SINTER PLANT

DESIGNED PARAMETERS
• Designed production :- 0.72 MTPA
• Productivity :- 1.39 Tonne/M2/Hour
• Daily Production Design :- 2184 T
• Plant Availability :- >90.4%
• Required raw material to produce 1T of Sinter :- (1450-1500)Kg
• Specific Solid fuel consumption (Net) :- 63Kg/T Sinter
• Specific Energy Consumption :- 35 KWh/TS
• Consumption of gaseous energy: ≤ 30000 kcal/t of gross sinter.
• Sinter machine area :- 75 m2
• Effective Suction Area :- 70 m2
• Width of Pallet car :- 2.5m
• Effective suction length :- 28 Meters
• Length of one pallet car:- 1 m
• Height of pallet car:- 0.65 m
• Sinter machine speed :- (0.4-2.4) m/min
• Sinter machine Capacity :- 220 TPH
• Capacity of one pallet car loading :- Approx. 3 T
 DESIGNED PARAMETERS
• Total numbers of Burner :- 20
• Drum Feeder Dimension :- 1032 * 2546 mm
• Drum Feeder Speed:- 2.1~6.34 RPM
• Inclination angle of Distributing Roller with Pallet Car Plane:- 38⁰
• Sinter Hot Breaker Capacity :- 205 TPH
• Each wind box length from WB#01 to WB#11 :- 2.5 m
• Cooling Area :- 110 m2
• Normal Processing Capacity of Cooler:- 200 ~ 260 TPH
• Width of Cooling Area :- 2200 mm
• Height of Cooler Pallet :- 1500 mm
• Speed of Cooler :- 0.3-1.0 rph (Speed Control range:- 300~980 rpm)
• One round rotation time of Pallet:- 60~195 Min
• Capacity of one pallet of cooler :- Approx. 06 T
• Total nos of pallet car in Cooler:- 45
• No. Of Cooler FD Fan- 3 Nos
• Cooler Fan Motor Capacity- 250 KW (737 RPM)
• Primary Product Screen Capacity(Design/Rated)- 220/165 TPH
 DESIGNED PARAMETERS
• Secondry Hearth Layer Screen(Design/Rated):- 145/110
• ESSB Vibro Feeder Capacity(Design/Rated):- 180/150 TPH
• Waste Gas Fan Drive:- VFD(Variable Frequency Drive)
• WG Fan Drive Capacity:- 3.7 MW (RPM:- 992)
• ESP Specific Collection Area:- 85 m2/m3/sec
• ESP Gas Flow Design:- 540000 m3/hr at 170⁰ at Operating Temperature
• Suction Pressure(Design/Rated) :- -2000/-1550 mmWC
• Dust Content in waste gas at Inlet of ESP:- 3 gm/Nmᶾ
• Dust Content in waste gas at outlet of ESP:- 30 mg/Nmᶾ (maintain less than)
• Process De-dusting :- Electrostatic Precipitator (5 No’s Field- 3 phase)
• Gas Velocity through ESP between:- 0.8~1.0 m/s
• Number of Plant De-dusting :- Bag filters (1 No’s)
• Dedusting Fan Motor:- 1.1 MW (Fixed Drive, RPM-990)

• PMD Dimension:-ɸ3000*9000 •Inclination Angle of Drum:- 1.6⁰

• PMD Production Capacity:- 240 TPH •Rotation Speed of Drum:- 6~7 rpm
• PMD Drive Capacity:- 132 KW • Retention Time:- 2.5~3 min
 SINTERING PROCESS
What is sinter?
Sinter is the agglomeration of blended iron ore fines, coke fines and fluxes created by incipient
fusion suitable for use in blast furnace.
Advantages:
• Gainfully utilization of huge quantity of iron ore fines which is generated in mining stage.
• Iron ore fines are easily available at much cheaper rate than lump ore.
• Gainfully utilization of solid metallurgical waste which is generated in integrated steel plants,
solving a major problem of solid wastes disposal.
• By using of super fluxed sinter in BF burden charging of raw flux is completely eliminated
hence coke rate goes down.
• Reducibility of sinter is better than lump ore.
• RDI of lump ore is much greater than sinter. Higher the RDI higher the coke rate & lower the
productivity of BF.
• Sulphur in iron ore fines is effectively reduced by sintering process. As such overall Sulphur in
Hot metal is reduced.
Disadvantages:
Sinter is brittle in nature. It is broken into fines particles during multiple handling.
Raw Materials:
Iron Ore fines(0-8) mm, Limestone (0-3) mm, Dolomite (0-3) mm, Coke (0-3) mm, Sand, Burnt
lime, Metallurgical waste (Cyclone Dust, Mill scale, BOF Slag, FeS Dust etc.).
BF Required Sinter Chemistry :
Requirement of Sinter Quality As per BF Requirement of Sinter Quality As per BF
Parameter Range
Parameter Range RI (>65)%
FeT (54-55)% MPS (16~22)mm
CaO (10.5-11)% BFRF +5mm <10%
MgO (1.8-2.0)%
SiO2 (5.5-6.0)%
Al2O3 < 2.8%
FeO (8.5-10.0)%
Basicity (CaO/SiO2) 1.8-2.0
Al2O3/SiO2 0.5-0.55
RDI (22-26)%
TI (>73)%
AI (<6)%

Types of Sinter:

1. Acidic Sinter (Sinter is made without flux)

2. Basic Sinter (Sinter is made with sufficient flux)

Basic Sinter is two types

a) Self Fluxed Sinter
b) Super Fluxed Sinter
Types of Zone:

1. Wet Zone
2. Preheating & Dry Zone
3. Combustion & Calcination Zone
4. Sintering Zone (Melting)
5. Cooling Zone
6. Sinter
Process Control Parameters:
• BTP should be more than 360 Deg C, at 10th no. wind box.
• Suction pressure should not be more than -1550 mmWC.
• ESP inlet temperature to be maintained in the range between 140-160 Deg.C
• Ignition furnace temperature should be between 1050 to 1100 Deg C.
• Coke crushing index >85%.
• Limestone & Dolomite crushing index > 90%.
• Cumulative VM of coke & coal should be less than 3%.
• Surge level should be maintain less than 60 for optimum material segregation.
• PMD Should be use as a dry & SMD should be use as a Wet Mixing of Raw Materials.
• Weigh feeder error should be less than ±1%
• Bed height – 650 mm, Hearth layer – 50 mm.
• Cooler loading should be uniform.
Raw Material Requirement Size (Sinter Quality optimizing):
• Bigger size of Iron ore fines (+8mm, max.5%) and BF return (+5mm, max.5%) are not
participated in sintering because of improper mixing.
• If micro fines (-0.5 mm) content in iron ore fines will go above the limit (40%max), the sinter
bed permeability will go down.

Higher the limits of above material will deteriorate the sinter quality (TI/RDI/MPS/FeO) as
well as the productivity.
Sulphur content in iron ore fines exists as sulphide and sulphate and in coke it exists as organic sulphur. Generally Desulphurization reaction is :
a) Sulphur oxidizes and forms SO2
Raw Material Quality and Size
b) Partially SO2 is absorbed by CaO to form calcium sulphate (CaSO4)
c) Calcium sulphate decomposes further
%(6- %-
% % 1)mm, %
IOF FeT % SiO2 % Al2O3 % P% LOI % +10mm, +8mm, max +0.5mm, 0.5mm,
Nil max 5% 30% >25% 40%
max
Illoyed IOF 63.9 2.86 2.5 0.063 2.8 3 15 28 15 39
NMDC IOF 61 5.4 2.9 0.06 3.95 6 5 29 20 40
Thakur IOF 64 4.3 1.3 0.098 1.6 2 4 40 14 40
WSL IOF 64.4 3.3 1.85 0.062 2.09 5 4 25 27 39
MSP IOF 63 2.8 2.5 0.062 4.4 3 15 26 16 40
BFRF+BF IOF 56 6.2 3.2 0.062 3.2 0 1544 11 30
%+5mm,
Metallurgical Waste FeT% CaO % MgO % SiO2 % Al2O3 % FeO% FC %
5% max
Mill Scale 65 1.5 0.5 1 1 4.5
BOF Slag 40 7.5 12 8 12
Cyclone Dust 38 15
FeS Dust 38 1.85
%
%+8mm, %+6mm, %+5mm,
FeT% SiO2% Al2O3% CaO% MgO% FeO% +10mm,
Nil Nil 5% max
Nil
BFRF 55 5.2 2.95 10.9 2 11 0 0.3 10 20
IRF 55 5.6 3.02 10.9 2 8.5 0 0 5.6 12
Quartzite 88
Reduction Process of Iron Ore (Indirect Reduction):

3C + 2O2 🡪 2CO+CO2

3Fe2O3 + CO 🡪 2Fe3O4 + CO2

Fe3O4 + CO 🡪 3FeO + CO2

FeO + SiO2 🡪 FeO.SiO2 (Fialite, at 1100-1200 Deg Celsius)

FeO + Al2O3 🡪 FeO.Al2O3 (Hersinite, at >1200 Deg Celsius)

Limestone (CaCO3):

CaCO3 🡪 CaO + CO2 (at 850 Deg Celsius)

CaO + SiO2 🡪 CaO.SiO2 (Calcium Silicate)

CaO + FeO 🡪CaO.FeO

CaO+FeO+SiO2+Al2O3 🡪 SiO2.FeO.CaO.Al2O3 (> 12500C)

At >12500C, SiO2, FeO, CaO and Al2O3 get together are called silico ferrite of calcium and
alumina (SFCA).
 Raw Material Charge
Raw IOF BFRF Limes Dolo Coke Flue Cal. IRF IPD
Materials +BF tone mite Dust Lime
IOF
Burden 46.8% 18% 8% 4% 4.2% 1.3% 1% 17% 1%
Specific 723 246 116 54 64.3 19.7 15 264 15
Consumptio
n(Kg/T
Sinter)
Desulphurization
● Sulphur content in iron ore fines exists as sulphide and sulphate and in coke it
exists as organic Sulphur. Generally Desulphurization reaction is :
● Sulphur oxidizes and forms SO2
● Partially SO2 is absorbed by CaO to form calcium sulphate (CaSO4)
● Calcium sulphate decomposes further

4FeSO2 + 11 O2 🡪 2Fe2O3 + 8SO2

Limestone (CaO):
The limestone fuses easily to agglomerate the high melting iron ore fines. It is added in sinter to
improve the reducibility and increases the porosity.
Alumina (Al2O3):
Aluminous iron ore required high temperature to fuse because it is refractory in nature, so coke
in charge mix has to be increased. When alumina increases in sinter the strength goes down. If
alumina increases in sinter RDI also increases, it may be countered by increasing of lime or
basicity.
RI:
• Reducibility of sinter means the rate of removal of oxygen from iron oxides present in sinter
in high temperature zone of Blast furnace.
• More the reducibility of sinter, better the productivity of blast furnace.
• RI of sinter has direct impact on wind acceptability in B.F. More the RI better the air input to
BF.
TI:
Tumbler index represents the cold strength of sinter.
SiO2:
Higher SiO2 in sinter will induce the formation of glassy phases in sinter and reduces the
strength of sinter. If SiO2 decreases in sinter then BF charges the quartzite to maintain the slag
chemistry (basicity) (CaO+MgO / SiO2+Al2O3) & fluidity.

MgO:
When alumina is increased in BF slag the fluidity of slag decreases So, MgO content of sinter
helps to increase the fluidity. As the melting point of MgO is higher so the sintering temperature
has to be increased due to which coke has to be increased in charge mix.
Low Al2O3/SiO2:
• Reducibility of sinter improves.
• RDI of sinter improves.
• Slag viscosity & slag chemistry improves, separation of slag from hot metal is better.
• Removal of gangue from hot metal is better.
• Improves primary slag formation in BF & improves softening temperature.
If alumina & silica will increase in input raw material in BF, the permeability goes down and air
blow will reduce so, the productivity of hot metal decreases.
FeO:
• More the FeO of sinter better the sinter strength.
• RDI, TI and MPS will improve.
• Viscosity of slag is better.
• Higher the FeO higher the softening melting temperature at BF.
• Higher the FeO thinner the cohesive zone and improves the permeability inside BF.
• Impurity pick up (Silica & Sulphur) in hot metal is less.
RDI (Hot Strength of Sinter):
• If RDI of sinter increases (>26%), the fines generation will be more inside the BF at low
temperature zone (350-6000C) and the permeability inside the furnace goes down
(pressurized), the coke rate will increase leading to low productivity of furnace.
• If RDI of sinter is less (<22%), the reducibility of sinter will decrease so, the coke rate will
increase leading to low productivity because of high slag volume and hot metal isn’t cleaned
as SMS point of view.
Basicity:
• Basicity of sinter, improves primary slag formation in BF which makes process in BF faster.
•
 Quality Control
RDI Improvement:
• Reduce Al2O3 in sinter.
• Improve crushing index of flux and fuel.
• Reduce +5mm particles in charge.
• Increase fine particulate in charge (2.5—3.0)mm.
• Keep optimum moisture in charge.
• Increase ignition temperature.
• Increase FeO in sinter.
• Maintain Al2O3/SiO2 ratio (0.5-0.55).
• Increase Bed height.
• Better Sintering process.
• Increase Basicity of sinter.
• Increase CaO in sinter.
• Reduce hematite phase.
• Avoid rapid cooling of sinter.
• Avoid water spraying on sinter.
FeO Improvement:
• Increase coke in charge.
• Improve crushing index of fuel.
• Increase moisture in charge (optimum).
• Increase ignition intensity.
• Better Sintering Process.
• Increase bed height.
• Reduce +5mm particulates in charge.
• Avoid rapid cooling of sinter.
• Avoid water spraying on sinter.
THANK YOU
Prepared By
Navin