Sinter Plant

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Sintering Plants

Sinter plants agglomerate iron ore fines


(dust) with other fine materials at high
temperature, to create a product that can
be used in a blast furnace. The final
product, a sinter, is a small, irregular
nodule of iron mixed with small amounts of
other minerals.

Sinter Plant - I
The Sinter Plant-I has a rated capacity of 1.5 million tonnes of
sinter per year based on 2-strand 3 shift running. There are two
sinter machines of the Dwight-lloyd down draft type with 125 sq
meter working area. The raw materials as specified above are
brought, stored, crushed and sent to proportionating bins. The
different materials are drawn from these bins in a fixed ratio on to a
common belt conveyor leading to the primary mixing drum. Here
water and return fines are added. The raw mix is stored in two
intermediate bins from where it is fed into the two pelletising
drums. Here further water is added to facilitate balling which
increases the permeability of the raw mix.

This is carried to the charging hopper over the sinter machine 1 &
2. The material is fed over the sinter machine pallets and the height
of the bed is maintained 400-450 mm depending upon quality of raw
material used and sinter to be made. The sinter machine is provided
with 21 wind boxes at the bottom to suck the air through the bed. As
the bed travels through the Ignition Furnace, the top layer is ignited.
This combustion zone proceeds downwards till the pallets reaches
the discharge end.
The temperature in the last wind box is maintained at around
250o C. The hot sinter coming out from the machine is broken by the
sinter breaker and then screened. The -6mm fraction is sent to the
Return fines bin. The sinter is then cooled in the cooling strand by
blowing air through it and finally it is sent to the double deck cold
screen. Here it is separated into 3 fractions.

The +25mm is either stored in the sinter storage bunker (1200T


capacity) or is directly sent to the Blast furnaces. The -25mm and
+15mm fraction is used as a bedding hearth layer on the sinter
machine in order to:
(i) Increase the permeability of the bed.
(ii) To protect the grate bars from the direct contact with the hot
sinter.
-15mm fraction is again screened with 6mm screen. +6 mm
fraction is sent to the Blast
furnace along with +25 mm fraction. -6 mm fraction is sent to return
fines bin. Two space dedusting fans with Electro Static Precipitators
are installed for dedusting from various transfer points. Two waste
gas fans with Electro Static Precipitators are installed for creating
suction in the sinter bed from bottom .

Input material:
The input materials and average consumption for one ton of sinter are:
1. Iron ore fines - 830 Kg
2. Lime stone fines - 80 Kg
3. Dolomite fines - 160 Kg
4. Coke Breeze - 69Kg (Dry)
5. Return fines - 30% (max.)
Output:
The output is sinter whose typical composition is:
1.Total Fe 54.0 %
2.FeO 9.50.5 %
3.SiO2 5.50.5 %
4.Al2O3 3.00.2 %
5.CaO 10.5 0.5 %
6.MgO 2.8 0.2 %
7.Basicity 1.8 - 2.0 %

SINTER PLANT-II
Process:
Sintering is the process of agglomeration of particle fines
by incipient fusion, which bind them together into hard,
porous, lumpy mass of material. Base mix, coke breeze
and flux fines are received at Sinter Plant I by a series of
belt conveyors from OBBP and collected in bins. There are
total twelve bins, four are for base mix, one for
miscellaneous, two each for flux fines, coke breeze and
Blast furnace return fines one for plant return fines. After
proportionating, the material comes to mixing and balling
drum for nodulising and moistening.

Then with help of a series of belt conveyors, it (raw mix) is laid


onto sinter machine pallets above a hearth layer. The top layer of
material on pallet is ignited in ignition furnace with the help of
mixed gas. As the sinter machine continuously moves on and
exhaust blower (Waste Gas Fan) sucks air from the bottom of
pallets, the combustion layer travels down. After the sinter
process is completed, the sinter cake is crushed, cooled,
screened for different sizes and the undersized (-5 mm) sent
back for recycling. The sinter +15 mm to -25 mm size is used as
hearth layer on sinter machine.

Lime Dolomite Brick Plant

Lime Plant:
Lime Plant has a twin shaft kiln and a single shaft kiln to
produce metallurgical lime for use in LD converters of SMS-I as
flux. Twin shaft parallel flow regenerating kiln namely Kiln No.5 is
of 150 T capacity per day and single shaft kiln namely Kiln No.8 is
of 80 T capacity per day. Lime stone is supplied by Ore Bedding
and Blending Plant. Feed size of Lime stone is 40mm to 80 mm
and CaO content is 53% min. Lime stone is stored in the High Line
bunkers of LDBP and charged in the Kiln by skip. Lime produced is
stored in Kiln Bunkers and Classified Bunkers and supplied to SMS
through Belt Conveyors.

Pitch used is obtained from Coal Chemicals Department of RSP.


Graphite (0.7 mm size) is obtained from outside sources. Magnesia &
Graphite are mixed uniformly with molten pitch at a temperature of
around 200oC. Hot pressing of this mix is done in hydraulic press of
1600 T capacity to produce green (untempered) bricks. These green
bricks are then tempered at a temperature of 300oC to achieve the
desired quality of bricks. The tempered bricks after cooling are stacked,
wrapped, stored and supplied as per requirement of Customers.

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