Professional Documents
Culture Documents
TECHNOLOGY
By:
Shukdeo Prasad
Chapters
Definition.
History of Sinter technology.
Process of Sintering.
Advantages of sinter over other Ferocious
materials. Used in B.F
Input Raw Materials to BF.
Process inside BF.
Performance assessment of BF.
Chapters
Effect of Sinter on BF operation.
Sinter quality requirement by BF.
Average quality of Raw Materials to Sintering
plant at JBL Durgapur.
Average Sinter quality at JBL Durgapur.
Standard Raw Materials quality for good quality
sinter making.
Average charge burden in Sintering Plant atJBL
Durgapur.
Chapters
Chemical specification:-
FeO 8—9 %
Basicity (CaO/SiO2) 1 .8 –2.0
CaO 10—11%
Al2O3/SiO2 0.4—0.6
MgO 2.5—3.0 %
SiO2 4.5—5.5 %
Al2O3 2.5%max
Reducibility Index (R I) 65 %.min.
Reduction Degradation Index (R D I) 20—30%
Average Quality of Input Raw
Materials at JBL
I OF T Fe(57—59) % ,Al2O3(5—7)%,SiO2(4.5-7)%
Flux (lime stone and dolomite mixed) CaO (38 –40)%,
MgO(10—11)% , SiO2(4—4.5)%, Al2O3 (1.1—1.3)%
Coke FC- (60—84)%, Ash(18—35)%, VM (3—4)%
Average charge burden in
sintering plant at JBL Durgapur
IOF (including B F Return) ---- 80.5 T/H 55.9%
Coke 6.6T/H
4.7%
Flux 18 T/H 12.6%
Internal Return 30T/H 21%
(Hot and cold return)
Water 6.5 T/H 4.5%
Quick Lime 2T/H 1.3%
Total charge rate 143.6 T/H
(So to say 144T/H)
100%
Average Sinter Quality at JBL
TFe 50-52 %
FeO 8-9%
CaO 12-13%
SiO2 6-7%
Al2O3 3-6%
MgO 3-3.3%
Basicity 1.9-2.1%
TI 70-71%
RDI 24-28 %
RI 69-71%
Mean size (MPS) 20-23mm
Standard Raw Material Quality for
Good Sinter Making
Specification of good quality raw materials for optimum Productivity and quality of
sinter is given below. While procuring raw materials for sintering plant both
chemical and physical specifications must be given equal importance.
1) Iron ore fines
Chemical specification Physical specification
T Fe 63% min. +10mm 5% max.
Al2O3 2% max. – 3mm 60 +_2%
SiO2 3% max. -0.15mm 15% max.
Ratio Al2O3 /SiO2 0.4 to 0.6 MPS 2.5to3.25 mm
Moisture 5%max.
Standard Raw Material Quality for
Good Sinter Making
2) Lime Stone
Chemical specification Physical specification
CaO 50%min. +40mm 5% max.
Al2O3 1.5%max -5mm 5%max.
SiO2 2% max. Size 5—40mm
MgO 2.5% Moisture 2.5% max
After crushing -3mm 90% min
3) Dolomite
Chemical specification Physical specification
MgO 20%min. +40mm 5%max.
CaO 30% -5mm 5%max.
Al2O3 1.5% max. Size 0---40mm
.SiO2
2%max Moisture 2.5% max.
After crushing -3mm 90%min.
Standard Raw Material Quality
for Good Sinter Making
4 ) Coke Breeze
Chemical Specification Physical Specification
Fixed Carbon 80% min. Size 0-----10mm
Ash 20% max. (-) 0.5mm 30% max.
Volatile Matter 2% max. Moisture 10% max.
After crushing -3mm 90% min
And -0.5mm 30% max
5) Quick Lime
Chemical Specification Physical Specification
CaO 90% min Size 0----3mm
Al2O3 1.5%max +3% 5%max.
MgO 2.5%max. L.O.I 5%max
SiO2 2% max. Bulk Density 1.25—1.47 T/m3
Reactivity 350min
6)Mill Scale
Chemical Specification Physical Specification
T.Fe 70% min Size 0----5mm
Al2O3 1.0% max ( +) 5mm 5%max
FeO 50% min. Oil and grease 2%max.
SiO2 1% max. more than 2% rejected
CaO 1.5% max. Moisture 2.5%max.
Standard Raw Material Quality
for Good Sinter Making
7)Flue Dust
Physical Specification Chemical Specification
TFe 30% 0---3mm 100%
Sio2 6%
C 45%
MgO 0.8% LOI 48%
Al2O3 4% CaO 3.5%
As this item is the metallurgical waste generated inside plant so chemical
Composition is not mandatory. Whatever has been shown here are only indicative.
8) E A F Slag
Chemical Specification Physical Specification
TFe 30% size 0---5mm
SiO2 15% (+)5mm 10% max.
MgO 7%
CaO 30%
Al2O3 7%
Other metallurgical wastes like SIP sludge ,DRI dust/granules, Pig Iron dust, Ferric Oxide from CRM etc. also
may be used in sinter making.
Standard Raw Material Quality
for Good Sinter Making
Other metallurgical wastes like SIP sludge ,DRI dust/granules, Pig Iron dust, Ferric Oxide
from CRM etc. also may be used in sinter making.
Iron Ore particles above 3mm and already sintered materials do not simulate and do not
take part in sintering ;they are trapped in molten (sintered) particles hence if +3mmparticles
are more in charge though physical appearance of sinter will look good but TI and FeO of
sinter will be less. +8mm particulates in charge work as heat sink . They are neither sintered
nor do they allow sinterable material to be sintered. Means they absorb more heat but do not
fuse and other useable materials around it starve for heat and do not fuse. So +8mm
particulate in charge should not be more than 5%. Closer the grain size range betters the
sinter properties. Therefore Mean Size of particulates should be within2.5 to 3.25mm only
(MPS should be 2.5 –3.25mm) as chemical and physical properties of sinter is dependent on
sintering temperature and proportioning (by weight) of constituent materials, therefore weigh
feeders and dosimeters in proportioning bins must be accurate and consistent. To monitor its
performance regular cleaning, zeroing and calibration after drop tests must be done. Sintering
property of ore fines varies from source to source (mine to mine).So source of better sintering
property should be earmarked and procurement to be maximized from that source only. Also
as far as possible no of sources to be minimized for better blending and consistency of
quality.
Sinter Process Control Parameters
Some of the standard quality/operating parameters are to be monitored constantly for better sinter
quality and productivity.
1)Mean Particle Size of charge should be 2.5 –3.25mm
2) Crushing index of coke should be (-) 3mm 90%min.and
(-) 0.5mm in crushed coke should be 30% max.
MPS of crushed coke should be 1.5 mm
Fixed carbon in coke should be 80%min.
VM in coke should be 2% max.
3) Crushing Index of Flux should be 90% min..
And (-1mm)in crushed flux should be 65%max.
4) Alumina to silica ratio in sinter (Al2O3/SiO2) between 0.4—0.6 gives better slag chemistry in BF
5)Good quality quick lime addition at the rate of 25to 40kg per ton of sinter gives better balling index and
pre heating of charge leading to better productivity.
6) 600---700 mm bed height gives better Sinter quality .Coke rate is less, TI is better ,FeO is Low ,RDI is
better
7) Flue gas flow in main flue duct @1500 –2000M3 per tone of charge gives optimum sintering
temperature/sintering speed.
8) Air filtration velocity through charge bed should be 0.3to 0.4m/sec. and air flow rate @100m3 per sq.m
sintering area per min.
9) Suction through charge ( Suction under grate, measured in flue duct) at 700mm bed height should be
1400—1550mm negative.
10) BTP temperature 300—325 degree centigrade at 13th. Wind box indicates good sin
Sinter Process Control Parameters
11) Charge level in mix bin should be maintained at 30—50% and charge level concave .This gives better horizontal
segregation of particulates.
12) Segregation plate angle to be maintained between 55—60 degree with horizontal. This will give better vertical segregation.
13) Maintain Ignition temperature in ignition furnace at1100-1200 degree centigrade by mix gas of C.V 2000KC/m3this gives
quick ignition of coke in upper layer and gives better sintering speed.
14) Moisture in charge after SMD to be maintained at 6.5 –7% of charge.
15) Balling Index after SMD (+3mm after SMD//+3mm after PMD) should be 1.6 min.
16) Sintering at 1300—1400 d.c gives better TI, better FeO, and better RDI.
17) Standard sinter yield (sinter output/charge input) is 0.625 (62.5%)
18) Sinter cake yield (sinter at SRC/total charge input should be 0.897or 89.7%
19) Sinter made with charge of finer grain size (with narrow size range 2.5-3.0mm) gives better TI and RDI even at lower FeO
20)Standard sinter size to Blast Furnace is MPS 18—22mm, with +50mm 5%max,and
-5mm5% max
21) Flue gas to main ESP temp. To be maintained between 125 d .c and170d.c
22) Dust input to ESP is 2g/M3 and from chimney it is 50mg/m3 ESP efficiency is (1950/2000 )x100=97.5% .
23) Steam addition in SMD @3-4t/hr.at2.5-3kg pr. And300dc temp. Helps in better preheating of charge and better balling
index.
24) Improving permeability of bed by improving balling index gives better sinter properties than that of improving by increasing
particulate size of charge
25) High FC coke gives better sinter quality than low FC coke with more coke rate. Heat value of coke is directly proportional
to carbon content in coke and so the temperature rise.
26) Total gangue material in sinter (SiO2+CaO+Al2O3+MgO+TiO2) 18—19 % gives better TI and RDI
27) If (SiO2+Feo+CaO+Al2O3)/TFe is between 0.48 –0.55, TI will be better.
28) Sinter with 1.6—1.8% Basicity gives lower TI. This range of Basicity sinter is more fragile. More than this range or lower
than this range gives better TI.
29) Al2O3+MgO+TiO2 in sinter should not be more than 4%.
30) In last but one wind box temperature should be highest above 300d.c and in previous and next to this wind box
temperature should be about 25d.cless than this temperature.
Charge Burden Calculation
method- 1
Feed rate calculation in sintering plant is done when plant is starting a fresh or after
major shut down or whenever raw material quality is changed or BF changes its
quality demand.
In view of BF quality demand and considering quality of available raw materials in
proportioning bins of sintering plant. Proportion of each ingredient is calculated before
hand, before feeding starts from proportioning bins . The proportion of each
constituent material (feed rate by weight) is done in proportioning bins.
Roughly it is done first with basic raw materials e.g. Iron Ore Fines, Lime Stone,
Dolomite and Coke.
Here sinter quality required by Blast Furnace and Raw materials quality are
hypothetical for learning purposes only. Actual may be different at Site:-
Sinter quality is FeO 8.5%
CaO 10%
MgO 2.5%
SiO2 5%
Basicity of sinter ( CaO/SiO2) = 2 .00
Charge burden Calculation
method -1
Let us suppose available Raw materials quality on dry weight basis is as:-
Iron Ore Fines TFe 64%
SiO2 2.5%
Al2O3 2%
Lime Stone CaO 50%
MgO 2%
Dolomite CaO 30%
MgO 20%
Coke FC 82%
Ash 18%
Now let us suppose dry weight of lime stone in charge is x kg/t sinter and that of dolomite is y kg /t of sinter
Keeping above sinter quality in mind CaO in 1 T of sinter = 100kg and MgO = 25kg
Hence 0.5x+0.3y =100------------------CaO balancing------(1)
0.02x +0.2y =25--------------------MgO balancing (2)
Multiplying equation (1) by 2 and equation (2) by 3 we get
1x + 0.6y =200 -------------- (3)
And 0.06x+0.6y =75 ---------------(4)
Subtracting equation (4) from equation (3) we get
0.94x =125--------------------------(5)
Therefore x = 125/0.94 = 133kg dry weight of lime stone
And y = (200-133)/0.6 =112kg dry wt. of dolomite
Charge Calculation (Method #1)
In sinter, lime stone is in calcined form, so in one ton of sinter calcined lime stone
weight is133x (1-0.43) =133x0.57=76kg as LOI of lime stone is 43% and
that of dolomite is 45%Calcined dolomite weight =
112x(1-.45)=112x0.55=61.6=62kg
Standard coke rate per ton of sinter at 82% FC is 60 kg
So ash in one ton of sinter =60x(1-0.82) =60x0.18=10.8=11kg/t of sinter
Now 1000kg sinter= Sintered iron ore +calcined lime stone+ calcined dolomite +coke
ash
=Sintered iron ore+76+62+11=Sintered iron ore+149kg
Therefore Sintered iron ore =1000-149=851 kg
Hence dry weight of iron ore in one ton of sinter =85/(1-LOI) =851/0.97 =877kg (as
LOI of iron ore =3%)
Therefore in one ton of sinter, dry weight of--
Iron Ore 877kg
Lime stone 133kg
Dolomite 122kg
Coke 60kg
Considering moisture in raw materials
Iron Ore fines--- 5%
Coke breeze 10%
Lime stone 5%
And Dolomite 5%
Charge burden Calculation
method -1
Natural weight of Raw materials, per ton of sinter comes--
Iron Ore 877/0.95 =923kg
Lime stone 133/0.95 =140kg
Dolomite 112/0.95 =118kg
Coke breeze =60/0.95=67kg
So total charge from proportioning bins per ton of sinter
= 923+140+118+67 =1248kg the constituent materials in percentage form =
Iron Ore Fines =923x100/1248=73.95% =74%
Lime stone =140x100/1248 =11.2% =12%
Dolomite =118x100/1248 =9.4=10%
Coke =67x100/1248 =5.3 %=5.5%
Now suppose pallet width is 2.2m, Charge bed height is 500mm,Sinter machine speed =1m/min
Total charge on sinter machine per hour =60x2.2x1x0.5x1.7 =112.2t/hour
Reducing water content from total charge from proportioning bins=
112-7=105t/hr
Individual raw materials will be
Iron ore = 105x0.739= 77.7t/hr
Lime Stone will be = 105x0.12 =12.6t/hr
Dolomite = 105x0.10 =10.5 t/hr
Coke will be = 105x0.55 =5.77t/hr
TOTAL = 106.5t/hr
Add water = 6.5t/hr
------------
Grand Total 113t/hr
Charge burden Calculation
Method -1
Here no sinter return ,no bedding layer has been considered;
but after a few hours of operation bedding layer and sinter
return (hot and cold) will also be generated, which are to be
consumed at the rate they are generated .As bedding layer is
not going in proportioning bins ; in burden calculation it is not
considered. Hot and cold sinter returns are already sintered
materials so no extra flux is added for sinter return extra coke
only at the rate of 5.5% of sinter return is added and extra water
at the rate of 6.5% of sinter return is also to be added .In that
case either we have to increase bed height to accommodate
extra quantity of coke, hot & cold sinter return and bedding
layer or keeping the total charge rate same we have to readjust
% of iron ore fines, coke and water. Standard bedding layer
consumption at 30—40mm thickness is 10to 12t/hr.for 2.2m
wide sinter machine. Hot and cold sinter return together at the
rate of 31% of sinter production.
Charge burden Calculation
Method -1
In sinter making, apart from basic raw materials
metallurgical wastes and quick lime are also used.
These materials depending on their chemical
composition may be categorized in three categories (1)
Iron bearing materials(2) Flux bearing material and (3)
carbon bearing materials. Seeing the maximum
percentage of an element present in the waste material it
is categorized as Iron bearing or flux bearing or carbon
bearing material.. For example Mill scale contains TFe
>70% FeO>50% CaO 4% MgO 1.5% SiO2 2.3% and
Al2O3 7%. As TFe is maximum in mill scale i.e. >70%
so it will be considered as Iron bearing material and will
replace Iron ore fines in the ratio of 70/60 where 60 is
average Fe in Iron ore fines.
Charge burden Calculation
Method -1
Similarly Quick Lime has CaO >90%,MgO
3.5%,Al2O3 0.5% and SiO2 1.5% .So it is a
fluxing material and will replace Lime Stone in
the ratio of 90/45.
Another material is Flue Dust, it contains TFe
30% C 45% MgO0.8% SiO2 6% Al2O3 3% and
CaO 3.5% .As C is maximum so it will be
considered replacement of coke in the ratio
45/82 and will also replace Iron Ore in the ratio
30/60.
Charge burden Calculation Method No.2
Charge calculation of raw materials feed is done from
proportioning bins of Sintering Plant to achieve the sinter
chemistry at BF end. Raw materials in proportioning bins
are in normal state & in separate bins with Moisture as
received from source and are not gone through any
processing ( drying / backing ) this material while making
sinter has a process route of
proportioning ,mixing ,loading on sinter M/C, drying ,
burning , sintering & finally coming out in the form of
Sinter. So when converted to sinter final weight of all
ingredients changes & proportion of each such material
in sinter form by weight changes to different value . In
computerized method of burden calculation (charge
calculation ) we go backward from sinter at the BF end
to raw materials at proportioning building.
before going further, following points should be kept in
mind --
Charge calculation method 2
Dry All chemical analysis of raw materials given by lab, are on dry basis.
weight of material =normal Wt.-Moisture
Moisture={(normal wt.- Dry wt.)/Normal Wt.}X100
To calculate dry weight 500gm material is heated at 500o C for 2 Hr.
LOI =Loss on Ignition
LOI={(Dry Wt. – Wt. after Ignition) / Dry Wt.} X 100
To find out LOI 500 gm of dry material is heated at 900oc for 1 Hr. then loss
in Wt. is found out.
Fe in sinter comes mainly from sintering iron ore fines & mill scale
CaO in sinter mainly comes from sintering of lime stone & Q/lime a little
from Dolomite.
MgO in sinter comes mainly from Dolomite & a little from Limestone
SiO2 in sinter mainly comes from Iron ore fines & a little from flux & coke.
Al2O3 in sinter mainly comes from Iron ore fines & a little from flux & coke .
Charge calculation method 2
Then we again forward calculation & chive the value of each
parameters after sintering & do the necessary correction in basic In
chart below we put sinter wt 1000 kg & as per BF demand other
parameters are put on 1000 kg basis .Than we calculate the basic wt
of iron ore ,limestone ,dolomite& coke doing backward calculation
LOI chemical analysis & moisture in raw materials as given by lab.
wt. to rich the final wt of each of parameters equal to or very near to
that given by BF
After 8 Hr of running with the charge rate calculated above sinter
analysis is done & course correction is done in the feed rate for
deviation if any in sinter parameters. For example ,CaO in sinter has
come 11 % against plan of 12 %.As explained above CaO in sinter
has mainly comes from Limestone/Q/lime. So if we do feed rate
correction in Q/lime feeding than we have to increased by 10/0.81 kg
=12.3 kg /T of sinter (CaO in Q/lime is 81 %).
Feo in sinter is achieve by sintering process & some extent by
increasing coke rate for which charge calculation not needed .It is
only by trail & error method
Other wise if we go for increasing CaO in sinter by 1% by in creasing
lime stone feeding than we have to increase lime stone feed rate
10/(1-moisture)XCaO in limestone=25.3 kg /ton of sinter
Charge calculation method 2
Other wise if we go for increasing CaO in
sinter by 1% by in creasing lime stone
feeding than we have to increase lime
stone feed rate 10/(1-moisture)XCaO in
limestone=25.3 kg /ton of sinter
Feo in sinter is achieve by sintering
process & some extent by increasing coke
rate for which charge calculation not
needed .It is only by trail & error method
Charge Calculation (Method #2)
Raw Material Chemistry% Sinter Chemistry
Sl No Mater Feed Moist Dry TFe CaO MgO SiO2 Al2O3 LOT( Sinte TFe Cao MgO SiO2 Al2O3 Basic
ial Rate ure( Wait %) red ity
(kg) %) (Kg) Wt(K
g)
1 I/O 908 8 836 64.0 3.00 2.80 5 795 535. 25.0 23.4
Fines 0 04 8 08
2 BF 50 2.5 48.7 52.0 11.6 3.30 5.50 3.50 48.7 25.3 5.65 1.61 2.68 1.70
Retur 5 0 0 5 5 5 1 6
n
3 L/S 76 1.5 75 0.60 45.0 3.00 7.00 1.25 40 45 0.45 33.7 2.25 5.25 0.93
0 5 7
4 Dolo 129 1.5 127 0.52 29.0 21.0 1.00 1.15 45 70 0.66 36.8 26.6 1.27 1.46
0 0 0 3 70 0
1 TFe (+/-)0.5%W.R.T Set Target (+/-) 1% W.R.T Set Target Analysis of Each ------
Sample
2 Basicity (+/-)0..08%W.R.T Set Target (+/-)0.12%W.R.T Set Target Analysis of Each As Per BF
(CaO/SiO2) Sample
3 FEo (+/-)0.5%W.R.T Set Target (+/-) 1% W.R.T Set Target Analysis of Each 7-14%
Sample
4 SiO2 (+/-)0.05%W.R.T Set Target (+/-) 16% W.R.T Set Target Ave. of All Sample As per BF
in 24hrs
5 Al2O3 (+/-)0.05%W.R.T Set Target (+/-) 15% W.R.T Set Target Ave. of All Sample As per BF
in 24hrs