SINTER MAKING

AT TATA STEEL

Goutam Bose
 TOPICS TO BE COVERED
• What is Sinter ?

• What is Sintering ?
• Why Sintering ?
• Sinter Making at Tata Steel ?
• Brief description of RMBB
• Brief description of Sinter Plants

• Raw materials for Sinter Making

• Definition and Mechanism of Sintering
• Factors affecting Sinter Quality
• Sinter Properties.

• Testing of Sinter
• Advantage of Sinter charging in Blast Furnace
DIFFERENT UNITS OF SINTER PLANT

• RAW MATERIAL BEDDING AND BLENDING

PLANT ( 1989 )
• SINTER PLANT 1 ( 1958 )

• SINTER PLANT 2 ( 1989 )

• RAW MATERIAL BEDDING AND BLENDING ( NEW )
( 2005 )

• SINTER PLANT 3 ( 2005 )

 NEED OF SINTERING

1. To utilize the fines generated during the mining

operation.

2 . To utilize different additives like Mill scale,

Flue dust, LD Slag ,LD Sludge, Rejected Lime Fines
etc generates in an integrated steel plant.
WHAT IS SNTER

IT IS AN AGGLOMERATE
 WHAT IS AN AGGLOMERATE

• AN AGGLLOMERATE IS A POROUS LUMP,

REDUCIBLE , HARD MASS
 WHAT IS SINTERING ?

Sintering is a process of agglomeration of iron ore fines

into a porous hard mass by INCIPIENT FUSION heat

generated within the mass itself

 TYPES OF SINTER: -
i) NON FLUXED OR ACID SINTERS:- Those where no flux is present
or is added in the ore.

(ii) BASIC SINTER OR SELF FLUXING SINTER: - Those where

sufficient flux has been added in the sinter mix to provide a basicity that is
desired in the final slag, taking into consideration only the burden acids.
An extra flux is added to the burden while charging to coke ash acids.

(iii) SUPER BASIC OR SUPER FLUXED SINTER: - In these type

of sinters an additional flux is added to the mix to provide for the desired
final slag basicity, taking into account the acids content of both ore as well
as the coke ash.
Desirable boundaries of Raw Material for Sinter making and actual values:
Sl. No. Material /Source Size range Chemical constituents Actual annual average

1 Iron ore fines/ -8mm to +0.15mm Fe: higher the better; silica: Fe: 64-66% Alumina:1.9-2.5%
Noamundi; consistent; Alumina and Phosphorous :0.07 –0.1%
Joda; Phosphorous: Lower the -0.15- 17% in Noa
Knondhond better

2 Lime stone -3mm* CaO:50% min; CaO:50%; MgO: 2% max;

(Crushed)/ (-0.125mm <10%) Silica:70% max; Mgo: 2% Alumina: 1% max; Alkali:
Central India max: Alumina and Alkali: 0.15 max (Top size as received
Lower the better <50mm)

3 Proximate/ Sukinda -3mm* SiO2> 45%; MgO <35%, Alumina SiO2: 50%; MgO 35%; max;
(-0.125mm <10%) and Alkali: Lower the better Alumina 2% max; Alkali:
0.15 max (Top size as received
<50mm)

4 Coke Breeze / In -6mm, -3mm to +0.25mm is Ash and phosphorous: Lower the Ash: 18%; Phos: 0.16% (Top size as
plant preferred size fraction; better received 8/10mm)
generation -0.25 detrimental

5 WRP metallic /In -8mm; -0.15mm as low as Fe:>35%CaO>21%; Phos: Lower Fe>38%; CaO:30%:
plant possible the better Phosphorus:0.8%
generation

6 L D Sludge / In plant -8mm; 0.15 mm as low as Fe:>58%:CaO>10%; Alumina and F>5858%; CaO>10%;
generation possible phos: lower better Alumina:2%; Phos:1.2%

7 L D Slag / Inplant
generation
8 Mill Scale
-3mm* (-(0.125mm <10%) CaO>48%;Alumina and phos: lower
the better
-8mm Fe: higher the better, Oil content
(-0.125mm <10%) and contamination : Lower
the better
CaO>10%; Alumina:2%;
Phos:1.3% (Top size as
received 80mm)
Fe>70%; Oil content<0.7%

9 Mixed material -5mm for sinter fines and – Same as Iron ore fines Same as Iron ore fines
8mm for Iron ore fines
 Components Chemistry

Wt% CaO,% SiO2,% Al2O3,% Phos,% MgO,%

Iron Ore Fine 71.4

Noamundi 35 0.15-0.20 0.60-2.7 1.8-2.7 0.076-0.118 0.08-0.30

Joda 34 0.10-0.22 0.61-2.07 1.9-2.55 0.050-0.078 0.05-0.25
Khonbond 1.5 0.10-0.20 1.80-4.10 2.3-3.6 0.018-0.047 0.12-0.25
Flux 11.6

SP grade Lime Stone 8.0 42.81.-55.3 1.5-5.0 1.0-1.5 0.022-0.042 5.0-10.0

RPD grade Lime stone 0.8 53.0-55.0 0.50-1.5 0.1-0.3 0.05 0.0-1.0
High silica Lime Stone 42.1-47.2 6.4-14.7 0.73-0.95 0.04 0.83-0.88

Pyroxenite (Sukinda) 1.8 0.70-1.10 51.9-56.9 0.95-2.2 - 28.5-32.5

LD slag 1.0 47.0-52.0 12.0-15.0 0.67-1.5 0.92-1.42 0.78-1.60
Wastes

LD 2.1 13.0-15.0 1.61-2.27 1.1-1.2 0.07-0.13 1.38-1.62

WRP metallics 2.1 25.0-30.0 9.4-13.50 0.9-2.4 0.22-1.07 0.96-2.66
Flue dust 50t 4.65-4.85 7.2-9.2 3.5-3.7 0.11 1.15-1.45
Mill scale 1.0 0.20-0.60 0.52-1.50 0.13-1.4 0.010-0.038 0.11-0.49
Mill sludge 0.8 30.0-40.0 6.3-12.50 1.32-3.5 0.303-1.190 1.35-2.54
Coke Breeze 5.5 - 7.1-11.8 3.5-4.8 0.09-0.17 -
Return fines Form BF
 FUNCTIONS OF RMBB
• Stacking of Raw materials

• Bedding and Blending of various raw materials

and other constituents of Sinter mix through
proportioning

• Homogenizing the mix components for

achieving consistent Sinter chemistry
 R.M.B.B.PLANT LAYOUT
TGH

WAGO
N
T/H
C/S
P
R
O
COKE SCREEN Ret. Sinter fines From G.Fce. P

B
U
I
L
ROD MILLS D
I
H/M
N
G

FLUX
CRUSHER
SCEEN

TBS#2 L R
SP1/SP2 S P
F D
WOB#2 P F
I Y
O
R
F D WOB#1
B/R Ld
(ELECON) U Slg.
B/R (L&T) TBS#1 N
 Different methods of stacking

Chevron Windraw Windraw: X-section

Continuous chevron Cone Shell

 MECHANISM OF SINTERING
2Fe2O3
Heating Heating Cooling
Single
lump
2Fe2O3

+ CaO 2Fe2O3CaO at 12000C

CALCIUM FERRITE
2Fe2O3.CaO+ Al2O3.SiO2 2Fe2O3 CaO.Al2O3.SiO2
2Fe2O3 (SFCA)
2Fe2O3
SILICO FERRITE OF CALCIUM
AND ALUMINIUM

SLAG BOND

2Fe2O3
MECHANISM OF SINTERING
CROSS-SECTION OF SINTERING ZONES
 PROGRESS OF SINTERING

WIND BOX
COMBUSTION JONE
SUCTION MAIN
WASTE GAS FAN GREEN MIX

SINTER
START OF SINTERING
PROGRESS OF SINTERING
REACHING OF BURN – THROUGH POINT
VARIOUS ZONES IN SINTER MAKING
 DIFFERENT ZONES IN DURING SINTERING

COLD SINTER
5
HOT SINTER
10 1350 deg
COMBUSTION ZONE
15 cent
PREHEATING ZONE
20
25 DRYING ZONE

30 COLD CHARGE
GRATE
CHARGING STATION ARRANGEMENT
 SINTER PLANT
Hot Air
Raw Hearth
Return Fines Lime Layer Combustion Air
Materials Dust
Spike Cold
Cooler Fan screen
Crusher
Wate
r
Ignition Hood
Proportioning
SINTER
Bins STORAGE
Sinter
Sinter Cooler
Machine
BF HIGH
Mix Segregati LINE

er on
Chute
Waste Gas Doubl
Hot Return e Sinter
Fan Waste Gas Roll Screening
Fines
Esp. Crusher
Cold Return Hearth
Fines Layer
 FEDDING SYSTEM
SHUTTLE CONVEYOR
GREEN MIX
GREEN-MIX
BIN
THERMO-VISION
HEARTH CAMERA
LAYER
BIN FLAP
GATES
LEVEL SENSOR

BED
HEARTH LAYER HEIGHT

FEED ROLL

CUT-OFF
PROBES PLATE
IGNITION HEAT TREAT
MENT HOOD
HOOD
 CONTROL OF SINTERING PROCESS

The operation of a sintering machine can be controlled by

proper adjustments of the following operational variables,
i) Fuel content for heat input.
ii) Ignition intensity.
iii) Moisture content Of mix to control its permeability.
iv) Machine speed to obtain complete “Burn through”.
v) Return fine addition.
vi) Bed height.
DIFFERENT RAWMATERIALS FOR SINTER MAKING
RAW MATERIAL MIXING AND NODULISING
GOOD SINTER BAD SINTER
 SINTER TESTING

TESTING DONE AT TATA STEEL

1. Room temperature physical testing.

2. Reducibility.

3. High temperature physical testing.

 Physical Testing
(A)TUMBLER TEST: The cold strength of sinter is determined by Tumbler
test. In this test, the drum used for tumbling the sinter is having 500 mm
wide with a dia of 1000 mm and is provided with two lifters of 50 mm
height. 15 Kg of sinter sample in the size range of 10-40 mm is subjected to
200 revolutions at drum speed of 25 r.m.p. after the test, the sample is
screened on 6.3 mm and –0.5 mm screens and the results expressed as
follows:-

TUMBLER INDEX = % + 6.3 mm

ABRASION INDEX = % - 0.5 mm

The good sinters have strength indexes between 70 and 80 at the skip. The
abrasion index should be less than 5.
METHOD FOR DETERMINATION OF TUMBLER STRENGTH OF SINTER
(as per ISO 3271/75)
: 15 kg
Wt. of the sample
Size of sample : 10-40 mm
Drying temperature : 105  50 C
Apparatus : ISO drum
INTERNAL DIA. : 1000 mm
Length : 500 mm
Thickness : 5 mm
Lifters : 50 x 50 x 5 mm
No. of revolutions : 200
Speed : 25  1 rpm
Time of rotation : 8 min
Presentation of Test Results
Tumbler Index : % + 6.3 mm
Abrasion Index : % - 0.5 mm.
1. REDUCIBILITY: -
The reducibility test essentially aims at measuring the rate of
reduction of iron bearing material under B.Fce. Condition.
Reducibility is the case with which the oxygen combined with
iron can be removed indirectly.
The test is carried out by exposing a known weight of sample to
30/70 CO/N2 mixture at 900oC and noting down the loss of wt.
It is always expressed in percentage dR
%
dt
Generally a porous, low FeO, high CaO sinter gives high
reducibility.
METHOD FOR DETERMINATION OF REDUCIBILITY OF SINTER
(as per ISO 8176/76)

Wt. of the sample : 500 gm

Size of sample : 10-15 mm

Heating : To 9000 C in a reduction

tube in inert gas at 5 lit/min

Gas composition : CO : 30%, N2 : 70%

Gas flow rate : 15 lit/min

Reduction temperature : 950  100C

Reduction time : 180 min

Cooling medium : N2
METHOD FOR DETERMINATION OF REDUCTION
DEGRADATION INDEX

(RDI ) OF SINTER
Wt. Of the sample : 500 gm

Size of sample : 10-15 mm

Reduction temperature : 550oC

Gas flow rate : 15 lit/min

Reduction time : 60 min

Cooling of sample : N2 gas

TREATMENT OF SAMPLE AFTER REDUCTION:

Tumbling the sample in a drum of 200 mm length, 130 mm dia with 2

lifters, at 30 rpm speed,
Tumbling time : 30 min

No. of revolutions : 900

Presentation of results
RDI : Wt. % - 3.15 mm
 EQUIPMENT DETAILS : SINTER PLANT 1 and 2
SP 1 SP 2
Capacity and 1.5 mtpa 2.63 (gross), 2.32 (net) mtpa, pallet
dimension width – 3.05 m, length -64 m, suction
area- 192 m2, depth of sinter Bed- 600
max.
Drums Primary Mixing Drum: 1 no, 2.5/3.5 m dia x 7.0 Mixing cum rolling drum: 450 tph
m long, v-belt drive with AC motor.
Secondary mixing drums: 2 nos, 3.0 m dia x 7.0
m long each.
Fans Exhauster fans : 2 nos, 6000m3/min, 1000 mm Waste gas fanp: 150 mbar, 200 Nm3/s,
water gauge. 3995 mm dia, 6.1 mw Motor

Strands Dwight lioyd type, 2 nos, 2.5 m wide x 30 m
long; 90 tph(net), 15 wind boxes.
Coolers Effective cooling area: 93.59m2, diameter:
18.15m, width: 2m, Volume flow: 4000m3/min.
Hot screens 2 nos, schenk design: 6 x 36 mm opening,
excitation frequency: 750 rpm, Feed rate:
200tph, dimension: 2m x 6.25m, Motor: 30 kw,
750 rpm.
Cold screens 2 nos schenk design: 6 x 16 mm herring bone,
double deck vibro M-11.
41 (gross), 35.96(net) t/m2/day,
Strand speed range: 1.5 to 6 m/min.
Circular deep bed dip rail type, cooling
area- 140m2, bed depth-1500mm, 335
tph, vibro feeder-335t
375 tph
335 tph, 250 tph, 150 tph
storage 8 x 600 t, plough Type travelling Reclaimer Sinter bin storage- 3000 t, ground
storage-4000 T.

Ignition furnaces 2 nos, 2.5 m wide x 3.5 m long; Co gas fired: 1900
Kcal/Nm3, side fired; Air/gas :- 1: 1.8

Sinter crushers 2 nos, single spiked Roll, V-belt Drive with AC

motor

Others Raw material bins: 15 nos, Inclined Wheeled Trays Dispatch circuit conveyor – 400 tph
conveyors, lift: 16.0 m, length: 25.7 m CRS
 Advantage of sinter in Blast furnace
1.Agglomeration of fines into hard, strong and irregular porous lumps which
gives better bed permeability.
2.Elimination of 60 - 70 % of sulphur and Arsenic (if present) during sintering.
3.Elimination of moisture, hydrated water and other volatiles on the sinter
strand with a cheaper fuel.iv) Increased the softening temperature and
narrowing down of the softening range.
4.As the calculation of flux takes place in sinter strand, super-fluxing saves
much more coke in the furnace.
5.It increases the Blast Furnace productivity.
6.Lime rich bosh slag hinders reduction of silica, absorbs vaporized silicon
and sulphur to produce low –Si, low-S iron.
7. Increase of sinter percentage in Blast Furnace burden, increases the
permeability, hence reduction and heating rate or burden increases, so the
productivity also.
8.Utilisation of solid wastes generate within steel works
SINTER PLANT OVER VIEW
MODERN CONTROL ROOM