 1400 1.5
SC – 16 62 1400 1400 1.5
5. Blast Furnace Input Circuits
5.1 Ore & Flux from Ore & Flux yard to BF

BF grade Ore & Flux is reclaimed from the yard with the help of two stacker-cum-reclaimers
(SR-1 and SR-2). CO-19 and CO-20 are the associated conveyors for SR-1 and SR-2
respectively. While reclaiming CO-19 connects to CO-23 via JH-9 and CO-20 connects to CO-
24 via JH-8. Again, CO-23 and CO-24 are Reversible Shuttle Conveyors which can discharge
material to any of the four conveyors namely FX-1, OF-1, CO-30 and CO-27 out of which CO-
27 is coming in Phase II.C0-23 and CO-24 are reversible conveyors which can discharge the
required material in the required circuit. CO-30 is associated with the BF grade Ore and Flux.
JH-10 connects CO-30 to CO-31, JH-17 connects CO-31 to CO-32, JH-18 connects CO-32 to CO-
33 and JH-19 connects CO-33 to CO-34. CO-34 leads to BF-Stock House.
Motor
Capacity
Conveyor Length (m) Width (tph) (m/s) (KW) Type
(mm)
CO-30 280 1400 1800 2
CO-31 625 1400 1800 2
CO-32 771 1400 1800 2
CO -33 47 1400 1800 2
CO-34 329 1400 550 2
5.2 PCI Coal from WT to PCI Coal Injection Plant
The above circuit shows the movement of Pulverized Coal across the plant; from Wagon
Tippler to BF Coal Injection Plant.
As shown, PCI coal follows a familiar route from the WT complex to junction house CJH – 1. It
is at this junction house that it changes track towards the PCI Coal Shed, where it is first
stacked and later reclaimed, instead of going towards the Coal Yard.
From the covered shed, PCI Coal is reclaimed by using a Portal Scrapper-Reclaimer and is sent
via conveyors to the BF Coal Injection Plant.
Wagon Tippler
PCI coal comes inside the plant boundaries via rakes which are unloaded at the WT complex
by using the Twin Wagon Tippler – 1.
The same has been explained in detail in Circuit 1.
To PCI Coal Shed
From the WT complex, PCI coal is taken up by CC – 1 and is transferred to JH – 1. At JH – 1, it

is routed towards the existing coal circuit and is carried by conveyor CC – 2 to junction house
CJH – 1. At this point, a flap-gate is operated at the tail end of CC – 2 to divert PCI coal towards
the shed (and not towards the Coal Yard).
The diverted PCI coal is then transported to the shed by the conveyors PC - 1 and PC - 2 via
junction house CJH – 14.
PC – 2 has a Travelling Tripper (CTT – 1) which helps dump the material on to the PCI stockpile
(capacity 80000 tonnes).
Reclaimation
The stacked PCI coal is later reclaimed from the stockpile by using a Portal Scrapper-
Recliamer.
PC-2 (Tripper Conveyor)
PC-2 has a travelling tripper (with two ways discharge chute) which can move to and fro to
discharge PCI coal in the PCI Cover Storage Shed.
Tripper Data Table (PC-2)
2 Conveyor No. PC-5
3 Location PCI cover storage shed
7 Material PCI

Technical Data of Tripper Conveyor (PC-2)
Discharge Pulley

Bend Pulley

Drive Wheel & Axle


Travel Drive
Portal Reclaimer
The purpose of the Portal Reclaimer is to scrape material from the store and convey it to a
yard conveyor PC – 4. The flow rate of the reclaimer can be regulated between 40 and 440
TPH. The reclaimer PR – 1 is used to reclaim coal. The material is conveyed by the yard
conveyor belt PC – 3 outside of the stockpile area. The stockpile area consists of 2 piles with
almost the same length.
The portal reclaimer consists of:
 A (main) scraper chain (hydraulic driven)

 A separate cooler unit for the hydraulic unit of the scraper chain.
 One automatic oil lubrication system for the main scraper chain.
 A (auxiliary) scraper chain (electro-mechanical driven)
 One automatic oil lubrication system for the auxiliary scraper chain.
 A lifting unit for the main boom.
 A lifting unit for the auxiliary boom.
 A travel system on the fixed side.
 A travel system on the pendulum side.
 A manual rail clamp on the fixed side.
 A manual rail clamp on the pendulum side.
 One automatic grease lubrication system for fixed side.
 One automatic grease lubrication system for pendulum side.
 A MV cable reel for 6.6kV supply.
 Tripper car.
 Central control station.
Operation Modes

 Automatic Mode
only. A movement of single drives in operation cabin is not possible. All machine interlocks
are active.
 Manual Mode
Technical Details
Main Scraper Chain
Length of main chain 30 m

Blade dimension 1600 X 350 mm
Pitch of blades 1000 mm
Number of blades 63
Chain pitch 250 mm
Type of chain special roller chain
Speed of chain 0.63 m/s
No. of guide rollers per blade 5 pcs
Drive design Hydraulic
Chain capacity (rated) 40-440 tph
Auxiliary Scraper Chain
Length of main chain 14.3 m

Blade dimension 1000 X 280 mm
Pitch of blades 630 mm
Number of blades 50
Chain pitch 315 mm
Type of chain special roller chain
Speed of chain 0.55 m/s
No. of guide rollers per blade 5 pcs
Drive design electro-mechanical
Chain capacity (rated) 150-165 tph
Number of motors 1
Lifting Unit For Main Boom
Steel rope controlled by

Drive system
electro-mechanical winch
Lifting range -10 to +40 degrees
Lifting distance 17.7 m
Operating range -10 to +40 degrees
Dia of drum 398 mm
Dia of rope 18 mm
Lifting force 50 kN
Rope speed 3 to 30 m/min
Lifting speed 0.8 to 8.7 m/min
Speed factor between rope and boom top 3.45
No. of rope layers 4
No. of motors 1
Lifting Unit For Auxiliary Boom
Steel rope controlled by

Drive system
electro-mechanical winch
Lifting range 0 to +39 degrees

Lifting distance 10.6 m
Operating range 0 to +39 degrees
Dia of drum 300 mm
Dia of rope 14 mm
Lifting force 30 kN
Rope speed 3 to 30 m/min
Lifting speed 0.75 to 7.5 m/min
Speed factor between rope and boom top 4
No. of rope layers 3
No. of motors 1
Travel System
Number of motors 5
Motors on pendulum side 2
Max travel distance (including transfer car) 293 m

Rail length fixed side 311 m
Rail length pendulum side 304 m
Distance rail fixed side to rail pendulum side 48 m
Pile width 44.7 m
Max travel speed (under no-load) 10 m/min
Travel speed (under load) 0.15 – 1.5 m/min
Gear ratio 300:01
To BF Coal Injection Plant
Upon reclaimation, the PCI coal is transferred on to the conveyor PC – 3. From there, it is
taken to the coal injection plant by a simple network of conveyors consisting of PC – 4 and 5
via junction houses CJH – 15, 16 and 17.
Motor
(tph) (m/s) Type
(KW)
PC – 1 221 2000 3500 3.8
PC – 2 353 2000 3500 3.8
PC – 3 519 1000 500 2.75
PC – 4 891 1000 500 2.8
PC – 5 176 1000 500 2.8

5.3 Coke from Coke Storage Yard to BF
Screened coke of size 34+ is taken from the coke storage yard by pay-loaders and is
transferred on to the conveyor CK – 31. The coke is then taken to junction house KJ – 2; where
it meets screened coke of the same size to be transferred directly to BF stock house. The
entire stock of coke is then conveyed along CK – 22, 23, 24, 24A, 25, 25A, 26 and 27 via
junction houses KJ – 3, 4 and 5 to Blast Furnace Stock Houses 1 and 2.
Coke Breeze (-10) and Nut Coke (10-34) are taken by pay-loaders from the storage yard and
are transferred on to the conveyor CK – 51, and passing through CK – 52, 53 and 54 these are
fed back in to Coke Stock Bin Building as input. At the exit side of CSBB, they are put on to the
conveyor CK – 41, but the material is then diverted towards BF (instead of storage yard) at
junction houses KJ – 9 and 10. CK – 45 and 43 take the coke from KJ – 9 and 10 respectively
and transfer the same to Blast Furnace Stock Houses 1 and 2.
Width
Length Capacity Belt Speed Motor
Conveyor (mm) Coupling Type
(m) (tph) (m/s) Capacity (KW)
CK – 22 7 1400 400 1.6
CK – 23 336.3 1000 200 1.6
CK – 24 34 1000 200 1.6
CK – 24A 339.33 1000 200 1.6
CK-26 53 1400 400 1.6
CK – 28 209 1400 400 1.6
CK – 29 82 1400 400 1.6
CK – 30 372 1600 400 1.45
CK – 31 406 1000 150 1.6
CK – 32 169 1000 150 1.6
CK – 35 (r) 19 1200 200 1.6

CK – 36 (r) 19 1200 200 1.6
CK – 37 (r) 25.5 1000 100 1.6
CK – 38 (r) 25.5 1000 100 1.6
Ck – 39 (r) 25.5 1000 100 1.6
CK – 40 (r) 25.5 1000 100 1.6
CK-41 269 800 100 1.6
CK-42 58 800 100 1.6
CK – 43 87 800 100 1.6
CK – 46 263.5 800 100 1.6
5.4 Coke from Coke Breeze Yard to BF

Coke is reclaimed from the Coke Breeze Yard by pay-loaders and is transferred to the BF
Stock House via conveyors CK – 51, 52, 53, 54 and 43 via junction houses KJ – 13, 12, 11 and
10
Belt Speed Motor Coupling

Length Capacity
Conveyor Width (m/s) capacity Type
(m) (tph)
(mm) (KW)
CK-51 334 800 100 1.6
CK-52 137 800 100 1.6
CK-53 187 800 100 1.6
CK-54 573 800 100 1.6

6. Blast Furnace Output
Circuits
This circuit shows the movement of BF slag and other outputs across the plant.
6.1 Slag to Corresponding Loading Stations
The primary movement of the slag happens from the Dewatering Bin Building to the Wagon
Loading Station. However, there are intermediate loading points where the slag can be
directly loaded on to the trucks to be carried away.
Also, the slag can be stored in Slag Stockpiles form where it can be reclaimed and fed back
into the conveyor system by reclaim feeders to be carried towards the Wagon Loading Station
again.
Dewatering Bin Building to SJH – 3
BF slag is first taken up by the conveyor SLC – 1 at the exit of Dewatering Bin Building. It is
then carried on towards SJH – 3 by the conveyors SLC – 1A, 2 and 3 via junction houses SJH –
1A, 1 and 2.
Truck loading
Inside SJH – 1 a flap-gate can be operated at the tail end of SLC – 1A to divert the incoming
slag towards Truck Loading Bin. From there the slag can be directly loaded onto trucks to be
carried away.
SJH – 3
The junction house SJH – 3 houses 2 incoming conveyors: SLC – 3 (from Dewatering Bin
Building) and SRC – 3 (from slag stockpile). It also has 2 exiting conveyors: SLC – 4 (towards
slag stockpile) and SRC – 4 (towards Wagon Loading Station).
Incoming slag from SLC – 3 can be directly transferred on to SRC – 4 to be taken away for
loading in to wagons, or it can be diverted on to SLC – 4 by a flap-gate.
Incoming slag from the slag stockpile is carried in by SRC – 3 and is transferred on to SRC – 4
to be taken away for loading in to wagons, or a flap-gate is operated to divert the material
towards a second Truck Loading site.
Slag Stockpile
SLC – 4 and 5 carry the slag towards the stockpile via SJH – 4 and 5. From SJH – 5, the conveyor
SLC – 6 with a travelling tripper is used to create the stockpile (capacity 20000 tonnes). In the
future another conveyor, SLC – 8, will be used to create a second stockpile of the same
capacity.
Later, slag is reclaimed from the stockpile and is fed into the conveyor system by reclaim
feeders. The reclaimed slag is taken to the junction house SJH – 3 by the conveyors SRC – 2
and 3 via junction houses SJH – 6 and 4.
Wagon Loading Station
The slag destined to be loaded into wagons exit SJH – 3 by SRC – 4, and reach the Wagon
Loading Station by conveyor SRC – 5 via junction house SJH – 7.
Inside the station, a reversible conveyor deposits the incoming slag into 6 slag bins of capacity
730 tonnes each.
On the other side of the slag bins are corresponding weigh feeders which finally load the slag
into positioned wagons to be taken away.
Motor
Length Belt Speed Coupling
Conveyor Width (mm) Capacity (tph) Capacity
(m) (m/s) Type
(KW)
SLC-1A 120 1000 750 2.65
SLC-1 305 1000 750 2.65
SLC-2 34 1000 750 2.65
SLC-3 625.5 1000 750 2.65
6.2 BF Sludge to CSBB and fines to PBB

Blast Furnace sludge, an outcome of wet scrubbing and thickening of crude gas, is collected
through press filter and is sent to CSBB by conveyors CK – 56A, 56 and 57 via junction houses
KJ – 4 an d 18. The fines generated from the same is sent to PBB by the conveyor RF - 1
Length Width Capacity Belt Speed Motor

Conveyor Coupling Type
(m) (mm) (tph) (m/s) Capacity (KW)
CK – 56A 25 1000 200 1.6
CK – 56 320 1000 200 1.6
CK – 57 72 1000 200 1.6

7. SMS Input Circuits
7.1 Limestone from Ore & Flux Yard to Lime Calcining Plant
Limestone is reclaimed from the yard with the help of two stacker-cum-reclaimers (SR-1 and
SR-2). CO-19 and CO-20 are the associated conveyors for SR-1 and SR-2 respectively. While
reclaiming CO-19 connects to CO-23 via JH-9 and CO-20 connects to CO-24 via JH-8. Again,
CO-23 and CO-24 are Reversible Shuttle Conveyors which can discharge material to any of the
four conveyors namely FX-1, OF-1, CO-30 and CO-27 out of which CO-27 is coming in Phase
II.CO-23 and CO-24 are reversible conveyors which can discharge the required material in the
required circuit. FX-1 is associated with the fluxes including limestone. JH-10 connects FX-1 to
FX-2 and JH-14 connects FX-2 to LSC-1. LSC-1 leads to Primary Screening Station.
Primary Screening Station

Flow Diagram of Primary Screening Station
Limestone from LSC-1 falls on Level Indicator for SMS Limestone (LSLI) of 100 T capacity, which
acts as a buffer for smooth and continuous flow of limestone, to Vibrating Screens (LSVS-1
and LSVS-2) of 700 TPH capacities each via Vibrating Feeder (LSVF-1).
Screening of limestone is done in three ranges of sizes:

i) + 80
ii) +40 -80
iii) -40
Limestone whose size is greater than 80 mm is collected by pay loader and sent back to ore
yard.
Limestone whose size is between 40-80 mm is sent to Limestone Storage cum Secondary
Screen House via LSC-3.
Limestone whose size is less than 40 mm is either sent to Flux Crusher House (via LSC -5 and
LSC-6) where it is crushed and sent to Proportionate Bin Building (PBB) just like other fluxes
or collected by pay loader and sent back to ore yard.
Number of Surge Hopper 1
Capacity of Surge Hopper 100 T
Number of Vibrating Screen for SMS Limestone (LSVS) 2
Capacity of each Vibrating Screen 700 TPH
Number of VIBR-Feeder for SMS Limestone (LSVF) 1
Capacity of VIBR-Feeder 700 TPH
Number of output bins 2
Capacity of output bins 50 T and 150 T
Number of Rod Gate for SMS Limestone (LSRG) 3
Number of Selector Gate for SMS Limestone (LSSG) 2
Number of Bulk Loading Sprout for Limestone (LSBLS) 2
Number of Level Indicator for SMS Limestone (LSLI) 3
Limestone Storage cum Secondary Screen House

Limestone Storage cum Secondary Screen House
Flow Diagram
Limestone whose size is between 40-80 mm is sent to Limestone Storage cum Secondary
Screen House via LSC-3. Limestone from LSC-3 falls on LSC-4, a Reversible Shuttle conveyor,
which can feed limestone to any of the 7 bins of 600 T capacities each. These bins act as
storage of limestone and five of the seven bins are coming in Phase I and the remaining two
are coming in Phase II. Lime stone from bins falls on four Reversible Shuttle conveyors (LSC -
7, LSC-8, LSC-9& LSC-10) via Vibrating Feeders.
Number of Limestone Day Bins 5

Capacity of each Limestone Day Bin 600 T
Number of Vibrating Screen for SMS Limestone (LSVS) 2
Number of VIBR-Feeder for SMS Limestone (LSVF) 7
Capacity of VIBR-Feeder 175 TPH
Number of Reject bin 1
Capacity of Reject bin 100 T
Number of Rod Gate for SMS Limestone (LSRG) 6
Number of Rack & Pinion Gate for Limestone (LS RPG) 6
Number of Flap Gate for Limestone 6
Number of Selector Gate for SMS Limestone (LSSG) 1
Number of Bulk Loading Sprout for Limestone (LSBLS) 1
LSC-7, 8,9,10 feed limestone to Vibrating Screens (LSVS-3, LSVS-4, LSVS-5 and LSVS-6) of 350
TPH capacities each, LSVS-5 and LSVS-6 are coming in Phase II.
After screening, limestone whose size is greater than 40 mm is sent to KILN-1, KILN-2 and
KILN-3 via Skip, KILN-3 is coming in Phase II.
Limestone whose size is less than 40 mm is sent back to Ore Yard via pay loader.
Motor
(tph) (m/s) Type
(KW)
LSC-1 25 1000 700 2
LSC-3 233.5 1200 700 1.5
LSC-5 45 800 140 1.65
LSC-6 58.5 800 140 1.5
7.2 Lime from LCP to SMS
Lime from KILN-1 and KILN-2 is carried further by LC-1 and LC-2. LJH-1 connects LC-1 to both
LC-3 and LC-4 by a Flap Gate (LFG-1) arrangement; similarly LC-2 is also connected to both LC-
3 and LC-4 by a Flap Gate (LFG-2) arrangement. LC-3 and LC-4 both lead to Refuse Bin Building
where a sample of lime is collected by Lime Sampler (LSMP-1) and inspected.
Half calcined lime is rejected by Flap Gates (LFG-3 at LC-3 and LFG-4 at LC-4) and falls on LC-
7, from where it is sent to Reject Bin of 100 T capacity and collected by pay loader and
dumped.
Full calcined lime is sent to Lime Storage Building via LC-5 & LC-6.
Lime Calcining Plant
Lime Storage Building

Lime Storage Building
Flow Diagram of Lime Storage Building

Lime from LC-5 falls on LC-8 which is a Reversible Shuttle Conveyor and from LC-6 falls on LC-
9 which is also a Reversible Shuttle Conveyor. Thereafter, lime from LC-8 and LC-9 falls on
Lime Storage Bunkers. There are 14 Lime Storage Bunkers of 150 T capacities each out of
which 10 are coming in Phase I and 4 are coming in Phase II.
Lime from Lime Storage Building is sent to Lime Primary Screen House via LC -10.
Number of Lime Storage Bin 10

Number of Lime Rod Gate (LRG) 10
Number of Lime Rack Pinion Gate (LRPG) 10
Number of Lime Vibrating Feeder (LVF) 10
Number of Limestone Level Indicator (LSLI) 10
Number of Lime Bin Vibrator 10
Capacity of output conveyor (LC-10) 300 TPH
Belt Speed of output conveyor (LC-10) 1.2m/s
Lime Primary Screen House
Flow Diagram of Lime Primary Screen House

Lime from LC-10 falls on Lime Bin Vibrator of 75 T capacity which acts as a buffer. Lime from
bin falls on Vibrating Screens (LVS-1 and LVS-2) via vibrating feeder (LVF-15) for smooth and
continuous flow.
Screening of lime is done in two stages:

i) +10 -80
ii) -10
Lime which is between 10 and 80 mm is carried by LC-16 towards JH-20 and from where it
either falls on LC-18 or Lime Bunker Boot (100 T capacity) by a Flap Gate arrangement. Lime
from LC-18 is sent to SMS building and lime from bunker is collected by pay loader and sent
to secondary metallurgy of SMS plant.
Lime which is less than 10 mm is sent to Lime Fines Reject Bin Building via LC-17 where it is
collected by pay loader or sent to Grinding Plant.
Number of Surge Hopper 1
Capacity of Surge Hopper 75 T
Number of Lime Vibrating Screen 2
Number of Lime Vibrating Feeder 1
Capacity of Lime Vibrating feeder 300 TPH
Number of Lime Rod Gate 1
Number of Lime Rack & Pinion Gate 1
Number of output conveyors 2 (LBS-4 & LBS-5)
Capacity of each output conveyor 250 TPH

Motor
(tph) (m/s) Type
(KW)
LC-1 85 1200 300 0.85
LC-2 85 1200 300 0.85
LC-3 187 1200 300 0.85
LC-4 LC-
187 1200 300 0.85
4
LC-5 86.5 1200 300 0.85
LC-6 86.5 1200 300 0.85
LC-7 11.5 1200 300 0.85
LC-8 (rs) 41 1400 300 0.85
LC-9 (rs) 41 1400 300 0.85
LC-10 562 1000 300 1.2
LC-16 86 650 200 1.2
LC-17 42.5 650 100 1.2
LC-18 387 1000 550 1.2
7.3 SMS grade Ore from Ore & Flux Yard to SMS
SMS grade ore is sent directly through tripper gallery by CO-16 which transfers
material to CO-18 at JH-4. CO-18 transfers the material towards JH-5 and from there
it is carried to SMS.
Motor
(tph) (m/s) Type
(KW)
CO-16 365 1600 3500 2.8
CO-18 86 1200 1750 2.8

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What is the purpose of the technical reference manual?

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What are the main sections/units covered in the manual?

RMHS & Logistics Department,

Technical Reference Manual

Special thanks to Mr B C Kedia for his guidance.

(Arindam Das) (Anshul Maheshwari)

Kalinganagar – Project Highlights

The department aims at an uninterrupted supply of raw materials to its customer

1. Coke Oven Input Circuits

1.1 Coal from Wagon Tippler to Coal Yard

Twin Wagon Tippler-1

TIPPLER TIME ASSESSMENT

1 No. of tips/wagons per hour 25 25

No. of wagons handled per

7 Cushion time to EOL time limit 1 hour 2 hours

9 handled in 21 hours leaving 3 = 5.43 or say = 7.826 or say

 Programmable Logic Controller (PLC S7-4H) is of Siemens make.

 Manual mode - Operation initiated from Control Desk by operator in predetermined

1 Material To Be Unloaded Coal

Boxn, Boy-25, Boxnha, Boxnhs,

4 Wagon Unloading Capacity 2*25 Wagons/Hr (Max.)

5 Rotating Speed Of Tippler Approx 1.5 M/S

6 Design Base As Per RDSO G-33(Rev-A) May

8 Tippling Angle 180 °

9 Top & Side Clamping Through Hydraulic Cylinder With

11 Positioning Device Indexer & Side Arm Charger

12 Installed Power 250 K.W * 2 Nos.

14 Total Weight Per Machine Approx 380 Tons.

2 Loaded Wagons To Be Pulled & 58

2 Type Of Luffing System Hydraulics Cylinder

Forward With Wagons 0.7m/s (Max.)

Max. No Of Wagon To Be 60 Loaded Wagons + 2 Locomotives On

2 Type Of Luffing System Hydraulics Cylinder

3 Rail (Track) Crs 1600mm

Forward With Wagons 0.6 M/S (Max.)

5 Type Of Power Supply Energy Drag Chain

No. Of Running Wheels – 630

7 No Of Guide Wheels- 800 Dia. 4

8 Travel Drive Arrangement Rack & Pinion Type

9 Drive Type Electro-Mechanical With VVF Drive

10 Electric Motor Kw 110

Disc Brake On Gear Box Input Shaft Of

Technical Detail of Apron Feeder for Twin Wagon Tippler 1:

Sl No. Equipment Specification

Sl No. Equipment Specification

Wagon Tippler lubrication system:

Lubrication Systems for Wagon tippler provided are:

Technical description of conveyors

CC-1 150 2000 3500 3.8 300 Scoop

CC-2 474 2000 3500 3.8 740 DFC

CC-3 746 2000 3500 3.8 580 DFC

CC-4 453 2000 3500 3.8 400 DFC

CC-5 (Tripper Conveyor)

Tripper Data Table (CC-5)

SL. No. Description Specification

1 Pulley Dia. * Face Width * BRG. Dia. 800 * 2200 * 240