INTRODUCTION OF MMIL

MAA MAHAMAY INDUSTRIES LIMTED is the first mini

integrated steel plant in and around Visahapatnam! It is lo"ated at
R!#!$eta %illage& 'hi"h is ( )M a'a* from the state high'a*
Visahapatnam and Mattili! The plant +ust ad+a"ent to Malli%eedu
rail'a* station in irandul otha%alasa ele"tri" tra"tion used for
,ringing ores from -ailadilla .NMD/ mines0 to Visahapatnam
"it*!
The "ompan* manufa"tures spe"iali1ed produ"t lines 'hi"h are
"ategori1ed as in the form of ,illets and TMT ,ars ,* esta,lishing
integrated steel plant!
This industr* in Visahapatnam 'ould fa"ilitate eas* a%aila,ilit*
for ,u*ers in the South India and redu"tion in the "ost of transportation
.'hi"h is a ma+or "onstituent of produ"t "ost0!
Visahapatnam ,eing a port "it* this plant has the option of
e2porting its produ"ts to tae ad%antage of pri"e differen"es lo"all*
and internationall*!
3or the main ra' material i!e! Iron ore the "ompan* is
dependent on pri%ate mines situated in the neigh,oring states!



INDEX
SUBJECT
INTR4DU/TI4N IN THE $LANT


SE/TI4NS IN THE $LANT

RA5 MATERIAL HANDLIN# SE/TI4N
DRI
STELL MA)IN# $R4/ESS
R4LLIN# MILL
$45ER $LANT
HISTORICAL DEVELOPMENT AND BACK GROUND
$rodu"ing sponge iron and then 'oring it 'as the earliest
methods used o,tain iron in the Middle East& Eg*pt and Europe& 'here
it remained in use until at least the 67
th
"entur*! There is some
e%iden"e that the ,loomer* method 'as also used in "hina& ,ut "hina
had de%eloped ,last furna"e to o,tain pig iron ,* 899 -/!

The ad%antage of the ,loomer* te"hni"al is that iron "an ,e
o,tain at a lo'er furna"e temperature onl* a,out 6699:" or so! The
disad%antage& relati%el* to using a ,last furna"e& is that onl* small
;uantities "an ,e made at a time!

Sponge iron pro%ided the main sour"e iron and steel for man*
"ountries ,efore the ,last furna"e 'as de%eloped around 6<99AD!
Sponge iron 'as produ"ed in relati%el* shallo' hearth or in shaft
furna"es& ,oth of 'hi"h used "har "oal as fuels!
The produ"t of these earl* smelting pro"ess 'as sponge mass of
"oales"ed granules of nearl* pure iron inter mi2ed 'ith "onsidera,le
slag! Usa,le arti"les of 'rought iron 'ere produ"ed ,* hammering
operation to e2pel most of the slag and "ompa"t the mass! -*
repeated heating and hammering& iron 'as further feed as slag and
forged into the desired shape!
All of the methods 'here ,* lo' "ar,on 'rought iron "an ,e
produ"e dire"tl* from the ore referred to as DIRE/T $R4/ESS
DEFINATION OF SPONGE IRON:
Sponge iron ma* ,e defined as porous mass of dire"tl* redu"ed
iron and asso"iated 'ith small amount of slag!
Sponge iron is also no'n as dire"tl* redu"ed iron i!e! iron is
redu"ed to its metalli" state ,* solid redu"ing agent in rotar* iln!
RAW MATERIALS USED IN PRODUCTION OF SPONGE IRON:
6! IR4N 4RE 8=(9 mm
(! /4AL 8=(9 mm
<! D4L4MITE 6=8 mm
PROPERTIES OF RAW MATERIALS:
6! IRON ORE:
$4R4SITY
SI>E AND SHA$E
STREN#TH
REDU/I-ILTY
REA/TIVITY
L4SS 4N I#NITI4N

(! COAL:

$4R4SITY
SI>E AND SHA$E
STREN#TH
The main propert* is rea"ti%it*! It indi"ates at 'hi"h
temperature the "oal gasifies to "ar,on mono2ide! It
determines the operating temperature of pro"ess!

<! DOLOMITE:
DESULPHURISING ABILITY
I!e! sulphur "ontent of the sponge iron should ,e normall* less
than 9!9(? sulphur is normall* introdu"ed through "oal into the
pro"ess and "an lead to a sulphur "ontent in the freshl* metalli1ed
iron!
To pre%ent this 8? limestone or dolomite is added as the
desulphuri1ation agent! The grain si1e of the "harged dolomite is
6=@mm!
TYPES OF ORES
4AIDES Bhematite& magnetite!
HYDR4AIDE B goethite
/AR-4NITES B siderites
SUL$HIDES B p*rite
/4M$LEA B illemenite
BASED ON GANGUE MATERIAL:
SILICEOUS ORES: main impurit* in sili"a
ALUMINIUS ORES: largel* alumina
ARGILLACEOUS ORES: it "ontains "la* matter
CALCAREOUS ORES: it "ontains lime
TITANIFERROUS: large amount of limenite

VALUATION OF IRON ORES:
RI/HNESS
L4/ATI4N
/4M$4TI4N 43 THE #AN#UE
TREATMENT AND $RE$ARATI4N NEEDED
TYPES OF COALS
6! $EAT
(! LI#NITE
<! -ITUNIN4US
@! ANTHRA/ITE
The spe"ifi" "onsumption of "oal per ton of produ"ed sponge
iron highl* depends on its fi2ed "ar,on "ontent!
Moisture& %olatite matter and ash in"rease the "oal "onsumption and
also "oal rea"ti%it* influen"e "oal "onsumption!
An important propert* is "oal rea"ti%it*! It indi"ates at 'hi"h
temperature the "oal gasifies to "ar,on mono2ide!
The sulphur le%el in the "oal should not e2"eed 6 9?
DOLOMITE:
To minimi1e the sulphur "ontent of the iln produ"t dolomite
should ,e added!
/a"o< /aoC/o(
Mg"o< MgoC/o(
/ao <9=@9?
Mgo 6D=<9?
Sio( 8?
3esC"ao 3esC"ao
3esCmgo 3esCmgo
To produ"e 6 ton of sponge iron the "onsumption of ra' materials are
RA5 MATERIALS $ER T4N S$4N#E IR4N
6! Iron ore 6!7=6!E tons
(! /oal 6!(=6!< tons
<! Dolomite E9 gs
PROCESS DESCRIPTION OF SPONGE IRON
The pro"ess is "hara"teri1ed ,* the use of a rotar* iln for the
redu"ing of iron ore lumps! 5hi"h are fed the part of the redu"ing "oal
and desulphuri1ation agent into an in"lined rotar* ilnF
/oal is heated "ounter "urrentl* to the gas flo'! Appro2imatel*
<9=89? of the "oal is "harged together 'ith the iron ore at the
"harging end of the iln! The ,alan"e 89=E9? is in+e"ted from the iln
dis"harged end!
In the rotar* iln there are t'o 1ones are e2isting i!e!
6! $re=heating 1one!
(! Redu"tion 1one
PRE-HEATING ZONE:
The preheating 1one "ontains iron ore and "oal 'hi"h is dried&
heated up to redu"tion temperature and 'here %olatiles of the fresh
"oals are released!
REDUCTION ZONE:
The redu"tion 1one "ontains the iron ore is redu"ed!
5ith in the "harge ha%e t'o rea"tions are taen pla"e
simultaneousl* i!e! the gasifi"ation of "oal 'hi"h results into "ar,on
mono=o2ide and ore redu"tion!
$art of the "ar,on mono=o2ide generated in the "harge ,*
'a* of redu"tion and "oal gasifi"ation flo's through the "harge and
gets to the iln spa"e 'here it is ,urnt ,* the se"ondar* air in+e"ted
%ia shell air fans!
The atmosphere in free spa"e mainl* "onsists of /4(N( H(
redepended on the t*pe of "oal used!
3rom the dis"harge end of the iln fresh "oal is in+e"ted
"ounter "urrentl* to the "harge in the dire"tion of the iln a2is this
"oal in+e"ted ,* "ompressed air ensured a 'ide spread distri,ution
in the high temperature 1one! It is 'ell mi2ed 'ith the "harge due to
rotar* mo%ement of the iln!
The %olatile h*dro"ar,on in the "oal is released and "ra"ed
and a"ts as an additional and %er* affe"ti%e redu"ing agent due to
the h*drogen "ontent!
Depending upon the rea"ti%it* of the "harged "oal
temperature in the range of G89=6689:" are ,eing o,tained in the
,urden!
Ver* rea"ti%e "oals permit lo'er operating temperatures than
less than rea"ti%e "oal 'hi"h re;uires a temperature of 6689:" in
order to attain a metalli1ation of at least G(?!
After the "harge has sta*ed in the iln for appro2imatel* 6( to
6@ hours! In this period the "harge has ,een e2posed for
appro2imatel* E to D hours temperature e2"eeding G99:"!
After it is dis"harged from rotar* iln into rotar* "ooler and it is
"ooled to ,elo' 689:",* 'a* of indire"t "ooling! In this 'a* re=
o2idation of sponge iron is pre%ented!
-* 'a* of s"reening and magneti" separation the sponge iron
is separated from the non=magneti" parti"les! The return "har is
separated from ash! In order to the "onsumption of fresh "oal!the
returned "har is re"*"led in this pro"ess!
The rotar* iln 'aste gases lea%e the rea"tor at the feed end
for elimination of soot& "oal dust and "om,usti,le gases! The* are
su,+e"ted to a post "om,ustion and are "ooled and "leaned ,efore
emit to the atmosphere through sta" or "himne*! /onsidera,le
energ* "an ,e remo%ed ,* utili1ing the 'aste heat in a ,oiler plant!
VARIOUS ZONES IN THE ROTARY KILN:
The rotar* iln mainl* "onsists t'o 1ones the* areH
6! $reheating 1one
(! Redu"tion 1one
In the preheating 1one the material is "harged heated up a,out
E99:" in appro2imatel* <9 minutes and rea"hed a temperature of
G99:" after appro2imatel* 89 minutes the heat transfer is mainl*
produ"ed ,* gas radiation!
At temperature ,et'een <99=E99:" the %olatiles of the "oal 'hi"h is
"harged together 'ith ore and dolomite are released into the iln
atmosphere and ,urnt 'ith air!
-et'een D99=G99:" the "al"ining of lime stone taes pla"e! Main
redu"ing and "oal gasifi"ation rea"tions start from a,out D99:"
on'ards!
In the redu"tion 1one the iron o2ide rea"ts 'ith "ar,on mono2ide!
/ar,on dio2ide forming in this pro"ess is "on%erted to "ar,on
mono2ide ,* means of "ar,on of the redu"tant!
/C/4( I (/4
In the order to "o%er the heat re;uirement for the pro"ess rea"tions
"ar,on mono2ide is ,urnt 'ith air supplied from the out side through
air tu,es!
/4C J 4( I /4(
Additional heat is pro%ided ,* the "oal 'hi"h is in+e"ted from the
dis"harge end of the iln! The "oarse parti"les of the "oal "ontri,ute
t'o essential effe"ts for the pro"ess!
Release of h*drogen 'hi"h supports the final redu"tion as
'ell as a desulphuri1ation of the metalli1ed material!
Release of %olatiles 'hi"h are partl* ,urnt and the*
pro%ides ne"essar* heat for final redu"tion!
/oal in+e"tion is "om,ination 'ith air in+e"tion %ia! Air no11les arranged
along the iln shell possi,le an optimum temperature profile "ontrol!
/ao C H(S I /aS C H(4
H(4 C / I H(C/4
3e(4< CH( I 3e<4@CH(4
3e<4@ CH( I 3e4CH(4
3e4 C H( I 3eCH(4
The temperature profile in the redu"tion 1one is ad+usted and
"ontrol ,* the
Rate of "oal in+e"ted from the dis"harged end!
Amount of air 'hi"h is supplied through the shell no11les
for ,urning "ar,on mono2ide and "oal %olatiles!
USE OF SPONGE IRON:
-loomer* sponge iron is not useful in it& ,ut must ,e pro"essed
to "reate 'rought iron! The sponge is remo%ed from the furna"e&
"alled a ,loomer* and repeatedl* ,eaten 'ith hammers and folded
o%er to remo%e the slag& o2idi1e an* "ar,on or "ar,ide and 'eld the
iron together! This treatment usuall* "reates 'rought iron 'ith a,out
three per"ent slag a fra"tion of a per"ent of other impurities! 3urther
treatment ma* add to "ontrol the amount of "ar,on& allo'ing %arious
inds of heat treatment .e!g! steeling0
Toda* sponge iron is "reated ,* redu"ing iron ore 'ithout melting
it! This maes for an energ*=effi"ient feed sto" for spe"ialt* steel
manufa"tures 'hi"h used ton rel* upon s"rap metal!
6! Using "oe to "on%ert iron ore molten iron and further refining
into steel in ,asi" o2*gen "on%erter on open hearth furna"es!
(! In ele"tri" ar" furna"e using ferrous s"rap!
In order to produ"e 6 ton of steel& 'e re;uire 6!E ton of ore and
6!< ton of "ooing "oal! In our "ountr* reser%es of prime "ooing "oal
from 'hi"h "oe "an ,e produ"e or limited!
In ele"tri" ar" furna"e route& it is e2perien"ing storage of s"rap
needed for the furna"es! Shortage of metallurgi"al "oing "oal and
s"rap also glo,al pro,lem!
The limited "ooing "oal reser%es in India "ontinued to get
depleted ,oth in ;ualit* and it is estimated that the reser%es ma* ,e
ade;uate for a,out 89 *ears onl*& at the present rate of "onsumption!
The reser%es of oil and natural gas are also limited!
So alternate routes of maing steel a%oiding ,last furna"eK
"ooing "oal dre' attention of steel maers! That is ho' sponge
iron Kdire"t redu"ing iron "omes to pi"ture!
ADVANTAGES OF SPONGE IRON:
Its "hemi"al "onsumption is uniform and is no'n as
e2a"tl*!
Unlie s"rap& sponge iron does not "ontain residual
elements lie /u& Sn& NiL!et"
Sponge ,eing a produ"t& unlie the s"rap& it allo's ,etter
"ontrol during its su,se;uent pro"essing to attain "orre"t
"ondition!
Steel maing trails using sponge ha%e *ielded satisfa"tor*
;ualit* and re"o%er* of metal %alues!
Eas* to transport& handle and use in pro"ess!
Eas* melt do'n and ena,le in"rease in furna"e "apa"it*
during steel melting pro"ess!
More predi"ta,le pri"e stru"ture!
$ermits automati"& "ontinues "harging at regular
inter%als!
APPLICASTIONS:
It is used as a se"ondar* s"rap in steel maing!
It is also used in foundries!
It is used as "oolant!
It is also used in ,last furna"e as an iron ,earing material
CHARACTERISTICS OF IRON MINERALS:

TYPE CLASS DECOMPOSITION
% Fe
SPECIFIC
GRAVITY
COLOUR
Iron Nati%e
.meteori"0
Usuall* allo*ed
'ith ni"el
E!<=E!D Iron gre*
Magnetite -la" o2ide
fe<o@
E(!@ @!G=8!( Iron ,la"
Hematite Red o2ide
.spe"ular
iron indl*
ore fe(o<0
E9 @!8=8!< Red to
,la"ish
Limonite -ro'n
hematite
(fel o< <h(o
79 <!@=@!9 All shades
,ro'n to
*ello'
#oethite -ro'n
fe(o< h(o
Varia,le ,ut more
than 79?
@!9=@!@ -ro'nish
,la"
$*rites Iron p*rite
fes(
7@ @!D=8!6 #reenish
or
,ro'nish
,la"
/hal*,ite /ar,onates&
spa those
iron or
siderite
fe"o<
@D <!E=<!G $ale
*ello'
,ro'nish
,la"
Illuminate 3eotio( @!8=8!9 -la"
TEST REQUIRE FOR IRON ORE:
CHEMICAL ANALYSIS PHYSICAL ANALYSIS
?3e .T0 ?laterite
?3e(o< ?porous
?L4I ?'asha,le dust
?gangue.sio(Cal(o<0 ?magnetite
?phosphorus ?moisture
?sulphur -ul densit*
/ao Tum,ler inde2
Mgo A,rasi%e inde2
SIEVE ANALYSIS:
C ((mm
C (9mm
C 6Dmm
C 69mm
C 8mm
C 6mm
= 6mm
REQUIRED PROPERTIES:
IRON ORE:
The iron ore supplied to the da* ,ins shall ha%e the follo'ing
"hara"teristi"sH
3e .T0 = 78 min
#angue = 8 ma2
Tum,ler inde2 = DD min
A,rasi%e inde2 = 8 ma2
TESTS REQUIRED FOR COAL:
Volatile matter
Ash
3i2ed "ar,on
Moisture
?sulphur
?phosphorus
-ul densit*
REQUIRED PROPERTIES:
The "oal supplied to the da* ,ins shall ha%e the follo'ing
"hara"teristi"s .on dr* ,asis0
Ash "ontent = (@!99? ma2
Volatile "ontent = <9!99? ma2
3!/ "ontent = @7!99? ma2
S "ontent = 9!G9? ma2
Moisture = 69!99? ma2
INITIAL DEFORMATION TEMPERATURE OF COAL ASH:
High ash "ontent means that the "alorifi" %alue of the "oal is lo'!
Ash is heated up in the iln does not tae part in the pro"ess itself!
Therefore& lo' ash "ontent helps to minimi1e the energ* "onsumption
and the 'ear at "hutes and the in+e"tion "oal pipe! The lo'er ash
"ontent& the lo'er is the danger of ,uilding ash a""retion in the iln!
Volatiles "ontained in the "oal "an ,e ,urnt in the iln and has a
"ontri,uted to the energ* ,alan"e! The pro,lem is that %olatiles 'hi"h
are released from the feed "oal during the heating up phase 'ill ,e
transported .from the feed "oal during the heating up phase0 out of the
iln at the 'aste gas their energ* "onsumption must ,e after ,urst in
the A-/ and need additional 'ater for "ooling the gas
The 3!/ represents the main energ* sour"e of the "oal! The
highest the /= "ontent in the iln& the lo'er is the total "oal
"onsumption! A high S "ontent has a "ontri,ute to the S ,alan"e of the
iln! To minimi1e the ash "ontent of the produ"t the S input to the iln
should ,e as lo' as possi,le!
High moistures "ontent means hot 'ater is fed into the iln!
Se%eral disad%antages 'ill o""ur!
6! The 'ater as to ,e e%aporated! That re;uires additional energ*!
(! The gas %olume is in"reased so that ID fan needs more energ*
to su" the gas %olume through "hutes and other e;uipment!
Espe"iall* in the 'aste gas s*stem!
<! 5et "oal is diffi"ult to transport through "hutes and other
e;uipments!
@! Espe"iall* the "oal feeders for "oal in+e"tion of the tenden"* to
get "oal deposits& in the rotating po"et 'heel and ad+a"ent
"hute e;uipment! That leads to ,lo"age 'hi"h re;uires
stoppage of the iln operation to ,e remo%ed! That un suita,le
operation "an "ause a""retion rings in the iln!
The grain si1e distri,ution of the feed "oal is important ,e"ause
after lea%ing the inlet pipe "oal 'ith its relati%el* lo' spe"ifi" 'eight
"an ,e ,lo'n out of the iln ,* 'astage gas! These "oal loses 'ill ,e
found in the re"*"led material stream& ,ut also in the dust of 'aste gas
s*stem! The finer the feed "oal& the higher are the losses of the "oal
'hi"h 'ill not enter the iln!
3or the in+e"tion "oal the influen"e is the different! The danger of
getting "oal depends at the "oal feeders and "hutes in "om,ination
'ith moisture is mu"h higher 'ith a high portion of "oal fines& on the
other si1e of the "oal si1e as influen"e to the in+e"tion distan"e! The
"oal parti"les are a""elerated in the in+e"tion pipe and "ertain ineti"
energ*! The "oarse parti"les 'ith high ineti" energ* are a,le to fl*
o%er a long distan"e until the* land& 'here as the fine parti"les drop to
the ,urden after a "ompara,le short distan"e from the dis"harge end
of the iln! The grain si1e distri,ution "an ,e related to the "oal si1e
distri,ution o%er the iln length to a%oid "oal star%ations in the se"ond
half the iln portion of fines must ,e limited to ma2 69? of =<mm!
another reason for limiting the fines fra"tion it is the danger of ,uilding
"oal ash a""retions!
The IDT of "oal ash should ,e higher than 6<99:"! The "oal
parti"les are heated up in the 'aste gas s*stem after ,eing
transported ,* the 'aste gas the higher the deformation temperature
the lo'er is the ris of getting ash softening and ash a""eration in the
iln or the 'aste gas s*stem!

REQUIRED PROPERTIES:

DOLOMITE:
/ao = (D? min
Mgo = 6D? min
Sio( = @? ma2

SECTIONS IN THE PLANT
RA5 MATERIAL HANDLIN#
ANDST4RA#E .RMHS0
DIRE/TLY REDU/ED IR4N
.DRI0
$45ER $LANT
SMS
R4LLIN# MILLS
RAW MATERIAL HANDLING SYSTEM:
The ra' materials iron ore& "oal and dolomite re"ei%ed at the
*ard are "arried to DRI se"tion 'ith the help of "on%e*or ,elts! In this
se"tion "rushing and grinding are "arried out and ,rought to re;uired
si1e! The material is "harged on to ground hoppers from tippers and
loaders!
EQUIPMENTS:
CONVEYORS:
/on%e*ors are used to transport the materials from one pla"e to
another! There are some t*pes of "on%e*ors lie
6! ,elt "on%e*or
(! "hain "on%e*or
<! s"re' "on%e*or
@! po"et "on%e*or
8! ,u"et "on%e*or
Among all the "on%e*ors 'e use ,elt "on%e*ors in feed group!
-e"ause ,elt "on%e*ors are more popular as the* run smoothl* 'ith
lo' maintains "ost
A ,elt "on%e*or usuall* "arries material on the upper run of the
,elt and dis"harges the material o%er the head pulle*! The 'hole ,elt
is supported ,* "arr*ing idlers! The head pulle* also a"ts as dri%ing
drum& 'ith a motor suppl*ing po'er through appropriate gearing 'hile
the tail pulle* a"ts as a tae up! The ,elt "onsists of la*ers of piles of
fa,ri" de" impregnated 'ith ru,,er and prote"ted ,* a ru,,er "o%er
on ,oth side!
BELT CONVEYORS MOTOR DETAILS:
"apa"it* = 68)5
R$M = 6@79rpm
Effi"ien"* = DG!8?
S"re' "on%e*or

-elt "on%e*or
VIBRO FEEDERS:
This is e;uipment used for feeding the material 'ith the help
4f %i,rations "reated in it! It feeds the material e%enl*& "ontinuousl* at
"onstant feed rate! It is slightl* in"lined to ensure the dis"harge of
material from %i,rofeeder! The amount of material dis"harge "an ,e
ad+usted manuall* ,* "hanging amplitude of %i,rations a""ording to
our re;uirement! There are three %i,rofeeders& one for I=,in& and other
for "oal and iron ore ground hoppers!
In RHMS "oal ground hopper "onsist of one %i,ro feeder 6! V36
6! Vi,ro feeder V3=6H ele"tromagneti" t*pe %i,ro feeder for the
"oal "ir"uit!
Sl!no Material Moisture
.ma20
Densit*
.gKm<0
Si1e
mm
/apa"it*
.T$H0
Muantit*
.noNs0
6 "oal 68=6D? 9!D =(99 699 6
In RMHS iron ore ground hopper "onsists of one %i,ro feeder 6! V3(
! V"#$% &ee'e$ #e(%) *+e ,$%-.' +%//e$ 0VF-1:
Un,alan"e motor t*pe %i,ro feeder for iron ore "ir"uit!
Sl!no Material Moisture
.ma20
Densit*
.gKm<0
Si1e
mm
/apa"it*
.T$H0
Muantit*
.noNs0
6 Iron ore 68=6D? (!@ =(99 699 6
CRUSHERS:
There are t'o t*pes of "rushers are used in the plantH
Oa' "rusher
Roll "rusher
Using these "rushers iron ore and "oal are "rushed and ,rought to
re;uired si1e there is one +a' "rusher P four roll "rusher in the se"tion!
In RMHS "oal "ir"uit ha%e t'o roll "rusher that are
6! /R6& (! /R(
6! $rimar* "rusherH 4ne num,er ./R= 60
T*pe H Dou,le toothed roll "rusher
/apa"it* H 699 T$H
Material H /oal
-ul densit* H 79 to (99mm& am,ient temp! & Moister
Up to 69?
Normal&.Higher i!e! up to 6D? in monsoon0
(! Se"ondar* "rusherH one num,er ./R=(0
T*pe H Dou,le toothed roll "rusher
Material H /oal
/apa"it* H 689 T$H
-ul Densit* H 9!DTKM
3eed si1e H .C0 (9=D9 mm& am,ient temp!& Moisture up
Normal&
.Higher i!e! up to 6D? in monsoon0
4utput si1e H .=0 (9 mm Q5ith Minimum 3ine B 8mmR
In RMHS iron ore "ir"uit "onsist
4NE Oa' "rusher /R<& T'o roll "rushers /R@& /RE
6! $rimar* "rusher ./R=@0
/apa"it* H 699T$H
Material H Iron ore
Densit* H (!@TK/u!M!
T*pe H Dou,le Toggle Oa' "rusher
3eed Si1e H .=0 (99 mm
4utput
Re;d H .=0 79 mm
(! $rimar* "rusher ./R=@0
Material H Iron ore
/apa"it* H 689 T$H
Densit* H (!@K /u!M
T*pe H H*dro /one /rusher
3eed Si1e H .=0 79 mm
4utput
Re;d! H .=0 (9 mm
VIBRATING SCREENS:
After "rushing operation material is s"reened in %i,rating s"reens!
These are the sie%es 'ith parti"ular mesh si1es 'hi"h are in %i,rating
/onditions! The material fed on to the s"reen "ontinuousl*& under
si1ed material is "arried ,* ne2t ,elt and %i,rating s"reens in %arious
Se"tions ha%ing %arious mesh si1es!
In RMHS& iron ore P dolomite are fed into ,uners through "oal
"ir"uit!
Vi,rating s"reens shall ,e free=floating& "ir"ular motion un,alan"e
'eight t*pe!
CONSTUCTION:
a0 The s"reen ,aset 'ill ,e of 'elded& ri%eted or s"re'
,olted "onstru"tion!
,0 The %i,rator assem,l* 'ill "onsist of a shaft on 'hi"h
un,alan"ed 'eights are fi2ed! This shaft 'ill run into
spe"ial self=aligning spheri"al roller ,earings sealed in
housing!
"0 The spring assem,l* 'ill "onsist of heli"al springs! Leaf
springs or "om,ination of ,oth ma* also ,e a""epta,le
a""ording to the design of the 4EM!
d0 S"reening de" 'ill "onsist of nitted 'ith s"reen "loth or
performed plate& or gri11l* t*pe 'edge 'ire ,ar
"onstru"tion or an* other t*pe!
e0 Dri%e 'ill ,e either through "ouplings or SVN ,elts!
f0 $rime mo%er 'ill ,e an ele"tri" motor of suita,le "apa"it*
as per design of the 4EM!
WORKING:
60 The %i,rator 'ill ,e dri%en ,* a dri%e motor through
/ouplings or SVN ,elts! Rotation of this %i,rator "auses
"entrifugal for"e e2erted or on the S"reen ,aset in a
%erti"al plane and this "auses the %i,rating ,aset to o,tain
"ir"ular %i,rating motion!
(0 The diameter of the "ir"ular motion .t'i"e the amplitude0 is
fi2ed ,* the %i,rator and un,alan"ed 'eight fi2ed on it and
is dependent on %i,rating 'eight of the ma"hine!
Therefore& an* modifi"ation in the s"reen ,aset or %i,rator
'ill distur, the ,alan"e of for"es P there ,* life of s"reen!
<0 The dire"tion of rotation of %i,rator 'ill ,e mared on the
ma"hine! 5ith normal free floating material and 'ith
normal in"lination .68: to 6D:0 the dire"tion of rotation 'ill
,e for'ard!
@0 The spring supports 'ill ,e so soft that their o'n %i,rating
fre;uen"* 'ill ,e 6K8 to 6K69 of the %i,rator fre;uen"*! Thus
the* 'ill transmit %er* little rea"tion to the foundation!
80 The material to ,e s"reened should ,e fed uniforml* o%er
the "omplete 'idth of the s"reen! The inlet "hute design
should tae "are of the uniform distri,ution of the material!
70 The diameter of the "ir"ular motion& fre;uen"* of the
%i,rations& the in"lination of the s"reen de"s& and the
dire"tion of rotation of the %i,rator shall ,e de"ided ,ased
on the e2perien"e for the parti"ular appli"ation for 'hi"h
the s"reen shall ,e designed!
I. RMHS 2%3( 2"$2-"* 2%.4"4*4 %& *)% V"#$3*"., S2$ee.4 *+e5
3$e
6! VS6 ! VS
6!
$$"73$5 42$ee. O.e .-7#e$ 0VS-61 &%$ Fee'
C%3(
T*pe Single De"& in"lined "ir"ular
motion& -ase mounted
Material /oal
/apa"it* 699 T$H
-ul Densit* 9!DTKm<
3eed si1e 9 to (99 mm& am,ient temp&
moisture up to69?normal&.higher
TTi!e! up to 6D? in monsoon0
4utput si1e .=0 79 mm
.C0 79 B (99 mm
(!
Se2%.'3$5 42$ee. O.e .-7#e$0VS-1
T*pe Dou,le de"& in"lined "ir"ular
motion ,ase mounted
Material /oal
"apa"it* 689 T$H
-ul densit* 9!DKm<
3eed si1e 9 to 79 mm& am,ient temp!
moisture up to 69? normal&
.higher i!e! up to 6D? in monsoon0
4utput si1e .C0 (9 mm
.C0 8 to (9 mm
.=0 8 mm
In RMHS iron ore "ir"uit "onsists of three %i,rating s"reens the* are&
6! VS< (! VS@ <! VS@
P$"73$5 42$ee. O.e .-7#e$ 0VS-81
T*pe Single de"& in"lined "ir"ular
motion ,ase mounted!
Material Iron ore
3eed rate 699 TH$
-ul densit* (!@TKm<
3eed si1e 9 to 79 mm
4utput si1e .=0 (9 mm
.C0 (9 mm
V"#$3*"., 42$ee.: O.e .-7#e$ 0VS-91
T*pe Single de"& in"lined "ir"ular
motion ,ase mounted
Material In+e"tion "oal
"apa"it* 699 T$H
-ul densit* 9!D t Km<
3eed si1e 9 to (9 mm
Separation .=0 68 mm
V"#$3*"., 42$ee.: O.e .-7#e$ 0VS - :1
T*pe Dou,le de"& in"lined "ir"ular
motion ,ase mounted
Material /ooler dis"harge material
3eed rate E8 T$H
-ul densit* 6!<8 to 6!7TKm<
3eed si1e Less than 89 mm
4utput si1e .=0 8 mm
8 B (9 mm
.C0 (9mm
Temperature 6(9 deg /
DAY BINS OR BUNKERS:

These are the huge "ontainers in 'hi"h the ra' materials
from RMHS is re"ei%ed P stored! iron ore& feed "oal& "oarse "oal& fine
"oal and dolomite are separatel* stored in there respe"ti%e ,ins! The
ra' material is supplied from these ,ins to DRI se"tion!
/A$A/ITES 43 DAY -INS!
Ra' materials Ma2 "apa"it*
iron ore E79 tons
feed "oal @69 tons
"oarse "oal (79 tons
fine "oal 6@8 tons
dolomite 6(8 tons
IRON ORE CIRCUITH

The iron ore from the *ard is "harged into iron ore ground
hopper and "arried on to -/=D through %i,ro feeder! The material is
"arried through a "hain of "on%e*ors& follo'ed ,* "rushing and
s"reening operations! 3inall* the ore is si1ed to 8=(9mm and stored in
da* ,ins
COAL CIRCUIT:
The "oal is "harged into the "oal ground hopper and as same as
iron ore "ir"uit& "oal is also "rushed and s"reened! /oal is di%ided into
three t*pes
6! 3eed "oal = 8 B (9 mm
(! /oarse "oal = 8 B (9 mm
<! 3ine "oal = 6 B 8 mm
These three "oals are finall* stored in their respe"ti%e ,ins!
DRI:
The 'hole DRI pro"ess in%ol%es si2 "ir"uits
6! 3eed "ir"uit
(! In+e"tion "ir"uit
<! )iln "ir"uit
@! /ooler "ir"uit
8! $S- "ir"uit
7! 5aste gas "ir"uit
FEED CIRCUIT:
In this "ir"uit& iron ore& feed "oal and dolomite are dis"harged on
-/=68 through 'eigh feeders from da* ,ins! This material is "arried
through -/=68& -/=67 P -/=6E and fed into the iln inlet through feed
"hute!
WEIGH FEEDERS:
The ra' materials to ,e fed into the iln should ,e sent 'ith a
spe"ifi" set point in T$H! 3or that purpose& 'eigh feeders are pro%ided
for a""urate 'eight! These are %er* sensiti%e e;uipment! The* gi%e
onl* =9!8 to C9!8? error! These are regular "ali,rated for ,etter
effi"ien"*!
The 'eigh feeders are pro%ided for iron ore& feed "oal& "oarse
"oal& fine "oal P dolomite at the da* ,ins!
WEIGH FEEDER DETAILS:
MA/HINE MATERIAL #RAIN
SI>E
-ELT
LEN#TH
/A$A/ITY
536 Iron ore 8 B (9 mm @!G8 mts (8 T$H
53( 3eed "oal 8 B (9 mm @!7ED mts 6( T$H
53< /oarse "oal 8 B (9 mm 7!(EG mts G T$H
53@ 3ine "oal U 8 mm 7!(ED mts 7 T$H
538 dolomite 9 B 7 mm @!(ED mts 6 T$H
T+e We",+ Fee'e$ E44e.*"3((5 S+3(( C%.4"4* O&:
6! -ase 3rame
(! Dri%e Unit
<! Head and tail $ulle*s
@! Idlers
8! Sit -oard
7! -elt /leaning De%i"e
E! Vi,rating /one
D! 5eighing e;uipment 'ith /omplete Ele"troni" $anel Displa*
Unit& Oun"tion -o2 and Instrument /a,les up to O- and to ,e
Suita,le for "ommuni"ation 'ith main $L/ of the "lient!
G! "ommissioning spares
69! T'o *ears normal operation spares

INJECTION CIRCUIT:
In this "ir"uit& "oarse "oal and fine "oal are dis"harged on -/=6<
through 'eigh feeders from the da* ,ins! This "oal is "arried through
"on%e*ors -/=6<& -/=6@ and in+e"ted into the iln outlet through RAL3
.rotar* air lo" feeders0 'ith "ertain pressure applied ,* lo,e
"ompressors!
COMPRESSORS:
/ompressors are used to produ"e air 'ith pressure and these
are t'o t*pes
6! s"re' "ompressors
(! lo,e "ompressors
6! SCREW COMPRESSORS:
These "ompressors are 'or under s"re' me"hanism!
These "ompressors produ"e high pressure i!e! E!8gKm<
This air "ontains moisture!
S"re' "ompressors are used to suppl* air to ,ag filters&
pneumati" pistons et"!
These "ompressors are used spe"iall* e;uipped 'ith air
reser%oirs!
S2$e) C%7/$e44%$4 'e*3"(4:
Muantit* re;uired (C6 .one standC( 'oring0
.after finali1ation of pneumati"
"on%e*ing s*stem0
T*pe Stationar* s"re' "ompressor air
"ooledK'ater
Medium Natural air& E9? humidit*
.normal0& 6!6G7 gKm< densit*
/apa"it* @89 / 3 M
5oring $ressure E gK"m(
Design pressure 69 gK"m(
AIR RESERVOIRS:
These are long "*linders& 'hi"h taes air from s"re'
"ompressors and stored in it! 5hen s"re' "ompressors are tripped&
the air from reser%oirs is utili1ed
! LOBE COMPRESSORS:
These "ompressors are 'or under lo,e me"hanism!
In this "ompressors "omparati%el* lo' pressure is produ"ed
i!e! 9!GgK"m(!
This air does not "ontain moisture!
Lo,e "ompressors are used to suppl* air for in+e"tion of "oal
into iln outlet through RAL3!
These "ompressors do not ha%e air reser%oirs!
L%#e 2%7/$e44%$4 'e*3"(4
Muantit* re;uired T'o noNs.6C60 'ith "ommon ,ase
frame
Medium Am,ient Air
Relati%e humidit* E9?
Temperature at Inlet Am,ient
Temperature at dis"harge 6@8:/ .ma20
Densit* 6!6G7 gKm<
3lo' rate 6@99 m<Khr
Differential pressure G68 m ,ar
Dis"harge pressure 6G99 m ,ar
The in+e"tion "oal ."oarse "oal and fine "oal0 from the da* ,ins
are in+e"ted into iln outlet through pipe 'ith "ertain pressure!
The pressure for "oal is supplied ,* lo,e "ompressors!
In MMIL& there are three lo,e "ompressors! These are
.60 Lo,e 6 .(0 Lo,e ( .<0 Lo,e <
DETAIL OF LOBE 6 ; :
-elt speed H 6678rpm
/apa"it* H 6@99 m<Khr
$ressure H 9!G<< gK"m(
$o'er H 699 H$K E8'
DETAIL OF LOBE 8:
-elt speed H 6@D8rpm
/apa"it* H 6899 m<Khr
$ressure H 9!G<< gK"m(
$o'er H 669'K 689H$
LDO PUMP:
3uel oil LD4& the name stands for light diesel oil is generall*
used for iln light up to start the operation of the iln! The diesel is
introdu"ed in the iln ,* using LD4 pump! LD4 pump is "onne"ted to
a pipe 'hi"h is inserted into the iln outlet 'ith a no11le and also air is
introdu"ed! Diesel is flo'n in the pipe air is pushed oil 'ith some
pressure! Then diesel is sent into the iln through a no11le!
RALF 0R%*3$5 3"$ (%2< &ee'e$1:
The in+e"tion "oal from the -/=6@ is dis"harged on RAL3
through dis"harge "hute! RAL3 "ontrols the suppl* of "oal into the /T
pipe and helps in uniform in+e"tion of "oal!
FUNCTION: The RAL3 has se"tion 'hi"h taes "oal 'hen it is in the
top position and 'hen it "omes to the lo'er portion the "oal gets
pushed 'ith pressure ,* lo,e "ompressors!
C%3( I.=e2*%$ A44e7#(5 0B(%) T+$%-,+ *5/e R%*3$5 Fee'e$1:
T%*3( Q*5! .%>4:
/apa"it* 6( TKhr
Dia! @68 mm
Length <E9 mm
End pipe G9 mm N- .I!D 7Dmm0
Material to ,e "on%e*ed /oal
Angle of response <E:
3ra"tion Si1e 9 B 68 mm
Moisture 69? normal up to 6D? in rain*
season
KILN CIRCUIT:
Rotar* iln is the main rea"tion %essel if the pro"ess& the ra'
materials fed into the iln are su,+e"ted to $*ro metallurgi"al "hanges
for produ"tion of sponge iron of a""epta,le ;ualit*! The ra' material
iron ore& feed "oal and dolomite are fed into the iln!
OIL PUMPS:
3our oil pumps are used for the lu,ri"ation of )MD P MAD gear
,o2es ,oth for master and sla%e!
ROTARY KILN:
This is the main dri%e e;uipment in the plant! It is a long
"*lindri"al %essel slightl* in"lined to hori1ontal! It has t'o ends the*
are feed end and dis"harged end 'hi"h are in "oni"al shape! The iln
has four t*res& ea"h t*re is supported ,* t'o supporting rollers!
It also has a gearth gear at its "enter 'hi"h helps in rotating the iln!
GEARTH GEAR:
)iln is dri%en ,* the help of gearth gear! #earth gear is
supported ,* t'o pinion rollers atta"hed to gear ,o2! #ear ,o2 is
"onne"ted to iln main dri%e motor as one side au2iliar* gear ,o2 on
other side is "onne"ted to iln au2iliar* motor! -* lu,ri"ation s*stem&
suffi"ient grease is supplied to the gearth gear! #earth gear "onsists of
6<( teeth and ea"h pinion "onsists of 6E teeth!
)ILN MAIN DRIVEH
It helps in rotating the iln using t'o motors!
)MD.master0P)MD.sla%e0! Master applies the load on iln to rotate
and sla%e re"ei%es the load! The operational running speed of )MD
motor %aries from (99=<99rpm!
)ILN M4T4R DETAILSH Integrated ele"tri" $%t! Ltd
D/ Motor
4utput =689)5
Speed =E89rpm
)ILN#EAR -4A DETAILSH Ele"tron Engineering "o! ltd
T*pe=S/N((8
)5 B 689
Speed =79
Ratio =G9K6
)ILN A/TUAL R$MH
)iln A"tual rpm V motor rpmWpinion teeth
#ear ,o2 ratioWgearth gear teeth
)iln A"tual R$M V Motor rpmW9!996@<9G
#earth gear ratio V G9
$inion teeth V 6E
#earth gear teeth V 6<(
)iln ma2 rpm V6!9E .motor rpm VE890
KILN AUXILARY DRIVE:
It rotates iln "omparati%el* 'ith a %er* rpm .9!9(G<0& generall*
used in iln hold "ondition! It also has t'o motors i!e! )AD .Master0&
)AD .Sla%e0!
)iln au2iliar* R$M V motor rpmWpinion teeth
#ear ,o2 ratioWgearth gear teeth
)iln au2iliar* R$M V9!9(G<!
CONE:
The material tra%els through the feed tu,e and enters into the
starting part of the iln i!e! /4NE! The ra' material enters into the iln
at this pla"e! -oth the ends of the iln are in the shape of "one .Inlet
"one P outlet "one0! Inlet "one 'ill re"ei%e the material and outlet "one
'ill dis"harge the produ"t!
SHELL AIR FANS:
There are eight shell air fans installed on the rotar* iln shell
'hi"h rotates 'ith iln
! These fans are used to suppl* air for in"reasing heat in the
iln and to "arr* the ,lo' "oal that 'as in+e"ting from the outlet up to
the re;uired 1one!
There 'ill ,e a shell air tu,e for e%er* shell air fan! At the end
of the tu,e and there 'ill ,e a s'eller!
S'eller is used to distri,ute the air uniforml* that 'as su"ed
,* the fan from the atmosphere!
It 'ill ,e "ir"ular and has some angles!
Shell air fans are pla"ed opposite to ea"h other to "o%er the
'hole portion of the iln! These are fa"ed to'ards the feed end!
There are dampers for e%er* shell air fan to in"rease the air
"onsumption and %i"e %ersa!
There air tu,es are made of stainless steel!
K"(. S+e(( A"$ F3.:
Muantit* H 6 No
Volume H 7999 m<Khour
Stati" $ressure H <8 m ,ar
Temperature H D9 deg /
Medium HandledH Air
3an Speed H (G99 R$M
! 3an effi"ien"* H D9? .Minimum desira,le0
/oupling H Dire"tl* "oupled through pin ,ush
/oupling
Motor Rating H 68 )5K<999 R$M .motor and fine
Impeller all "oupled through suita,le
/oupling0

K"(. S+e(( A"$ F3.:

Muantit* H E No
Volume H D999 m<Khour
Stati" $ressure H <8 m ,ar
Temperature H D9 deg /
Medium HandledH Air
3an Speed H (G99 R$M
! 3an effi"ien"* H D9? .Minimum desira,le0
/oupling H Dire"tl* "oupled through pin ,ush
/oupling
Motor Rating H 6D )5K<999 R$M
CB FAN:
Another fan "alled /- ./entral ,urner0 fan is installed at the
outlet end to suppl* air into the iln! This air affe"ts the temperature of
outlet 1ones the air %olume "an ,e regulated ,* "hanging the damper
of /- fan is 6(999 NM<KHr!
DETAILS OF C%7#-4*"%. A"$ F3.:
Muantit* H 6 No 'oring C 6 stand ,*
Volume H 6(99 m<K hour
Stati" $ressure H E889 $as"al
Temperature H @8 deg /
Medium handled H Air
3an Speed H (G99 R$M
3an Effi"ien"* H D9 ? .Minimum desira,le0
/oupling H Dire"tl* "oupled through suita,le
/oupling
Motor Rating H @8 )5 K (G69 R$M
V%(-7e 2%.*$%(:
-utterfl* t*pe .at the fan inlet0 %ane "ontrol damper shall ,e
pro%ided along 'ith the fan 'ith motori1ed a"tuator from 9 to 699?
rated %olume "ontrol! The fan shall ,e pro%ided 'ith the %enturi for
periodi" "ali,ration of the fans at the site! The a"tuator shall ,e a,le to
gi%e feed,a" of per"entage opening to the "ontrol room $L/KD/S! 4
4rifi"e plate shall ,e in"luded in the s"ope of suppl* 'ith suita,le
ele"troni"s and transmitter shall ,e also in the s"ope of the Tenderer
for gi%ing flo' measurement in the Main $L/KD/S of the D!R $lant!
AIR TUBES:
The air su"ed ,* shell air fans is transferred through du"t into
air tu,es! Air tu,es are long and thi" 'hi"h are inserted into the iln
up to half if the inner diameter! These air tu,es help in ,lo'ing
suffi"ient air into the iln a""ording to pro"ess re;uirements! The air
dis"harge end of the air tu,es are pro%ided 'ith s'ellers to ,lo' the
air uniforml* and a2iall*!
DISTANCE BETWEEN AIR TUBES:
INLET /4NE = SA36 6@!7mtrs
SA36 = SA3( E!Dmtrs
SA3( = SA3< E!Dmtrs
SA3< = SA3@ 7!Emtrs
SA3@ = SA38 7!Emtrs
SA38 = SA37 8!Dmtrs
SA37 = SA3E 8!Dmtrs
SA3E = SA3D 8!Dmtrs
SA3D = 4UTLET 6(!9mtrs
/4NE
SWELLER ANGLES:
SA36 V <9 R
SA3( V <9 L
SA3< V (8 R
SA3@ V (8 L
SA38 V (9 R
SA37 V (8 L
SA3E V 68 R
SA3D V 68 L
KILN THRUST AND SUPPORT ROLLERS:
3or the purpose of supporting these t*res are atta"hed to the
rotar* iln! The rotar* iln is supported ,* roller stations! Ea"h of
then is e;uipped 'ith t'o supporting rollers! -et'een the third and
fourth in the dire"tion of material flo' gearth gear is arranged! 3or
lu,ri"ated of surfa"e of these rollers graphite ,lo"s are arranged!

T*res are made of surfa"e up to 89mm M n=Steel .-aring
Material0! -oiler ;ualit* steel is to resist hea%* impa"t loads and
'ith stand at high temperatures! Mn=Steel .-aring Material0 is to
resist 'ear and tear at the surfa"e!
THRUST ROLLERS:
The h*drauli" a2ial displa"ement for the rotar* iln "onstant
maintenan"e longitudinal mo%ement of the rotar* iln to a%oid an*
groo%ing ,et'een the t*res and rollers! This is pro%ided at the
se"ond t*re from the "harging end of the iln! This guides to mo%e
up'ards and do'n'ards E9=6(9mm in the a2ial dire"tion!

SLIP RINGS SEALINGSH
Slip ring sealing pre%ents iln gases at the ,oth ends of the
rotar* iln! The sealing is operated ,* means of 6D pneumati"
pistons& 'hi"h are uniforml* pla"ed around the sealing ring
"ir"umferen"e!
PNEUMATIC CYLINDERS:
These are used to "lose the slip seals 'hen the* are opened
due to high pressure! These "*linders are operator , pneumati"
s*stem! #rease is spra*ed into these "*linders "ool them from high
temperature! As,estos rope is 'ounded to these "*linders to eep
them resistant to heat!
NOSE COOOLING FAN:
Nose "one& "ast a,le 'ill ,e present and ,e"ause of high
temperature to 'ith stand this 'e ha%e arranged nose "ooling fans!
The pressures that are formed in the iln 'ill affe"t near the "one&
due to this the "one 'ill ha%e the possi,ilit* to e2pand! To a%oid this
'e ha%e pla"ed three nose "ooling fans those are at the iln inlet&
outlet and "ooler inlet!
De*3"(4 %& K"(. I.(e*?O-*(e* ; C%%(e$ I.(e* N%4e 2%%("., &3.:
Muantit* H < No .4ne ea"h0
Volume H 7999 m<K hour
Stati" $ressure H 6989 $as"al
Temperature H @8 deg /
Medium handled H Air
3an Speed H (G99 R$M
3an Effi"ien"* H D9 ? .Minimum desira,le0
/oupling H Dire"tl* "oupled through suita,le
/oupling
Motor Rating H <!E )5 K 6@89 R$M
TRANSFER CHUTE:
It is a "hute 'hi"h "onne"ts iln outlet to "ooler inlet! It allo's the
flo' of the iln dis"harge material into "ooler! It has a door 'hi"h "an
,e pneumati"all* operated! It helps in the remo%al of huge a""retion
pie"es during transfer "hute ,lo"age or in shut do'n!
THERMOCOUPLES:
The temperatures in the iln are measured ,* the
thermo"ouples! In MMIL& thermo"ouples are used in t'o 'a*sH
6! 'oring thermo"ouple
(! ;ui" response thermo"ouple
The temperature of the gas and ,ed are measured ,* the
thermo"ouple in the rotar* iln!
-e"ause of the ,urden of 'oring thermo"ouples are often
"o%ered 'ith a""retion la*ers temperature indi"ation ma* ,e
in"orre"t! Then MRT 'ill ,e taen!
The pro%isions that are inserting thermo"ouples are opposite to
the shell air fans!
$lug is used for transmission of the ele"tri"al signal is "onne"ted
to ,oard! Then the remains at position for or t'o rotations and
ele"tri"al signals should ,e re"orded!
5hen the thermo"ouple is lifted to gas temperature& the
ma2imum temperature sho's the gas temperature represents
,urden temperature!
Another t*pe of thermo"ouple "alled RTDs .resistan"e
temperature dete"tor0 is used for measuring lo' temperatures!
Thermo"ouple used at higher temperatures are "alled NRT
.normal radiant thermo"ouple0
The material of thermo"ouple element is "hromel Alumel!
HEAT TRANSFER IN A ROTARY KILN:
The net heat transfer o,%iousl* depends on the e2tent of
e2othermi" and endothermi" rea"tions& ,ut the pro"ess needs suppl*
of heat!
The me"hani"al of heat transfer in the rotar* iln is "ompli"ated!
i! /on%e"tion ,et'een the gas and solid
ii! /on%e"tion ,et'een the gas and the 'all of the iln!
iii! Radiation ,et'een the gas and 'all of the iln!
i%! /ondu"tion ,et'een the solid and the 'all of the iln!
In the rotar* iln& the "hare normall* o""upies a small area
and large area of refra"tor* 'all is e2posed to flame or hot
gas!
Due to rotation of the iln heated lining gets "o%er 'ith
material& heat transfer o""urs ,* "ondu"tion& radiation
1one to "om,ustion 1one!
Redu"ing atmosphere should ,e sa"rifi"ed ,* redu"tion
1one to "om,ustion 1one!
At lo' temperatures& heat transfer depends on "ondu"tion&
,ut at high temperature depends on radiation!
Volatile matter in the solid fuel fed is not suffi"ient to
generate heat! To raise the heat that 'as produ"ed shell
air tu,es and se"ondar* air tu,e pla"ed at o%er all length!
SLIP RINGS:
6! $45ER SLI$ RIN#S
(! INSTUMENTATI4N SLI$ RIN#S
6! POWER SLIP RINGSH
The main purpose of these slip ringers is to suppl* the
po'er to the shell air fan motors! This is a""omplished 'ith four
"opper slip rings and the motors!
! INSTRUMENTATION SLIP RINGERS:
These are used to "olle"t the signals from thermo"ouples
and represents temperature on "onsole!
-oth the po'er and instrumental slip rings are prote"ted
against 'eather influen"es!
K"(. 4("/ $"., 454*e7:
The slip rings 'ill ,e mounted on the re%ol%ing iln and the
speed of iln 'ill %ar* from 9!96D rpm to 9!789 rpm! The
temperature of the iln shell is nearl* <99:"! The purpose of these
slip rings is to pro%ide po'er to D noNs! Shell Air 3ans& 'hi"h 'ill ,e
mounted on rotating iln and for the iln temperature measurement!
These slip rings are di%ided into three groups& 'hi"h is as
des"ri,edH
#roup 6 < noNs slip rings= for @68 V& 89 H1
po'er suppl* to Shell air fans
6 noNs Slip ring B for earthing
#roup ( @ noNs Slip rings B for signal
"urrent 699mA& 668V P Signal
"urrent return "ir"uit 9!6& 79 A& 668
V
#roup < ( noNs slip rings B for transmitting
thermoele"tri" ele"tri" "urrent in
mV
6 no! slip ring B for measuring
"urrent return line for ,oth
measuring s*stem
These slip rings "onsist of profile "opper and are supported of
insulators made of "reep resistant hard paper 'ith spe"ial paint& 'hi"h
are mounted on elasti" flat sheets! The "urrent "olle"tors for signal
"urrent are pro%ided 'ith t'o ,ron1e "ar,on ,rushes ea"h! The
"urrent "olle"tors for measuring "urrent are pro%ided 'ith t'o spe"ial
,rushes ea"h! The sil%er impregnated spe"ial "ar,on is for measuring
"urrent transmission and the "ar,on ,rush 'ith insulated ,rush holder
arm is used!
COOLER CIRCUIT:
The material from the iln outlet enters into the rotar* "ooler
through transfer "hute! This material "onsists of sponge iron in"luded
'ith "har "oal P more amount of fine dust at high temperatures! This
hot material is "ooled do'n to a temperature of around 699:" to 689:"
through indire"t "ooling s*stem! Rotar* "ooler is a long "*linder of
@(mts length and <!7mts diameter 'hi"h rotates hori1ontall* at its o'n
a2is! It is in"lined to hori1ontal to allo' material to flo' to'ards "ooler
dis"harge end! Its inlet is in shape of "one 'hi"h re"ei%es hot material!
/ooling of material taes pla"e indire"tl* ,* spra*ing into "ooler
dis"harge hopper!
/ooler rotates 'ith the help of "ooler main dri%e ./MD0 at 6 rpm
,* using gearth gear ha%ing 66( teeth supported 'ith ( pinions ha%ing
6G teeth ea"h! /AD ./ooler au2iliar* dri%e0 is used to rotate the "ooler
in hold "onditions! A nose "ooling fan .N/3=<0 is present at "ooler inlet
to 'ith stand high temperatures!
OIL PUMPS:
T'o oil pumps are used for the lu,ri"ation on /AD P /MD gear
,o2es!
COLD WELL PUMP:
This pump taes "old 'ater to the tre*s situated a,o%e the
"ooler! This 'ater is spra*ed on the "ooler and the heat of the material
is taen up ,* the 'ater and some the 'ater gets e%aporated!
Remaining hot 'ater is "olle"ted ,* hot 'ater ,asin at the ,ottom of
the "ooler!
HOT WELL PUMP:
The hot 'ater from the hot 'ater ,asin is "olle"ted at the hot 'ell
and this 'ater is taen to "ooling to'er ./T0 fan ,* hot 'ell pumps
.H5$0 6 P (!
DETAILS OF COOLING TOWER IN DRI PLANT:
AREA DRI $$LANT
Model
No! of 'oring "ells one
/apa"it*& /MH .ea"h "ell0 @99
Hot 'ater temp! :/ 89 B 88
/old 'ater temp! :/ Am,ient .<9 B <80
Design 'et ,ul, temp :/ (E
Design 'ind load gKm( 689
-alan"ing D*nami"
COOLER DISCHARGE HOOPER:
The material from the "ooler outlet passes through a mesh
ha%ing mesh si1e of 79W79mm inside the "ooler 'hi"h rotates along
'ith it! The under si1e material of this mesh dis"harges into /D hopper
and o%er si1e material dis"harges through o%er si1e "hute!
OVER SIZE CHUTE:
The o%er si1e material from the "ooler is dis"harged into the
"ooler o%er si1e "hute pla"ed ne2t to /D hopper! This "hute has a
door as its end "an ,e opened and "losed pneumati"all*!
WASTE GAS CIRCUIT:
The gases from the iln inlet enter into the 'aste gas "ir"uit!
Here the /4 gas is "on%erted into /4( and sent to po'er plant
through A-/ .After ,urning "ham,er0 and el,o' DU/T! The suffi"ient
air re;uired for rea"tions inside the A-/ se"tion is supplied ,* A-/
fans 6 P (! The temperature inside the A-/ se"tion .lo'er& upper
A-/0 should ,e maintained around G99" B 6999"! To "ontrol the
temperature inside the A-/ 'ater spra* guns "an ,e inserted into the
A-/! The guns arranged at A-/ are as follo'sH
Upper A-/= <
Lo'er A-/= <
El,o' B (
T'o more fans of A-/ =< P A-/=@ are arranged at the el,o' to
a%oid the "oating of dust to the inner surfa"es of upper A-/ and
el,o'!
De*3"(4 %& ABC &3.4:
Muantit* H one operating C one stand,*
Volume H D999 mXK hour
Stati" $ressure H 8989 $as"al
Temperature H @8 deg /
Medium handled H Air
3an Speed H (G99 R$M
3an Effi"ien"* H D9 ? .Minimum desira,le0
/oupling H Dire"tl* "oupled through suita,le
/oupling
Motor Rating H (( )5 K (G69 R$M
DUST SETTLING CHAMBER:
The dust settling "ham,er 'ith gases from the iln inlet enters
into the 'aste gas s*stem! It is designed in su"h a 'a* that the
dire"tion of the gases is re%ersed and its %elo"it* ,e"omes 1ero! Then
the dust from the gases is "olleted at the ,ottom of the DS/! This dust
is hot and %er* light parti"le .parti"le si1e less than 6 mm0! This dust
settles at the ,ottom of the DS/! The entire DS/ is lined 'ith
refra"tor* ,ri"s! At the ,ottom of the DS/ split ,ars are present to
redu"e the %elo"it* of falling dust!
WET SCRAPER:
The 'et s"raper is in"lined to "arr* all the dust parti"les 'hi"h
are settled at the ,ottom of the DS/! This dust is %er* hot ha%ing
temperature of around G99:" and to2i"& therefore it is mi2ed 'ith 'ater
and redu"ed to temperature of a,out G8:" dra'n out in the from of
slurr*! The "apa"it* of 'et s"raper is 69tKhr!
De*3"(4 %& )e* 42$3/e$:
Sl!no DES/RI$TI4N S$$E/I3I/ATI4N
96 TY$E 43 /4NVEY4R 5et s"raper "on%e*or
9( MATERIAL T4 -E HANDLED Ash dust K iron 4re P
/oal dust
9< MATERIAL INLET TEM$ERATUE G99:" normall*
9@ MATERIAL 4UTLET TEM$ERATUE G8:"
98 MATERIAL $RA/TI/LE SI>E Less than 6 mm
normall*
97 -UL) DENSITY 6999 gKmX for %olume
9E /A$A/ITY DESI#N D!9 T$H .min0
69!9 T$H .ma20
9D /HARA/TERISTI/S 43 MATERIAL Highl* a,rasi%e
9G /4NVEY4R $R43ILE Hori1ontall* or in"lined
69 INLET T4 4UTLET /ENTER T4
/ENTER DISTAN/E
D6(8mm ma2
66 MATERIAL 43 /4NSTRU/TI4N
a0 T4$ $LATE
,0 -4TT4M $LATE
"0 SIDE $LATE
d0 -4TT4M LINES
@!9mm .IS (97( #R!A0
7!9mm .IS (97( #R!-0
8!9mm .IS (97( #R!A0
/ast ,asalt liners
6( TY$E 43 /HAIN LIN) 3orged
6< MATERIAL 43 /4NSTRU/TI4N
34R /HAIN
Lo' allo* steel
6@ HARDNESS 88K79 HR/
BACK FLOW CHUTE:
If the material inside the iln .,ed %olume0 in"reases& then the
material spills out ,a" at the iln inlet ."ommonl* "alled as ,a" flo'
material0! The amount of ,a" flo' material is ,ased on %arious fa"tors
su"h as feed rate& iln rpm& a""retion ring et"! ,a" flo' "hute re"ei%es
,a" flo' material from the iln inlet!
PRODUCT FROM COOLER DISCHARGE:
The produ"t from the "ooler dis"harge is the mi2ture of mag
.sponge iron0& non mag ."har "oal0 and dust! The material is "arried on
the %i,rating s"reen .VSG0 through ,elt "on%e*ors 6D& (6 P ((! the
mi2ture of mag and non=mag are separated using single drum and
dou,le drum magneti" separators! The dust from the produ"t is
separated ,* ,ag house du"ts!
SINGLE DRUM 0SDMS1 AND DOUBLE DRUM 0DDMS1 MAGNETIC
SEPARATOR:
In MMIL& t'o magneti" separators are used for separation of
"har "oal from the produ"t! These magneti" separators 'or 'ith the
help of motors! SDMS has magnets atta"hed to the drum 'hi"h
rotates 'ith the help of the motor! SDMS has onl* one drum 'hile
DDMS has t'o drums! SDMS is used for separation of non mag from
the DRI lumps and DDMS is used for DRI fines!
DETAILS OF SDMS:
6! Magneti" Drum Separator .Single Stage0 = 6 No!
Design data
Material handled H "ooler dis"harge material
/omponents H Dire"t Redu"ed Iron P Non=magneti"
Mass 3lo' Rate H 89 T$H
-ul Densit* H 6!@ TKmX
Angle of repose H <8 deg
Temperature H 699 deg / ma2
$arti"le si1e H @ B (8 mm
G$3". 4"@e 3.3(54"4 %& 73,.e*"2 /$%'-2*:
68 B (8 mm = 68?
6( B 68 mm = 68?
69 B 6(mm = (9?
D = 69 mm = 68?
7 B D mm = (9?
G$3". 4"@e 3.3(54"4 %& .%.-73,.e*"2 /$%'-2*:
D B 68 mm = (8?
7 B D mm = <9?
DETAILS OF DDMS:
(! Magneti" Drum Separator .Dou,le Stage0
Design data
Material handled H "ooler dis"harge material
/omponents H Dire"t Redu"ed Iron P Non=magneti"
Mass 3lo' Rate H <9 T$H
-ul Densit* H 6!@ TKmX
-ul densit* of
"omponents H 6!7K9!8 tK mX
Angle of repose H <8 deg
Temperature H 699 deg / ma2
$arti"le si1e H @ B (8 mm
G$3". 4"@e 3.3(54"4 %& 73,.e*"2 /$%'-2*:
< B @ mm H <9?
6 B < mm H @9?
9!8 B 6 mm H 68?
U9!< mm H 68?
PROCESS DESCRIPTION FOR MAGNETIC DRUM SEPARATORS:
PROCESS DESCRIPTION:
6! #eneralH
The main "omponent of the permanent magneti" drum separator
is the magneti" drum 'hi"h "onsists ofH
The magneti" s*stem& and
The rotating drum around it& 'ith drum shell and end
plates!
(! Magnet s*stemH
The magnet s*stem in the interior of the drum "onsists of a pole
,od* on 'hi"h "erami" permanent magnets are arranged in su"h a
'a* that the polarit* of the magnet s*stem alternates se%eral times in
the rotating dire"tion! The magneti" field starts at the highest point of
the magneti" drum and e2tends o%er almost 89? of the drum
"ir"umferen"e! The pole ,od* is ,olted to the shaft& and the same is
mounted to the pedestal ,earings of the magneti" drum ,* the means
of pressure s"re's! After undoing these& the magnet "an s'ung out ,*
means of the a"tuating spindle!
<! Drum 'ith Drum ShellH
D$-7 S+e((:
The drum shell 'hi"h rotates around the fi2ed magneti" s*stem
has lateral ,order rings and "onsists of non=magneti" plate! It is fi2ed
to t'o end plates running in ,earings 'hi"h& in turn& are "arried in the
lateral +ournals of the a2les!
The drum shell ,e made of 'ear resistant non B magneti"
stainless steel material& prefera,l* A6(9Mn6(!
@! WORKING PRINCIPLE OF THE MAGNETIC SEPARATOR:
The material to ,e separated is fed o%er an ele"tromagneti"
%i,rator through on to the magneti" drum!
To "ontrol the feed ;uantit* the follo'ing steps are to ,e taen
and suita,le "onstru"tion features to ,e in"orporated in the design
Regulation of the feed rate ,* ad+usting the un,alan"e
'eights of the un,alan"e motor of the %i,rating feeder or
ad+usting the same from the "ontrol room for the ele"tro
magneti" %i,rating feeder!
3eed "ontrol ,* ad+usting the material ,ed height on the
feed "hute ,* ad+usting the slide gate at the outlet of the
feed "hute inside the magneti" separator!
As soon as the feed material ./ooler dis"harge material0 tou"hes
the magneti" drum& the magneti" material .sponge iron0 is attra"ted ,*
the drum shell and on the under side of the drum 'here the magneti"
field ends& the material drops off! -* the spe"ifi" pole "onfiguration
.alternating poles0 the material is aerated and attra"ted o%er and o%er
again so that the entrapped non=magneti" material "omes free!
The non=magneti" material is thro'n off due to the "entrifugal
for"es& and it lea%es the magneti" separator in the front part! The
separation pro"ess "an ,e 'at"hed through an inspe"tion flap!
An ad+usta,le partition plate di%ides the non=magneti" from the
magneti"=material! The separation pro"ess "an ,e influen"ed as the
dri%e permits ad+ustment of the respe"ti%e speed& 'hi"h "an ,e
a"hie%ed ,* repla"ing the pulle*s of the dri%e!
WORKING PRINCIPLE OF MAGNET DRUM
The magneti" field produ"ed ,* the ele"tromagnets permeates
through the drum shell and runs& starting at the uppermost point of the
shell& in drum rotating dire"tion do'n to the underside of the drum
'here it graduall* fades!
The magnet is in its proper position 'hen the lateral tor;ue le%er
is in a hori1ontal position! It is ad%isa,le to use a pie"e of iron B for
instan"e a 'asher B to tra"e the point 'here the magneti" field start!
3or ad+ustment of the magnet s*stem& undo the lateral "lamping
s"re's& lo"ated in the lateral "lamping +ournals and ad+ust the magnet
"ore ,* means of the spindle at the tor;ue le%er!
At a lo' "ir"umferential speed& the non=magneti" material onl*
drops in the hori1ontal position or is "arries a'a* in dire"tion of the
"ir"umferen"e! The ,ottom separation plate maes sure that the non=
magneti" material does not drop into the area or the magneti"
material! Therefore& the e2a"t position of the separation plate must ,e
determined during operation! The magneti" material is onl* released in
the lo'er 1one ,ehind the separation plate!
OVER BELT MAGNETIC SEPERATIONS 0ORMS1:
4-MS is a ,ig magnet using pla"e o%er the ,elt! It helps in
separating magneti" pie"es lie nails& nuts& ,olt& 'ashers& small s"rap
pie"es et"! "oming along 'ith material! #enerall* it is pla"ed a,o%e
the dis"harge end of the ,elt "on%e*ors! These are present at the
dis"harge end of -/=6@ and -/=(<!
BAG HOUSE FILTERS:
-ag house filters are pro%ided to "olle"t the dust from the dust
"arr*ing gases passes through it! As the su"tion is applied from the top
through a fan& the gas enters into the ,ags and the dust parti"les are
"olle"ted at the outer surfa"e of the ,ags! The ,ottom portion has
large %olume 'hi"h fa"ilitates the remo%al of "oarse dust! -* gi%ing
hea%* pressure ,* purging the "ompressed dust parti"les settles do'n
at the ,ottom and is dis"harged through s"re' "on%e*or! The 9!(mm
fines are "alled dedusting fines!
I-BIN:
I=-IN stands for intermediate ,in!
In "ase if $S-Ns is tripped or grate drops& then /D material is di%erted
to I=-IN! The material from -/=6D and -/=6DA is dis"harged on to the
re%ersi,le ,elt 'hi"h is -/=(6 in re%ersed in re%ersed "ondition on to
-/=6D and dis"harged into I=-IN!
I-BIN BLENDING:
If the material from the /D hopper is ha%ing a metalli1ation of
a,o%e G9? then the material is ,lended 'ith I=,in material to o,tain a
good metalli1ation! The material from I=-in falls on the ,lending
"on%e*or -/=(9 through %i,ro feeder .V3=70 and dis"harged on to -/=
(6 in for'ard "ondition and sent to $S-! This ,lending is "alled as I=-
in ,lending!
TECHNICAL DATA OF DRI 0MMIL1:
6! )iln length E<999mm
(! 4uter diameter of iln @<99mm
<! Inner diameter of iln <D99mm
@! Inner dia of iln inlet "one (6G9mm
8! Inner dia of iln outlet "one 68@9mm
7! In"lination of the iln (!8? of iln length
E! )iln inner %olume D(9!G7G mX
D! )iln "asta,le thi"ness (<9mm
G! )iln "asta,le %olume
= %olume for 6 mt area
= total %olume for "asta,le
(!G@( mX
(9D!E8@ mX
69! )iln thi"ness (8mm
66! )iln thi"ness at t*re area @8mm
6(! #earth gear shell thi"ness <7mm
6<! /ooler length @(999mm
6@! /ooler inner diameter <7999mm
68! In"lination of the "ooler (!9? of "ooler length
67! /ooler gri11le 79W79mm
6E! Air tu,e length (E69mm
6D! Air tu,e outer diameter 898mm
6G! Air tu,e inner diameter <98mm
(9! Air tu,e thi"ness (@mm
(6! Air tu,e s'eller inner dia (D9mm
((! Air tu,e s'eller outer dia (G9mm
(<! )iln inlet "one to supporting roller6 7@89mm
(@! Distan"e ,et'een roller to roller (9999mm
(8! 3eed tu,e length @D99mm
(7! 3eed tu,e outer dia <@9mm
(E! 3eed tu,e inner dia (G8mm
(D! 3eed tu,e angle 8< deg
(G! Transfer "hute angle @8 deg
<9! /- pipe length <999mm
<6! /- pipe outer dia <@9mm
<(! /- pipe inner dia (G8mm
<<! /- pipe material #!R!H)=@9
<@! /T pipe outer dia G9mm
<8! /T pipe inner dia E9mm
<7! /T pipe material (D999mm
<E! Distan"e ,et'een thermo"ouple and
MRT
D99mm
<D! A-/ height 69<89mm
<G! DS/ height G76Emm
@9! Stroe length of transfer "hute 6799mm
@6! Stroe length of sta" "ap 6799mm
@(! Stoe length of iln h*drauli" thruster @99mm
@<! Stoe length of pneumati" "*linders (79mm
@@! /ooler 'ater "onsumption 7 mXKhr
@8! A-/ pump "apa"it* 67 mXKhr
@7! A-/ fan ma2 air %olume D999 mXKhr
@E! Standard air %olume of lo,e (999 mXKhr
@D! I=-in height 7@89mm
SMS:
S"rap and pig iron sto"ed in open s"rap ,a* is ,rought
near Indu"tion furna"e 'ith the help s"rap ,u"et transfer
"ars and E4T "ranes! DRI from the da* ,ins is "on%e*ed to
operating platform of indu"tion furna"es! -efore starting the
I3& the "ru"i,le is inspe"ted! Initial ;uantit* of s"rapKpig iron is
"harged into the I3 'ith transformer at full load!
After the s"rapKpig iron is full* melted and the temperature
of the melt rea"hes a,o%e 6799:/& DRI "ontinuousl* "harged
into the furna"e! Initial "harging of s"rap is done 'ith the help
of s"rap ,u"et and o%erhead "rane! The su,se;uent feeding of
"harge materials is done ,* #oliath "rane& Main a"ti%ities of
the operation su"h as "harging of input materials& melting and
dislodging are done simultaneousl*!
As soon as "harge is melted& ,oth sample is taen and
temperature measured! The steel at this stage is read* for
tapping! $redetermined ;uantities of ferroallo*s are added in
the ladle during tapping& 3our Indu"tion furna"e heats& ea"h of
si1e 69t& 'ill ,e "om,ined and tapped in (9t ladle for further
treatment in ladle furna"e!
LADLE FURNACE:
The ladle is lifted from ladle transfer "ar and pla"ed
on ladle stand of L3 station! The L3 roof is lo'ered
o%er the ladle rim and heating started ,* striing the ar"s!
Inert gas .argonKnitrogen0 is dou,led through a porous plug pro%ided at
the ladle ,ottom thought the L3 treatment!
During the treatment& temperature is measured and
samples are taen periodi"all*! Lime& ferroallo*s&
Aluminum and fluorspar are added as needed and the final
temperature and anal*sis are ad+usted! 4n demand from
"aster& the ladle is transported to the easter 'ith the help
of E4T "rane for "asting!
BILLET CASTER:
The li;uid steel ladle after treatment at the ladle
furna"e is lifted ,* the E4T "rane and pla"ed on the ladle
stand of the ,illet "aster! In the mean time a tundish lined
'ith "old insulating ,oard and pare=heated no11les and
mounted on the tundish "ar is mo%ed from the no11le
preheating position to the "asting position! Ladle slide gate
is opened to allo' flo' of li;uid steel into the tundish! The
li;uid steel stream from ladle to tundish is prote"ted ,*
"erami" shroud to ensure superior ;ualit* of "ast produ"t!
At the end of "asting& the tundish is shifted to the
reser%e position for drainage of remaining slag and metal!
The empt* tundish is lifted ,* the "rane and transferred to
the tundish preparation area 'here fa"ilities are pro%ided for tundish
preparation!
ROLLING MILL:
A (9
th
pusher t*pe furna"e has ,een en%isaged for
the heating of ,illets! The furna"e 'ill ,e end "harging and
side dis"harging! It 'ill ha%e single ro' as 'ell as dou,le
ro' "harging fa"ilit*! The follo'ing si1e of ,illet 'ill ,e fed
to furna"e!
699 2 699 2 6899 mm = <999mm
The furna"e 'ill ,e heated 'ith furna"e oil 'ith /V of GD99
)"alKg! The furna"e "om,ustion s*stem 'ill "omprise of
air ,lo'ers! 3urna"e oil storage& suppl* and preheating
s*stem 'ill "omprise of air ,lo'ers& and other asso"iated
fa"ilities! The produ"t of "om,ustion 'ill lea%e the furna"e
at "harging end and e2hausted through under ground flue
tunnel and passed through a metalli" tu,ular re"uperator
,efore finall* let off to a self supporting steel "himne* of
suffi"ient height! A set of instrument 'ill ,e used for
smooth operation of the furna"e!
-AR AND R4D MILLH A "ross "ountr* t*pe mill has ,een
en%isaged for the plant! The stands ha%e ,een grouped into
roughing& intermediate and finishing groups! Roughing group
'ill ha%e ( .t'o0 stands& intermediate group 'ill ha%e 7 .si20
stands! Roughing group 'ill ,e dri%en ,* one motor! @ nos!
of intermediate stands 'ill ,e dri%en ,* t'o motors and
,alan"e ( nos! 'ill ,e dri%en ,* a separate motor! Ea"h stand
of finishing group 'ill ,e dri%en ,* single motor! Ne"essar*
guides and troughs 'ill ,e pro%ided at entr* and e2it of mill
stands!
POWER PLANT:
CAPATIVE POWER PLANT :
$rodu"tion of sponge iron in DRI iln generates huge ;uantities of
flue gases "arr*ing "onsidera,le sensi,le heat! The "har produ"ed ,*
DRI iln "ontains a,out <8? "ar,on! 3urther& the "oal fines from DRI
iln of si1e=<mm 'ill ,e generated during "rushing "oal! These fuels if
not used properl* 'ould ,e simple 'asted leading to ineffi"ient use of
energ* as 'ell as "ausing disposal pro,lems and to some e2tent
pollution ha1ard in the plant premises! Ho'e%er& a "apti%e po'er plant
'ould ,e an ideall* suited proposition to effe"ti%el* mae use of
sensi,le heat of DRI iln of gas and "oal fines and "har generated 'ith
in the plant! The ;uantities and heat "ontent of DRI iln off gas and
"oal fines and "har generated in the plant
along 'ith ,alan"e EK3 grade pur"hased "oal are enough to produ"e
a,out (9M5 po'er! Thus the "apti%e po'er plant 'ould not onl* mae
the plant less dependent of e2ternal sour"e of ele"tri" po'er ,ut 'ould
also result in energ* "onser%ation and en%ironment impro%ement!
/apti%e po'er plant 'ill redu"e the "ost of produ"tion! /ost of
po'er supplied ,* all state ele"tri"it* ,oards has ,een steadil*
in"reased in the last fe' *ears! This has resulted in in"rease of
operational P output "osts for industries dependent on po'er suppl* in
,ig 'a*! This "oupled 'ith unrelia,le grid fre;uen"* P distri,ution
pattern has resulted infre;uent tripping in the grid! These ha%e made it
diffi"ult to full* rel* on state ele"tri"it* ,oards for po'er! These fa"tors
ha%e made it ne"essar* for the promoters to go for a "apti%e po'er
plant! A 'aste heat re"o%er* ,oiler 'ill run this po'er plant! This ,oiler
uses the heat "omponent of the 'aste flue gases generated ,* the
sponge iron plant to generate po'er! This 'ill result
in po'er produ"tion at %er* lo' "ost!