Malaviya National

Institute of Technology

DURGAPUR STEEL
PLANT
PROJECT ON SINTER
DURGAPUR STEEL PLANT
PLANT
PROJECT ON SINTER PLANT
Submitted By: Submitted
To:
UTKARSH AGARWAL Dr. V.K
Sharma
2011umt2514 Dr. N.C
Contents
OVER VIEW
RMHP(Raw Material Handling Plant)
COKE OVEN PLANT
SINTER PLANT
BLAST FURNACE
SMS AND CCP
OVER VIEW OF DSP
DSP was Initiated during the 1950s.
DSP is the firstIngot (1960) producing steel plant in
India.
An initial annual capacity of DSP one million tonnes of
crude steel per year.
Enhancement in the capacity of the plant to 2.088
million tonnes of hot metal, 1.8 million tonnes crude steel
and 1.586 million tonnes saleable steel in 2000.
DSP is the sole manufacturer of wheels.
PRODUCT -MIX TONNES/ANNUM

Merchant Products 2,80,000

Structural 2,07,000

Skelp 1,80,000

Wheels & Axles 58,000

Semi finish products 8,61,000

Total Saleable steel 15,86,000

Raw Materials

Iron ore, coal and limestone are the three basic raw
materials for the steel industry. (7.4 million tonnes)
Durgapur Steel Plant draws its coal from the
adjacent Jharia-Ranigunj coal belt. (1.84 million
tonnes)
Bulk of iron ore lumps and fines come from the
mines at Bolani in Orissa.(2.9 million tonnes)
Lime stone comes from a variety of sources:
Birmitrapur (Orissa), Jaisalmer (Rajasthan), and
Jukehi and Nandwara (Madhya Pradesh).
Raw Materials Handling

To improve and ensure consistency in raw material

quality, the facilities, which have been installed, are:
Beneficiation/washing facilities, both for lump ore and
fines at Bolani
Screening of lump iron ore inside the plant,
Selective crushing of coal at Coal Handling Plant,
Base blending facilities for Sinter Plant,
Blending bunkers
Coke Ovens& Coal Chemicals
No of batteries 5
No. of ovens per
battery
78
The coke ovens plant is divided into four basic sections namely
coal preparation plant, coal carbonization plant, coke handling
plant and coal chemicals.
The Blast Furnace grade coke produced in Coke Ovens is directly
used in Blast Furnaces while the undersized coke is used for
sinter making.
The volatile matters, which emanate during the process of coke
making subsequently produce a variety of by-products like
naphthalene oil, heavy creosote oil, light oil, crude tar partially
distilled tar, Raja brand fertilizer, nitration grade benzene,
nitration grade toluene, industrial grade toluene, light solvent
naphtha etc.
The coke oven gas is generally used in combination with the
Blast Furnace gas and BOF gas as fuel.
Sinter Plant

Sinter is an agglomeration of iron ore fines, coke and

limestone in the form of cakes.
To ensure sinter burden in the blast furnaces at 75 per
cent, a total of 3 million tonnes of sinter was envisaged
for a production of about 2 million tonnes of hot metal.
A sintering machine having 198 sq meters sintering area
has been added as part of the modernization scheme to
produce 1.7 million tonnes of sinter.
DSP have two sintering machine . these are follow:

1.RAW MATERIAL PREPARATION
FOR RAW MATERIAL PREPARATION THESE STEP IS FOLLOW
Screening of Iron Ore Fines Optimum size of Iron Ore Fines is below 8 mm is
selected .
Size > 8mm -Iron Ore Fines acts as chiller .
Size < 2mm -Iron Ore Fines reduces permeability and hence reduces Sinter
Machine productivity.
Flux Crushing & Screening Mainly lime stone and dolomite both blended in
a definite proportion -
Optimum size for flux is -3 mm
Size >3mm- flux leads to fragile sinter and increases return sinter which in
turn reduces sinter productivity. Crushing index for flux is -3 mm 92% min.
Coke Crushing -coke crushing index for coke -3 mm is minimum 92%.
size >3mm-sinter mix leads to sticker formation.
size <3mm -coke particles does not generate sufficient heat for melt formation.
 Required Quality of Raw material
for sintering

IRON ORE FINE +8mm =70% max

-1mm =30% max

COKE -3mm=80% max

LIME STONE -3mm=85% max
DOLOMITE -3mm=85% max

sinter quality for high productivity blast furnace may be summarized

as follows:
Consistent sinter chemistry.
Consistent sinter granulometry.
High strength index(T.I)
Low reduction degradation index(R.D.I)
High reducibility index(R.I)
2.Chemical parameter
Fe 56% min
FeO 8-11%
SiO2 4.8-5.2 %
Al2O3 2-3 %
CaO 9-10%
MgO 2.6-2.8%
Available lime 3.4-3.8 tonnes
Basicity 1.6-1.8
Tumler index 70% min
Reducibility index (RI) 65% min
Reducation degradation index 30 %max
(RDI)
RAW MATERIALS USAGE PATTERN FOR AIMED SINTER
QUALITY REQUIREMENTS W.R.T. RAW MATERIALS QUALITY
Blend Wet Analysis of Input Materials,%
Blend
compo Wet
blend Analysi
Fe SiO2 Al2O3 CaO MgO Moist. LOI
compo
nents blend
(%) s of
ne (%)
Input

Iron ore 63.85 62.50 2.20 2.80 0.00 0.00 10.00 6.00
L/Stone( 3.60 1.00 9.00 0.50 42.50 4.50 2.00 38.34
BF)
L/Stone( 2.40 0.70 1.50 0.50 50.00 1.00 2.00 40.39
NL)
Dolomit 8.00 1.00 9.00 0.50 26.50 16.50 2.00 38.97
e
Mill- 1.10 35.00 7.00 1.00 0.90 0.16 2.00 2.00
scale
Ferro- 0.00 57.40 4.40 2.90 9.40 1.90 2.00 9.70
scrap
BF flue- 0.00 19.60 0.94 4.18 2.50 0.80 1.00 56.70
dust
BOF 2.00 17.00 17.00 1.50 44.00 10.00 0.00 0.00
slag
Ret. 12.80 56.08 5.13 3.06 8.63 2.58 0.00 1.00
Sinter(B
F)
Sand 0.00 0.70 93.00 1.50 1.50 0.50 0.00 0.50
BOF 0.00 56.80 2.30 2.20 9.60 1.90 32.00 4.20
sludge
Coke 6.25 4.50 56.00 26.00 1.80 1.50 Coke Ash
 Coke Analysis Coke Addition

Coke % Base Trim.

Ash 20.0 4.25 2.0

Moist. 10.0
V.M. 0.7

COMPUTED ANALYSIS Yield CaO:Si CaO-

(%) O2 SiO2

78.4 1.68 3.50

Finis Fe SiO2 Al2O3 CaO MgO
hed
sinte
56.08 5.13 3.06 8.63 2.58
r
Specific Consumption
of Raw Material per
Unit Ton of Sinter
Iron Ore Fines 830 kg/T

Limestone 93 kg/T

Dolomite Fines 85 kg/T

Calcined Lime 5 kg/T

Mill scale 25 kg/T

Coke Breeze 79 kg/T

2.RAW MIX PROPORTIONING, MIXING AND BALLING

Constituents of sinter mix are proportioned in a definite

proportion to achieve desired sinter quality as per
demand of Blast Furnace.
Mixing and balling at mixer has a big effect on
productivity and sinter quality.
For balling definite amount of water is added to sinter mix
in spray form and again mixing takes place. This
determines permeability of sinter mix.

CHARGING OR LOADING OF
SINTER MIX OVER PALLETS
Sinter Mix charging over pallets should be such that coarser
particles segregates at bottom and finer particles are at top of
sinter bed.
Sinter Mix loading should be uniform. This will lead to goof
ignition condition and more cut off volume should be maintained
at near the side plate of pallet to minimize wall effect.
Important points during Charging to Sinter Machine
are shown as follows:
Get good permeability by high void ratio
Coke segregation along material bed height
Uniform feeding across and longitudinal
IGNITION OF CHARGE MIX

Following points should be considered for good

ignition.
To start the sintering reaction, surface of the raw mix is
ignited at the ignition
Uniform ignition and combustion of coke
Minimum air leakage from outside
Maintain surface strength of sinter bed
3.SINTERING PROCESS
BASIC PRINCIPLES OF SINTERING MACHINE
The sinter mix undergoes ignition and there is suction
below.
as suction is applied and ignition takes place .

hot products of combustion of gases are

sucked through the bed and transfer their

heat to a very narrow layer of sinter mix
at the top.
removing the moisture from this layer and
creating conditions for the beginning of
combustion of the coke particles in the mix.
Then ignition is stopped.
 the sinter gets cooled by the air which gets preheated
and this heat is utilized in the combustion zone.
the combustion products coming out of the combustion
zone give up their heat to a very small layer of cold mix
quickly heating it. Hence the temperature of the waste
gases near the exhauster remains at round 50C for a long
time and only in the last few minutes of the process raises
to 300C.
The temperature at the combustion zone reaches
1400C.
The raw mix adjacent to the combustion zone is
preheated quickly.
The water vapors condense on the layers of cold mix
below and create a zone of re-condensation of moisture in
which the moisture of mix exceeds the initial moisture.
In the preheating zone chemical reaction between solid
Sinter Machine
Dwight Lloyd Process

The sintering of iron ore fines by suction is defined by

the heat transfer between gas and solids.
heat occurring due to passage of air through the bed
determines the temperature level of heating of solids
and cooling of sinter and also the rate of sintering.
The temperature level to a considerable extent
determines the strength of sinter
4.CRUSHING OF SINTER
Single roll crushers are used as sinter crushers that
perform the task of primary crushing in the iron and steel
industry.
Sinter crusher is usually equipped with a directly-driven
crushing roll that has strong crushing teeth .
Crusher is used to reduce size of sinter.
5.COOLING OF SINTER

Average temperature of sinter cake discharge from sinter

machine is about 800C. In this case material cannot be
conveyed from sinter plant to B.F. using belt conveyor,
therefore sinter should be cooled up to below 80C to
avoid belt conveyor burning.
Also sufficient cooling of sinter improves room
temperature properties. For this
dip rail deep bed circular type
cooler is latest off late.
6.SCREENING OF SINTER

Screening of sinter is essential because of below mentioned

reasons.
Big lump of low reducibility in B.F. increases coke consumption at B.F.
When feeding small particle to B.F. permeability in B.F. decreased
and hanging slip will occur
Also 25mm -16mm size of
sinter is required as hearth layer
during sinter mix charging.
+25mm size sinter is used in B.F.
-6mm size sinter used as return sinter
 ADVANTAGES OF USING SINTER
1)To utilize Iron Ore fines and Coke breeze.
2)To utilize Metallurgical wastes of fines, nature like Mill scale,
Ferro scrap, LD slag ,LD Sludge etc.
3)Reduction of Coke Rate in Blast Furnace
4)Productivity Improvement of Blast Furnace
5)Smooth Gas Dynamics inside BF stack.
6)Better Operation of Blast Furnaces as Sinter is engineered
product.

BLAST FURNACE
Blast furnaces are referred to as the mother unit of an integrated steel
plant.
Iron ore is charged into a blast furnace either as lump ore or in the form of
sinter and reduced to molten iron by the coke at temperatures ranging
from 1, 200 1, 400 degrees centigrade.
The limestone, acting as flux, absorbs the impurities in the molten iron
and goes out as slag.
The major portion of liquid hot metal is transferred to steel melting shop
for conversion to steel and the rest portion is cast into pig iron in pig
casting machines.
Blast furnace slag high in lime-content is used for cement making. In the
blast furnace process iron ore and reducing agents (coke, coal) are
transformed to hot metal, and slag is formed from the gangue of the ore
burden and the ash of coke and coal. Hot metal and liquid slag do not mix
and remain separate from each other with the slag floating on top of the
denser iron
 Process Flow of Blast Furnace
Coke Oven Sinter Plant RMHP
(Coke) (Sinter) (Iron Ore & Fluxes)

Charge GCP BF
Network
High BF
Gas BF Gas
Line Double
bell Holder
system

Skip
Stock
House Sla SGP

O2 g
SMS/Pig
Hot casting M/c
Ho Met
t al
Air Ladle
Cold Air Stoves

Steam
 BLAST FURNACE
No 1 No 2 No 3 No 4
Parameter (being
s modernize
d)
Capacity 1, 250 1, 820 1, 820 2, 340
(tons/day)
Useful 1, 323 1, 400 1, 400 1, 800
volume
(cub.m)
Stoves 3 3 3 3
1.000 1.3 1.3 1.3
Productivity
(tons/cub.
m/day)
 Steel Melting Shop

Mixers - 2 x 1, 300 t
Converters(L.D.) - 3 x 110 t (nominal heat size)
Molten iron is further refined at the Steel Melting Shop (SMS) to produce
steel, which is hard and malleable.

At DSP, there are 3 converters (Basic Oxygen Furnace) of 110-130 tonnes

each. The SMS also has a Vacuum Arc Degassing (VAD) unit for making
special grades of steel.A major portion of the steel is routed through the
Continuous Casting Plant.
Another major portion of the steel is taken to the teeming bay, where it is
top poured into 8 tonne ingot moulds for making ingot steel.
A portion of highly controlled steel is cast at the Special Casting Bay into
fluted ingots and special quality blooms. Fluted ingots are bottom poured
and are used for making wheel steel for DSPs Wheel & Axle Plant.
A portion of the liquid steel is also bottom poured to make axle ingots.
 Continuous Casting Plant

The state of the art CCP has 2 Nos machines having 6

strands each. The other basic details are as follows: -
Design limits- 80-150 sq mm

Casting radius 6m

Casting time 85 min

Cut off length 6/9/12 m

No of ladle treatment station 2

Mould level controller Automatic (radio active Co-60)

The steel ladle from BOF is taken to the ladle treatment station.
There liquid steel is rinsed with nitrogen to homogenize its
temperature and composition.
After , the ladle containing liquid steel is placed on the turret
and brought over the tundish.
The tundish acts as a buffer and enables the liquid steel to
move homogeneously down through the six nozzles, provided
at the bottom of the tundish into moulds.
The subsequent primary and secondary cooling transforms the
liquid steel into billets of the required dimensions and is drawn
out with the help of a withdrawal and straightened unit and cut
into the required length by the shear provided in each strand.
The continuous casting process is the result of a unique
synchronization between Basic Oxygen Furnace and CCP.
Once a ladle is emptied, another ladle is brought into casting
position and the casting continues.
The billets are gradually shifted to the cooling beds.
HANK YOU