Sinter plant operation pdf

Pdf optimization of sinter plant operating conditions using. The total energy use distribution 24 by various units of the steel plant coke ovens, sinter plant, blast furnaces, steel shop, rolling mills, and power plant is shown in figure 4. Understanding sinter and sinter plant operations sintering is a process of agglomeration of fine mineral particles into a porous and lumpy mass by incipient fusion caused by heat produced by. Presently more than 70% of hot metal in the world is produced through the sinter.

The raw materials for an integrated steelworks can be classified into four categories, which are iron ores, fluxes, fuels, and reverts. The characteristics of these raw materials strongly affect the metallurgical properties of. Now, most sinter plants in the usa are the garbage disposal for the steel mill processing pellet fines, dust, and mill scale into blast furnace feed. Kasama s, yamamura y, watanabe k 2006 investigation on the dioxin emissions from a commercial sintering plant. Since then sinter has become the widely accepted and preferred blast furnace burden material. Apply to 273 sinter plant operation jobs on, indias no. The principal raw materials used in the blast furnace operation consist of. Four operating parameters, including the water content wc. Large sinter strands 6 m wide and with a sintering area of. Table of contentsprocess control of sintering plantoxide use in sinteringenergy savings of the sintering process the sintering process for the preparation of raw materials to be fed to the imperial smelting furnace i.

This study set out to reduce polycyclic aromatic hydrocarbon pah emissions from the iron ore sintering process by optimizing its operation parameters obtained from the taguchi experimental design. Major air pollutants, particles, nox, sox and dxn, have been managed in the sinter plant. The sinter tests were carried out in triplicate for each mix condition. In the eu27, 14 countries operate 34 iron ore sinter plants with 63 iron ore sinter strands, which in the first decade of the 21st century manufactured million tons of sinter annually 6. Pdf sintering is a thermal agglomeration process that is applied to a mixture of. Epa600279203 november 1979 sinter plant windbox recirculation and gravel bed filter demonstration. These characteristics are useful for stable operation of a blast furnace, in order to secure good gas and solid reaction by keeping permeability in a blast furnace. Sintering theory was traditionally developed either as the application of complex diffusion or viscous flow mechanisms to a simple geometry or as complex. The process which utilizes dust to convert it into lumps is called sinter. It can be noted that the major share 72% of energy is required during iron making which includes coke making 12%, iron ore sintering 6%, and blast furnaces 54%. The objective of balling is to eliminate fines by layering them on the coarser size fractions which act as seed or nuclei, that is, by an autolayering mechanism of growth1. Blast furnace operation an overview sciencedirect topics.

Sinter having size 5 mm will go to the cooler and then it will go to bf. Optimization of sinter plant operating conditions using advanced. Explore sinter plant operation openings in your desired locations now. Outotec has built more than 400 iron ore sinter plants worldwide. Sinter plant windbox recirculation and gravel bed filter.

The proper performance of sinter plants is vital for efficient and uniformly blast furnace operations. The process of sinter making originated from a need to make use of fines generated in mines and in ore beneficiation plants. Sinter with size pdf by sintering, the pelletisation of finegrained, smeltable ores, iron ore in particular, to compact lumps by heating nearly to the. Current national steel corporation weirton steel division p. Optimization of sinter plant operating conditions using advanced multivariate statistics. 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. This process, primarily used for iron ores, can also be used for sintering manganese and nickel ore fines. Sinter plant operation pdf by sintering, the pelletisation of finegrained, smeltable ores, iron ore in particular, to compact lumps by heating nearly to the. Exclusions in this process we want to focus solely on the use and exposure of sinter and its constituents. An experimental plan was established where the sinter mix composition remained unchanged while the amounts of fuels varied to allow the best possible assessment of the use of charcoal and its results, keeping the mass participation in the total mix between 3 % and 6 %. Two conceptual designs were developed from the wierton report, one for standard sinter plant operation and one for a sinter plant with windbox gas re circulation.

It consists of two proprietary measuring gauges with associated control systems. The process of sinter making originated from a need to make use of fines. Optimization of sinter plant operating conditions using. Sinter plant operation metallurgist mineral processing 1 1 2012 d r morris p evans in energy money materials and engineering 1982materials preparation section sinter plant attention will be focussed on the sinter plant figure 1 only since energy usage in the materials storage conveying and proportioning plant is small relative to the energy effects of the sintering process. Understanding sinter and sinter plant operations ispatguru. Research group in siderurgy, metallurgy and materials, department of. Phase 2 construction, operation, and evaluation by g. This paper describes bed blending and sinter plant operational features, pollution control systems, and the application of computers for control. The final product, a sinter, is a small, irregular nodule of iron mixed with small amounts of other minerals. Integrated steel plant in scunthorpe, uk raw material.

The objective of the sintering process is the agglomeration of a mixture of iron ore mineral fines 0. Every step in the sintering process each plant area and piece of equipment, and their optimized design and the overall integration required for a highperformance sinter plant all add up to. The process, called sintering, causes the constituent materials to fuse to make a single porous mass with little change in the chemical. From process and production analysis that examine sinter productivity, quality, raw materials, and end product logistics to increased material recycling in the. This sinter plant operation consists of firing iron ore fines, coke dust, and occasionally mill scale on a slowly moving grate to produce a suitable charge material for blast furnaces by agglomerating and fusing these fines into a usable form. A screen of the user interface of the raw mix calculation model is shown in fig. Of the fact that the capacity of sintering plants in india is limited, it requires to produce. In india, approximately 50% of hot metal is produced using sinter feed in blast furnaces. Sinter plant raj kumar goel, managing director, vankam vasu, dgm slr metaliks limited, email.

In daily plant operations, it is necessary to address the. In comparison to the other preparation process for zinc extraction, i. Jnil what is sinter sinter word comes from the greek word sint which means dust. In combination with the expert system, the raw mix calculation model is a central part of the closedloop operation, which is a unique highlight of the vairon sinter automation solution. Production cost reduction feature of cdq process are follows.

The product, known as a green sinter ball quasiparticle, is larger in size with a mean size of 3. Introduction since philippine sinter corporation psc began operation in 1977, it has built a position as a key overseas raw material processing base for jfe steel while adapting to. The invention discloses a control system of a sinter plant, comprising a sinter apparatus, a control network, a mobile operation terminal, a control station which is connected with the control network and used for receiving state information of the sinter apparatus and generating an operation instruction for the sinter apparatus, and a remote station which is used for. Sinter plant control excellence in optimization systems the best system for sinter plant process optimization the irm group sinter plant optimization system is a complete and wellproven tool for maximizing productivity and sinter quality control. Operational and environmental assessment on the use of. Latest generation sinter process optimization systems. The main results which are of interest for the plant operation are the specific energy flow in the sintering process, bed temperature, exhaust gas temperature, coke consumption as well as calcination and sulfation, dryingcondensation, and sinter quality. The rmm for environment should mirror what is written in the iron and steel bref 2009 as referenced above on page 1. History and prospect of philippine sinter corporation. Pdf sintering is a process by which a mixture of iron ores, fl uxes and coke is agglomerated in a sinter plant to manufacture a sinter product of a. Pdf optimization of sinter plant operating conditions. Successful integration of partial fgd and scr at sinter plant yubin hong sinter plant of ironmaking department china steel corporation air pollution is a serious issue in ironmaking, especially the sintering process.

Reduce environmental impact with low fuel consumption and ultraefficient gas cleaning. Reducing pah emissions from the iron ore sintering process. Total plant monitoring for an integrated steel plant. Available and emerging technologies for reducing greenhouse gas emissions from the iron and steel industry prepared by the sector policies and programs division office of air quality planning and standards u. Since startup, the plant has operated at 95% availability and produces highstrength, superfluxed sinter of very consistent chemical composition. Automation and control systems are vital tools to assist plant operators in the monitoring of each stage of the sinter production process. The technology of sinter making has undergone radical changes both in operation and process throughout the world. As on today, sinter has become widely accepted and preferred burden material in blast. With the development of sintering technology, a sintering plant has become a tremendous success for providing a phenomenal increase in productivity and saving in coke rate to the blast furnace. First water sealed sinter cooler was put into operation in 1996, second in 1996. After solving initial issues caused with dusty cooling gas and higher cooling gas temperature, water sealed sinter coolers are. Our processes for sintering and pelletizing have been the worlds leading solutions for iron ore sinter and pellet production for over 50 years. This paper seeks firstly to describe some design considerations of sinter plants. For successful operation of the blast furnace, recommended quality of sinter is as follows.

In this regard it is necessary to consider the widely held and simplistic view that sinter feeds containing iron ores with high. Environmental protection agency research triangle park, north carolina 27711 september 2012. If the sinter plant is an independent operation, rail will be needed to bring raw materials in and sinter out. Sinter plant operation jobs, 273 sinter plant operation. Sintering is an agglomeration process which involve heating raw material to incipient temp below its melting point to convert it into hard lumpy and porous mass. For smooth sinter plants operation, changes to the operating conditions should be few and. A sinter feed with good permeability from ignition until burnthrough is required for efficient operation of a sinter plant. Total plant monitoring for an integrated steel plant july 20 20, hcl technologies, ltd.