PLANTPROCESS OPERATION& CONTROL

AREA:INDURATION

PROJECT: 1.2 MTPA PELLET PLANT

FOR
Client:

M/s:- JAYASWAL NECO INDUSTRIES LIMITED

Consultant:

M/s GANG ENGINEERING PVT LTD

RAIPUR , C.G

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Revision 0.
Dated Jan. 3rd .2013

Table of Contents
1. Introduction..........................................................................................................................
2. Induration Process Review.................................................................................................
2.1
2.2
2.3

The Indurating machine.................................................................................................

Process Areas, Process Fans.......................................................................................
Material flow through the machine.................................................................................
2.3.1 Drying...................................................................................................................
2.3.2 Preheating............................................................................................................
2.3.3 Firing....................................................................................................................
2.3.4 After-firing.............................................................................................................
2.3.5 Cooling in the 1st cooling zone.............................................................................
2.3.6 Cooling in the 2nd cooling zone............................................................................
2.3.7 Machine Discharge...............................................................................................
2.4 Gas flow through the machine.......................................................................................
2.4.1 Overview...............................................................................................................
2.4.2 Primary Process Gas Stream...............................................................................
2.4.3 Secondary Process Gas Stream...........................................................................
2.4.4 Other Features of the Process Gas System.........................................................
3. Control Review.....................................................................................................................
3.1

Operating Modes...........................................................................................................
3.1.1 Local Mode...........................................................................................................
3.1.2 Remote Mode.......................................................................................................
3.1.3 Manual Mode........................................................................................................
3.1.4 Automatic Mode....................................................................................................
3.1.5 Cascade Mode.....................................................................................................

3.2

Principal Control Mechanisms in the Induration machine..............................................

3.2.1 Grate Speed and Bed Depth.................................................................................
3.2.2 Hood Temperature Profile.....................................................................................
3.2.3 Burn-through Control............................................................................................
3.3 Secondary Control Mechanisms in the Induration machine...........................................
3.3.1 Cooling Air Flow....................................................................................................
3.3.2 Updraft Drying Windbox Pressure........................................................................
3.3.3 Updraft Drying Temperature..................................................................................
3.3.4 Downdraft Drying Temperature.............................................................................
3.3.5 Windbox Exhaust Fan Flow..................................................................................
3.3.6 Downdraft Drying Hood Pressure.........................................................................
3.3.7 Updraft Drying Hood Pressure..............................................................................
4. Operational Review..............................................................................................................
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4.1

Starting Up the Plant after a Planned Shutdown...........................................................

4.1.1 Routine Checks....................................................................................................
4.1.2 Utilities..................................................................................................................
4.1.3 Heating-up of the Firing Hood.............................................................................
4.1.4 Starting the Main Burners...................................................................................
4.1.5 Heating Up and Starting the Plant.......................................................................
4.2 Cold Shutdown of the Induration System....................................................................
4.3 Interruptions and Failures............................................................................................
4.3.1 Interruption of the Indurating Machine................................................................
4.3.2 Interruption Less Than 7 Minutes.......................................................................
4.3.3 Interruption More Than 7 Minutes.......................................................................
4.3.4 Power Failure.....................................................................................................
4.3.5 Emergency Diesel Generator Failure..................................................................
4.4 Faults during Operation...............................................................................................
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
4.4.12
4.4.13
4.4.14
4.4.15
4.4.16
4.4.17
4.4.18
4.4.19
4.4.20

Breakdown 0f Vibrating Feeders ........................................................................

Breakdown for Belt Conveyor ............................................................................
Breakdown of the Hearth Layer Feeding System................................................
Breakdown of the Travelling Grate. ....................................................................
Breakdown of the Green Pellet Conveyor System..............................................
Breakdown of the Green Pellet Undersize System.............................................
Breakdown of the Double Deck Roller Screen....................................................
Breakdown of Cooling Air Fan............................................................................
Breakdown of Windbox Recuperating Fan. (This option should be authorized
by Senior Manager PP)......................................................................................
Breakdown of Updraft Drying Fan.......................................................................
Breakdown of Windbox Exhaust Fan..................................................................
Breakdown of Hood Exhaust Fan.......................................................................
Breakdown of Burner cooling (Cooling) Air Fan..................................................
Unsatisfactory Permeability of Pellet Bed...........................................................
Too Much Charge Supplied to Travelling Grate...................................................
Windbox Temperature Profile Too High...............................................................
Pellet Temperature at Travelling Grate Discharge Too High................................
Firing Hood Pressure Too High...........................................................................
Breakdown of Cooling Water System for the Travelling Grate............................

5. Interlocks and Alarms........................................................................................................

5.1

Interlocks.....................................................................................................................
5.1.1 Travelling Grate..................................................................................................
5.1.2 Hood exhaust air fan ..........................................................................................
5.1.3 Updraft Drying Fan, Windbox Recuperation Fan , Windbox Exhaust Fan ..........
5.1.4 Cooling Air Fan...................................................................................................
5.1.6 Associated Ancillary Systems.............................................................................

6. Alarms.................................................................................................................................
7. Required Logic and Instrumentation...............................................................................
7.1
7.2
7.3

Bed Level and Grate Speed........................................................................................

Pallet Change Facility..................................................................................................
Pallet Car Identification................................................................................................

1. Introduction

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The purpose of the induration section is to dry, heat harden and cool the green pellets to
produce a fired pellet with properties suitable for processing into sponge iron in the Direct
Reduction plant.
The pellets are hardened on a 3-meter wide Straight Grate induration machine. The machine
has a Parea of 189m2. Green pellets are dried in two stages, updraft followed by downdraft
drying gas flow. The dried pellets are preheated to a progressively higher temperature. The
pellets are then fired at approx. 1300oC to provide the recrystallisation and slag bonding
which will give the pellets adequate strength. A short section designated as after-firing allows
the heat front to completely penetrate to the bottom of the bed without the application of
additional high temperature heat.
Cooling is accomplished on the travelling grate in two stages by updraft passage of ambient
air supplied by a cooling air fan. The cooled pellets leave the induration machine at 100 oC or
less.

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2. Induration Process Review

2.1 The Indurating machine
The pellet induration machine consists of a continuous strand of cast steel pallets which
carry and contain the green pellets and which conveys the pellets in a layer in continuous
motion through the machine. The strand comprises of 108 rail mounted pallet cars and gassealed at the hood and windbox sides. The bottom of the pallet car (the suction area)
consists of narrow spaced separate grate-bars, which allow passage of the gaswhile
preventing the pellets from falling through.
The pallet cars are drawn from the return strand and pushed along the upper strand by a
toothed sprocket wheel driven by a variable speed motor at the feed end of the machine.
Pallets are lowered from the top strand to the return strand by a similar non-driven sprocket
at the discharge end. The expansion in the strand, which varies according to temperature of
the components, is provided by a counter weight tensioning unit which controls the horizontal
position of the lowering wheel.
The grate is provided with a refractory-lined hood above the machine and windboxes below
the machine. The hood is provided with water-cooled side and transverse lintels. Separation
of the zones in the hood is provided by internal dividing baffle walls and in the windboxes by
movable shell-shaped dead plates. Two false windboxes are connected to the exhaust gas
system to provide clean and cool conditions at the feed end of the machine.
Below the induration machine is a dribble conveyor which collects spillage from the tail
(drive) pulley of the machine, pellets dislocated from the return strand pallets and dust and
spillage from windboxes, which pass through a series of air-operated double pendulum
valves.
The speed of the strand, temperatures, gas volumes and pressures can be varied to obtain
optimal process conditions.

2.2 Process Areas and Process Fans

There are 7 process areas in the indurating machine, divided as follow:
Updraft Drying area
Down Draft Drying area
Pre heat area

9 meters, corresponding towindbox 1 to 3.

6 meters
9 meters

to 4 to 5.
to

6 to 9.
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Firing area

16 meters

After Firing area

2 meters

Primary cooling

16.5 meters

Secondary Cooling

4.5 meters

to

to

to

to

10 to 13

14.

15 to 201/2

201/2 and 21.

Total process area 63 m. in length X 3 m. in width. or 189 meters Square.

There are five Fans which transport process gas (essentially air) through the induration
machine. These are:

Cooling Air Fan (G5002)

Updraft Drying Fan (G5012)

Windbox Recuperation Fan (G5022)

Windbox Exhaust Fan (G5032)

Hood Exhaust Fan (G5042)

In addition, a Hood Sealing Air Fan (G5045 046) is provided.

All fans are centrifugal design and the flow through them is controlled by VVVFD.

2.3 Material flow through the machine

Prior to the green pellet feed a hearth layer of 100-125 mm is laid on the grates of the pellet
cars. At the same time, a 50mm wide side layer is placed against the inside each of the
vertical sides of the pellet cars. The hearth layer level is controlled by 3 ultrasonic probes
(G3L111,112,113).
The hearth layer and side layer consist of already fired pellets to protect the grate bars (or
sides as the case may be) from the high temperature of the process gas. The green pellets
are then deposited on the hearth layer from the roller screen in a layer of approx. 400mm.
The total bed height (approx. 500mm) is detected by ultrasonic probes. The speed of the
grate is varied automatically from this signal to maintain a constant bed height (loop
No.G3L106) . This ensures that the gas can flow through uniformly at all points.
The pellets then undergo the following operations: drying, firing and cooling.

2.3.1 Drying
The first zone is the updraft drying zoneand covers windboxes Nos. 1 to 3. In this zone
hot gas (approx.280C) from the second cooling zone flow from bottom to top through
the pellet bed. The gas absorbs the moisture present in the pellets and leaves the pellet
bed saturated and at a low temperature (80C) and high moisture content.
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The second zone is the downdraft drying zone extending from windbox no. 4 to 5. Here,
gas with 280 to 300C is used to dry the pellets from top to bottom. The remaining
moisture in the upper layer is thus removed.
The gases used for downdraft drying come from the induration zone windboxes (10 to
13). After they have passed through the pellet bed they contain much moisture and little
heat; they are now no longer useful and are discharged via a ESP to the stack.

2.3.2 Preheating
After drying, the pellet temperature has to be gradually raised to the required firing
temperature otherwise thermal shock may damage the pellets (spaalling). In this zone
the gas temperature is progressively raisedto approx. 650-750C. This takes place in the
preheating zone which covers windboxes Nos.6 to 9. The gas in this zone comes mainly
from the 1st cooling zone and flows through the bed in downdraft. The temperature
profile of the gas above the bed is controlled either by tempering air from the windbox
recuperation fan or by F/O burners. After flowing through the preheating bed, the
process gas is discharged together with waste gas from the downdraft drying zone via a
ESP collector and with the Windbox Exhaust Fan to the stack.

2.3.3 Firing
In this zone there is a downward gas flow which is raised to a peak temperature of
approx. 1260 to 1310C by the burners (depending on % carbon addition). The firing
section extends from windbox No.10 to 13.As the material flow of pellets passes through
this zone, the hot gas cause the heat front to descend progressively through the pellet
bed. The temperature of the gas in the hood and the quantity of F/O burned in each
group of burners is not uniform, but conforms to a thermal profile selected and adjusted
by the operator based on the raw materials used for pelletizing and the physical and
metallurgical properties of the product pellets, as indicated by laboratory quality control
test results.

2.3.4 After-firing
When the end of the firing zone has been reached, the approx. 1260 to 1310C heat
front has still not reached the lowest layer of pellets, The material now enters the afterfiring zone, which extends for windboxe No. 14)where the gas temperature is
immediately lowered to approx. 1230-1280C without the use of burners. This lower gas
temperature is boosted sufficiently by the hot top layer, and thus the very lowest layer of
pellets is brought to the correct induration temperature.
The exhaust gas from the firing zone and after-firing zone are partly discharged to the
stack and partly used again for downdraft drying and preheating. The exhaust gas of the
preheat zone and the first parts of the firing zone contain moisture and are low in
temperature and are thus discharged to the stack.

2.3.5 Cooling in the 1st cooling zone

If the machine is properly set up, the 1260 to 1310C heat front after leaving the afterfiring zone will have passed completely through the full green pellet layer. The 100 to
125 mm thick hearth layer, however, still protects the grate bars against the heat front.
When all the pellets have been brought to the correct temperature by the heat front, the
gas flow is reversed and cold air is now blown in to cool the grate bars and the pellets on
them. This prevents overheating of the grate bars. Tha gases leaving the top of the pellet
bed range from about 1230-1280C to about 650-700C .The first cooling zone extends
from windbox No. 15 to half of windbox No.20 (Partial).

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2.3.6 Cooling in the 2nd cooling zone

In the second cooling zone the pellets are cooled still further.Gas heated during the
process are used in Updraft drying. The second cooling zone extends from half of
windbox20,towindbox No. 21.

2.3.7 Machine Discharge

The lowest layer is taken closeto the ambient temperature, while the topmost layer is 200 to
300C. As a result the average layer temperature becomes 80 - 100C. The hotgas from the
second cooling zone hood are used for the UpdraftDrying zone.
The pellets, sufficiently cooled to be transported on rubber conveyor are discharged from the
pallets at the tipping wheel into a discharge hopper mounted on load cells. Pellets are fed
out of the discharge hopper at a controlled rate onto two vibrating feeders which feeds the
product belt G7002A.

2.4 Gas flow through the machine

2.4.1 Overview
All process gas (essentially air) used in the machine is derived from the Cooling Air Fan
(G5.002) and by in-leakage of ambient air into the sides and ends of the induration machine.
The cooling air fan (G5002) draws in ambient air and forces it up through the cooling zones
at a pressure of up to500 mm WC.The air flows through the pellet bed and cools the fired
pellets. The air, which is now hot, enters the hood of the 1st and 2nd cooling zones. The
process gas derived from the cooling zones can be considered as two separate streams
designated as primary and secondary process gas streams.

2.4.2 Primary Process Gas Stream

The larger part of the cold air which passes through the hot pellet layer has, after cooling
these pellets reach an average temperature of about 800-950C (in 1st cooling zone) and is
conveyed into the preheat and firing zone via the direct recuperation header and through
downcomers to the burner chambers arranged on each side of the grate. .
In the hood of the firing zone, F/O burners heat up the gas from 800-950C to a peak
temperature of approx. 1310C. The temperature to which the gases is raised in each
section of the firing zone is set by the Control Room Operator depending on the raw material
conditions and the quality results from the product pellets.
The windboxes under the latter part of the firing zone and the after-firing zone(windboxes
Nos. 10 to14) are drawn through the bed by the Windbox Recuperation Fan (G5.022), which
conveys the approx. 280-300 C gases to the Downdraft drying zone. Here the gases finally
dries the green pellets.
The waste gas from Downdraft Drying, Preheating and the first part of Firing zones (windbox
Nos.4 to 9) is then pulled through ESP by the Windbox Exhaust Fan (G5.032) and forced to
the stack.

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2.4.3 Secondary Process Gas Stream

Part of the cooling air is drawn from above the second cooling zone by the Updraft Drying
Fan (G5.012) is fed to the updraft drying zone at approximately 280-300 OC.. This air is
discharged to atmosphere, after passing through the bed, by the Hood Exhaust Fan
(G5.042).

2.4.4 Other Features of the Process Gas System

The primary and secondary process gas streams are interconnected at two points:
Interconnecting ducts from the discharge of the Windbox Recuperation Fan to the
inlet of the Updraft Drying Fan (G5.012) through dampers G5H.102(G5.025)
Bleed off from Windbox Recuperation Fan to the Updraft Drying hood through damper
G5H.110
Because there is an over-pressure in the entire 1st cooling zone, the seal between the hood
of this zone and the pellet cars is provided by sealing air supplied by the hood seal fan
(G5045)).

3. Control Review
3.1 Operating Modes
3.1.1 Local Mode
Equipment is started, stopped or adjusted in the field. Related equipment is:
a) Burner systems always started and normally stopped from Local Panel. Burning
rate is set by at the Control Room Workstation (HMI/ MIMIC)
b) Travelling Grate May be started, stopped and speed controlled from the Local
Panel. Permission to switch between Local and Remote Control is granted at the
Control Room Workstation.
c) All other equipment which can be run in TEST mode.

3.1.2 Remote Mode

Equipment is started or stopped from the D C S at Central Control Room Workstation
This applies to all equipment in the Induration section, with the exception of the burners and
optionally the travelling grate..

3.1.3 Manual Mode

The output of an instrumentation loop controller is directly set by the Control Room Operator
from the Central Control Room Workstation, irrespective of the relative values of the process
variable and the set-point.

3.1.4 Automatic Mode

The output of an instrumentation loop controller is directly set by the DCS depending on the
relative values of the process variable and the set-point.

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3.1.5 Cascade Mode xx

a) The setpoint of an instrumentation loop controller (slave) is set by the output from
another (master) instrument.
b) When the Expert System is implemented, this will be the nominated mode when
instructions and set-points are determined by the Expert System and acted on by the
DCS.

3.2 Principal Control Mechanisms in the Induration machine

Control of the process is achieved by varying the temperature and flows of process gas
through the machine. Some operating parameters, such as bed height, Hood temperature
Profile in thePreheat and Firing Zones and Burn-through are adjusted by the Control Room
Operator according to the production schedule and the quality of the product pellets.
Other parameters, such as drying zone temperatures, are set by the operator based on
operating procedures and Process section instruction and are not frequently adjusted.
Process gas flow is not measured directly and the balance of the gas is obtained by
maintaining pressure set-points in various points of the hoods and windboxes of the furnace.
These set-points are rarely adjusted by the operator unless otherwise instructed in normal
operation.

3.2.1 Grate Speed and Bed Depth

The grate is a volumetric conveying device and at a constant total bed height, the speed of
the travelling grate is directly related to the quantity of green pellets fed to it. If green pellet
production (after screening) increases, the grate speed increases to maintain a preset bed
height as detected by the ultrasonic probes at the feed of the machine (loop No._G3L106_).
The converse is true. The normal setpoint for bed height will be 500mm The normal grate
speed is 1.5 m/min or lower. If production rate rises to such an extent that a grate speed
reaches 1.65 m/s, the bed height may be raised further, provided that green pellet quality
provides sufficient bed permeability, as determined by pressure in the windboxes of the
Cooling zone (PI G5P121 to G5P126B).

3.2.2 Hood Temperature Profile

The principal process control is the attainment of the correct temperature profile of the gas
entering the bed from the hood in the preheating and firing zones. The burners are divided
into ten control groups along the length of the machine in the preheat and firing zones. The
first two of the down comersactually contain no burners.. The temperature for each zone is
set manually by the Control Room Operator. Deviation from the setpoint for a burner pair
causes the quantity of Fuel oil to be burned to be automatically varied. The atomizing air and
cooling air is supplied to all burners by a Air Fan G4.041 & G4.042.
In the case of the first two pair of down comer (in the preheat area), process gas to this zone
is provided by the direct recuperation header and also, at a lower temperature, by the
Windbox Recuperation Fan through additional ducts into the preheat zone down comers.
Control valves G4.033 &G4.034 in this spider are indicating the temperature detected
above the bed in the preheat zone. The PH 1 and PH 2 temperature are set to control the
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valves G4.033 & 034. For wet feed and/or high tonnages these should be set as low as
possible to avoid spalling.
First 2Down comers- No burners
Typical hood profiles are indicated in the table below:
Burner No. (pairs)
No burner Zone
Burner Zone 1/1
Burner Zone 2/2
Burner Zone 3/3
Burner Zone 4/4
Burner Zone 5/5
Burner Zone 6/6
Burner Zone 7/7
Burner Zone 8/8
Burner Zone 9/9
Burner Zone 10/10
Burner Zone 11/11

Typical Set
Point No
coke
450C
650C
855C
1000C
1150C
1250C
1310C
1310C
1310C
1310C
1310C
1280C

Typical
Setpoint with
1.4% coke
425C or less
625C or less
800C
900C
1050C
1150C
1200C
1250C
1275C
1275C
1275C
1230C

3.2.3 Burn-through Control

3.2.4 The most important controls in the machine is burn-through. This determines the
point at which the heat front reaches the bottom of the bed and the intensity of this heat front
and has a direct influence on pellet quality, particularly Abrasion Index and is varied by
adjusting the quantity of process gas drawn through last part of the firing zone and the afterfiring zone by the Windbox Recuperation Fan. The burn-through control loop modulates the
motor speed of the Windbox Recuperation Fan (G5022)according to the average
temperature of the penultimate two windboxes (windbox number 12 (2 T/C),13 ( 1 T/C) in the
firing zone (TIR G5T111,G5T112). If this average temperature falls below set-point, the motor
speed of fan G5022 increased until setpoint is restored. The normal setpoint for burnthrough is approximately 400OC without carbon addition and 370OC with carbon addition at
arate of about 1.4 %. The last windbox in firing (windbox no 13) has only one (1)
thermocouple included in the burn-through control because this temperature is usually lower
(on one side) than actual, due to the leakage of cold air from the cooling air windboxesThis
burn-thru control loop must be correctly tuned and used at all times for automatic control. It
controls the tumble index and affect the compression strength. Manual operation of this loop
is only for starting the machine and under exceptional conditions.

3.3 Secondary
machine

Control

Mechanisms

in

the

Induration

These controls are used to balance the process gas flow through the machine and maintain
the required pressure differentials between process zones. In normal operation, these
conditions change as a consequence of adjustments in the principle control mechanisms
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outlined above. Once established the set-points of these loops are rarely changed by the
operator during normal operation.

3.3.1 Cooling Air Flow

The flow through Cooling Air Fan G5002 is controlled by maintaining a slightly negative
pressure of 3 - 5mm WG in the firing zone hood (loop no. G4P305).
If the Windbox
Recuperation Fan VVVFD CONTROLLED (possibly due to low burn-through temperature),
the above-bed pressure will become more negative and Cooling Air flow will increase (by
VVVFD) until the setpoint is restored.

3.3.2 Updraft Drying Windbox Pressure

The speed of the Updraft Drying Fan G5012 is controlled to maintain a set pressure of
approximately -25mm WCin the hood above the second cooling zone (loop no. G4P306).
If the windbox pressure in the Updraft Drying zone exceeds a maximum setpoint of 500mm
WC, process gas is directed around the bed by a bypass duct containing damper G5015
(loop no.G5H106to the inlet of the ESPH1002, rather than through the bed.

3.3.3 Updraft Drying Temperature

1. If Updraft Drying temperature is too high, it can be tempered by air drawn in from
atmosphere into the duct from 2nd cooling zone through bleed-in damper G5016 (loop
G4T303). This is very unlikely as the grate absorbs 70% of the heat and the bottom of the
bed sees lower temperatures.
2. If the UDD temperature is too low, at start up for instance, it can be boosted by bleeding
process gas from the outlet of the Windbox Recuperation Fan G5022 to the suction side of
the Updraft Drying Fan by damper G5025 and Loop No.- G5T125.

3.3.4 Downdraft Drying Temperature

If the temperature of the process gas for Downdraft Drying is too high(maximum 320C)it can
be controlled at the inlet duct of the Windbox Recuperation Fan by bleeding-in cold air from
atmosphere through Tempering Air Dampers G5021 (loop G5T124).

3.3.5 Windbox Exhaust Fan Flow

Flow through the Windbox Exhaust Fan, which draws process gas from windbox Nos. 4 to9
and includes downdraft drying, preheating and the first part of the firing zones, is controlled
by the temperature of windboxes Nos.7 or 8, as selected by the operator (loop no G5T117).

3.3.6 Downdraft Drying Hood Pressure

This pressure, typically -15mm WG, is set by the operator(loop no.G5P115) and is controlled
by damper G5PH110.

G5H110- Bleed off from Downdraft Drying Hood to Updraft Drying Hood controlled by
P/T G5P 115.

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3.3.7 Updraft Drying Hood Pressure

Typically -25mm WG, this pressure is set by the operator and controls the speed of the Hood
Exhaust Fan G5042 through loop no. G5P114.

4. Operational Review
4.1 Starting Up the Plant after a Planned Shutdown
4.1.1 Routine Checks
1) Once the operation department, process department, electrical department, repairs
and maintenance department, instrumentation and control department, utilities
department (water/compressed air/instrument air/fuel oil) have given clearance for the
plant to start operating, it can be started up from the control room.
2) All belt conveyors and material transfer points must be checked to make sure they
are free from foreign matter.
3) All interlock equipment must be set for interlock operation, so that starting can be
done from the control room.
4) All safety trip cords and safety switches must be set in the correct position for starting
up.
5) All inspection ports must be closed and secured.
6) All process control dampers must be closed

4.1.2 Utilities
1) A check must be made that the cooling water circulation system is operating and that
sufficient cooling water is available to the individual users.
2) The following users must be checked:

Cooling water system for the lintels of the travelling grate.

Coolingwater for the shuttle belt conveyor hydraulic system.

Cooling water for the hydraulic system of the mixer.

3) The travelling grate operator must check the lintels water discharge points to ensure
that the correct water flow rates are set to water compartments (lintels) along the
travelling grate and cross beams (lintels) between the individual zones.
4)

LPG must be available at the correct pressure, temperature and supply rate to start
up the plant.

5) Compressed air must be available in sufficient quantities and at a pressure of 5 bars

for the following users:

Double flaps valves under the windboxes.

RAVS under the ESP. H1.001,002

Ploughs on conveyor G1.016 to feed mixed bins.

Lubricating systems for the balling disc.

Lubricating system for the travelling grate,air supply to indurating machine

burners.
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6) The entire length of the travelling grate must be filled up to a depth of 350 mm with
hearth/side layer. The hearth layer bin should be full.
7) Instrument air must be available at a pressure of 5 bar.
8)

Process fans:
a)

Start hood exhaust fan G5.042 to provide a slight negative pressure in the
furnace hood

b)

Start one of the Burner Atomizing air fans ./ G4.042 from the control room.

c)

Start UDD process fan G5012

d)

The motor speed of the process fans are adjusted such that a slight negative
pressure develops in the firing hood.

4.1.3 Heating-up of the Firing Hood

In the temperature range below approx. 700OC, the firing hood is heated up with the
temperature controllers in manual mode. In this case, it is essential that the operating staff
pay special attention to monitoring the individual burners. When the temperature in the firing
hood reaches about 700OC, the temperature controllers can now be switched over to
automatic mode.
From ambient temperature to 700OC, pilot burner are required to maintain F/O combustion,
above 700OC self ignition of F/O is ensure and pilot burners have to be removed and stored
properly.
At the start of heating-up, four LPG gas burners (2 on each side of the firing hood, but not
opposite each other) are ignited. To ensure a gradual increase in temperature, the gas flow
rate is kept to a minimum. As higher temperatures are required, more burners are ignited one
after another, and the gas flow rate at the burners already running is slightly increased.
Heating up must be done in line with the heating-up curve. After each major shutdown
heating curve and instruction are given by pellet plant management to control room operator
and shift in charge.

4.1.4 Starting the Main Burners see bloomxxxxx

Provided that all conditions for starting are fulfilled and that natural gas is on line up to the
safety shutoff valve, the individual burners can be started once the following conditions are
fulfilled:
1)

That one of the cooling water pumps is in operation. G6.014 OR G6.015

2)

The hood exhaust fan G5.042must be in operation.

3)

The updraft drying fanG5.012must be in operation. (Optional, not required

below 250OC).

4)

No emergency switch may be actuated.

5)

One of the Burner cooling air fans G4.041orG4.042must be in operation.

6)

Burner cooling air must be available at the correct pressure.

7)

The LPG gas temperature and pressure may be correctly adjusted.

8)

The instrument air pressure must be available.

9)

Once these conditions are fulfilled, the burners can be started.

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4.1.5 Heating Up and Starting the Plant

After a planned shutdown where some refractory repairs/installation had been done, the
firing hood should be heated up from ambient to 800C at a rate of 40C/h. From 800C on, a
rate of 70 C/h is used.
Heating up too fast, with an excessive number of burners and with long flames must be
avoided to protect the refractory lining from thermal shocks (which shorten its service life).
During heating up, the travelling grate must be covered with a fired pellet, hearth/side wall
protection layer of 350 mm minimum.
As already described, the hood exhaust fan and the updraft drying fan are operating. One
Burner atomizing air fan is also in operation. Bleed-out damper G5015 is closed.
1) The first pilot gas burners are ignited; two burners on either side are normally
sufficient.
2) Until temperature reaches at around 350 to 400 C, no further burners are
required.
3) The E S P andDust conveying system are started.
4) The conveyor system for hearth layer and product is checked and started.
5) The process gas flow rate is checked and set with slightly negative pressure in the
firing hood.
6) The lubrication system for lubricating the drive and driven sprocket and
travellinggrate seal bars is started.
7) The travelling grate is started up every hour locally in manual control at
minimumspeed. Two pallet cars are then moved in the machine every hour.
8) When the temperature reaches about 750C, pilot burners are removed.
9) At this stage, several burners should be in operation ( on each side of the firing
hood).
10) Once all burners which are not yet running and installed in the machine, the shutoff
devices for atomizing air to the burners must be opened to get sufficient air for
cooling.
11) Once the temperature reaches approx. 900C, the following pressures should be
set:

Table 1
Zone

Pressure

Up-draft drying hood

-25 mm WC

Downdraft drying hood

-15 mm WC

Preheating
zone

-3 / -5 mm WC

and

Second cooling zone

firing

-15 mm WC

Those pressure adjustments are possible by modulating the motor speed on HE

fan G5.042 and UDD fanG5.012. Over-pressure damper G5P114,G4.306.
12) When temperature reaches approx. 950C to 1000C, nearly all burners should be
ignited.
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13) The operating staff should take care of the following rules:
Reducing the process gas flow rate raises the temperature in firing and cooling
zones. Increasing the process gas flow rate lowers the temperature in the firing
and cooling zones. HEF fan G5.042, exhaust temperature should be followed
closely, if temperature rise above 200C, HEF fan G5.042, inlet damper will close
automatically.
14) WBE G5.032, WBR G5.022 and CAFG5.002 Fans are now started.
15) Once enough air is being circulated through the direct recuperation line (indicated
by pressure in cooling zone I) the burner control system can be switched from
manual to automatic mode. This means that all interlock conditions in the burner
safety system now apply.
16) When the temperature reaches approx. 1200 C or when the temperatures in the
windboxes rise above the intended operating levels, the depth of the hearth layer
is reduced to 125 mm, and possibly three balling disc (roughly 200 t/h) are started.
The depth of pellets of 500 mm is regulated by means of varying the speed of the
travelling grate.
17) Once the green pellets have reached the up-draft drying zone, all the firing zones
temperatures must be adjusted to their normal operation temperature. Hood
pressure in up-draft drying zone must be set to - 3 mm WC PIC G5P.114
18) Once the green pellets have reached windbox3, the control vanes of the WBE fan
G5G113 is opened approx. 25%.
19) Once the green pellets reach windbox6, the SPEEDon the WBR fan G5.022 also is
increase by approx. 25 - 30%.The temperature in firing zone should reach normal ,
1250 to 1300C at the peak.
20) Once the green pellets have reached cooling zone I, a check must be made of
whether the windbox temperature profile has settled down right. The temperature
in windbox14 should now be approx. 360 to 370 C. (assuming no coke addition)
21) If the temperature there is lower, the gas flow rate of WBE G5.032 and WBR
G5.022 fans must be increased; if the temperature is higher, the gas flow rate of
both fans must be reduced, by adjusting fan motor speed accordingly.
22) Approx. 1 hour later, when the correct windbox temperature have developed, the
discharge material from an another balling disc is diverted to the travelling grate.
23) As already described, once green pellets are reaching the various zones, the gas
flow rate of fans WBE G5.032 and WBR G5022 must be adjusted, so that the
correct windbox temperature profile is maintained.
24) The cooling airflow rate of CAF G5.002 is adjusted automatically, by means of
controller PCR G4P305. so that a negative pressure of approx. -3 mm WG
develops in the firing zone.
25) The UDD Fan G5.012 must be set, so that a negative pressure of approx. -3 mm
WC develops in cooling zone II (PIC G5P306).
26) This procedure is now repeated, until (possibly) 3 balling discs are feeding to the
travelling grate with an inlet feed of 160 T/H.
27) Once the travelling grate has been operating at design capacity for approx. 1 - 2
hours, all process conditions must have settled down correctly. All control Systems
now get switched over to automatic control from D C S .
28) It must be remembered that as the green pellet volume increases step by step, the
travelling grate speed is increased, which can lead to the pellet temperature at the
travelling grate discharge rising for a short time. If the pellet temperature is too
high, the water sprinkling system (G7T.101 at product belt conveyor G7.002 or
Page

G7.002A is started/ opened automatically.

29) As the green pellet volume increases. To protect the green pellets in the heating
and firing zone, it is advisable to adjust pressure in windboxes 6 to 14.xxxx
When the plant is operating at design capacity, the following pressure profile
should be established:
Windbox No.6 to 8
G5T105 to 107.
- 400 mm WG
Windbox No. 10 to 14 G5T109 to 113. - 400 mm WG
30) Approximate set points for the process fans and motor speed, with the plant
operating at design capacity:

Table 2
Item

Instrument

Set point

CA Fan G5002

G4P305

- 3 mm WG

HE Fan G5042

G5P114

- 25 mm WG

WBR Fan G5022

G5T115

300 C

WBE Fan G5032

G5T117

180 deg C

UDD Fan G5012

G4P306

- 15mm WG

4.2 Cold Shutdown of the Induration System

The description assumes that:
a) The plant is operating normally
b) All control systems are in automatic control. D C S
c) Inspection or repair work on the refractory lining makes it necessary to cool the hoods
down.
1) The depth of the hearth layer is increased to 350 mm. The supply of green pellets is
cut off. The travelling grate speed control system is switched over from automatic to
manual control.
2) The green pellet conveying system to the travelling grate is emptied; it can then be
stopped.
Note:During shutdowns, the mixed material bins above the balling discs should
not stay filled otherwise bridges of material will form around the bin outlets. It is
therefore advisable to empty the bins or, at the very least, to keep the bin level
below 20%.
If the bins at the weighting belt scales are required to be empty for shutdown
work, the supply of mixed material should be stopped earlier, and the supply of
green pellets to the travelling grate be stopped as soon as every single bin gets
empty.
3) The undersize green pellet conveying system is emptied and then stopped.
4) The fans WBE G5.032 and WBR G5.022 are switched over to manual control, and
motor speed adjusted.
5) The travelling grate speed is manually adjusted at maximum 1.6 m/min.
6) The over pressure damperG5.021 gets opened to 100%.
7) The firing curve is adjusted as follows with no coke addition.
.
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Zone no burner

450C

Burner Zone 1/1

Burner Zone 2/2
Burner Zone 3/3
Burner Zone 4/4
Burner Zone 5/5
Burner Zone 6/6
Burner Zone 7/7
Burner Zone 8/8
Burner Zone 9/9
Burner Zone 10/10
Burner Zone 11/11

650C
855C
1000C
1150C
1250C
1310C
1310C
1310C
1310C
1310C
1280C

A negative pressure of - 3 mm WG is kept in the updraft drying zone.

9)

The temperatures in windboxes 10 to 14 are controlled by the motor speed of fan

WBR G5022. The damper G5021 gets opened to 100% if required. Maximum
temperature should not exceed 400C.

10)

When full hearth layer reach end of windbox14. All burners are stopped; WBR
G5022, WBE G5032 and CA G5002 Fans are stopped. Burner cooling air must be
available to cool the burners.
All burners are removed for general inspection and maintenance.

11)

Vent door are opened on suction duct of fans WBE G5032 and WBR G5022.
Thus it is not absolutely required; inspection door can be open on windboxes
number 15 to 21.

12)

All dampers are put in manual mode and closed and fan speed on HE G5.042 and
UDD G5.012 fans and damper G5G.114. Damper G5G111 is kept at 100 % open
in manual mode. Only motor speed is adjusted accordingly.

13)

Temperature of HE fanG5.042 should be followed closely, if temperature exceeds

200OC, inlet damper will close automatically.

14)

Machine should be cooled down at a rate of 70 OC/hr. by adjusting both fan motor
speed.

15)

Once the hood temperature has dropped below 250 C:

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a) In the case of major repairs to the refractory lining, the gate valves for
hearth/side layer get closed and the travelling grate gets emptied. The hearth
layer bin is filled up by means of the hearth layer conveying system. As soon
as the travelling grate is empty, the grate and the conveyor systems are
stopped. The greasing system for the travelling grate is stopped.
b) In the case of inspections and minor repairs to the refractory lining, the
travelling grate is stopped. Once the conveyor systems beyond are empty,
they are stopped.
c) The greasing system for the travelling grate gets switched off.
16)

At this point, if faster cooling is required, WBE fan G5.032 can be started and
motor speed adjusted accordingly.

17)

The dust collection systems for the plant are switched off.

18)

As-soon as the refractory lining has cooled down far enough (below 50 C); the
remaining fans can be stopped. When WBE fan G5032 the auxiliary oil pumps is
starting automatically. After a preset time, that pumps automatically stop.
The damper of HE fan G5042 to be opened, so that the flue effect causes a slight
draft.

19)

The cooling water system for the travelling grate should stay in operation, until the
inspection of the hoods (lintels and cross lintels) has been done.

4.3 Interruptions and Failures

4.3.1 Interruption of the Indurating Machine
The firing hood temperature to be set up for an interruption mainly depends on the following
conditions:
a) The length of the interruption
b) The reason for the interruption
It is perfectly possible to maintain the firing hood temperature at 900C for few hours,
provided that the travelling grate can be operated should the temperature raise for some
reason.
However, it is not advisable to keep the temperature above 900C, if the indurating machine
will not start soon. In this case, either the travelling grate must be capable of moving again
after a few hours or the temperature in the firing hood must be lowered further.

4.3.2 Interruption Less Than 7 Minutes

A stoppage of the travelling grate is one of the most dangerous emergencies that can occur.
The control room staff must take action at once.
1) The burners are switched to "Low fire". Automatically until they reach the hold
temperature the F/O flows to each burner group is reduced to minimum.
2) All fan motor speed and controllers are kept in automatic mode. If the control system
of WBE G5.032 and WBR G5.022 fans were switched over to manual control. It is not
advisable to operate the indurating machine in manual mode for long period of time,
since; during stoppage this can produce very hazardous and dangerous conditions.
(Overheating of pallet car, fan, etc.).
3) Bleed-in damper on WBE G5.032 and WBR G5.022 fans are opened at 100%.
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4) With the fans and burners in operation, the firing hood temperature should stay same
while running. If hood temperature rises excessively, burner should be tripped. If
windboxes temperatures rise excessively, WBE G5032 and WBR G5022 fans speed
should be reduce.
5) As soon indurating machine can be started again, green pellet feed system should be
put in operation and all other operating conditions resume on the indurating machine.
6) If travelling grate is stopped for more than 7 minutes WBE G5.032, WBR G5.022 and
put on turning gear (automatically)CAF G5.002fans must be stopped.

4.3.3 Interruption More Than 7 Minutes

1) If travelling grate is stopped for more than 7 minutes WBE G5.032, WBR G5022 and
CAF G5002fans must stop. Burner cooling air must be available to cool the burners.
2) All the burners are put on hold condition, 900C.(low fire followed by temperature
hold).
3)All motor speed control are put in manual mode except HEG5.042, UDD G5.012 and
bleed-in dampers G5.019 and G5.016.
4) Bleed-in damper are opened on suction duct of fan WBR G5.022. This it is not
absolutely required; inspection door can be opened on windboxes number 6 to 13.
5) Temperature of HE fan G5042 should be followed closely. If this temperature exceeds
200 deg. C inlet damper will close automatically.
6) Hood temperature will drop to 900C. At that time a few burners must be started (if
required) to maintain this level of temperature.
7) As soon it is confirmed when plant will be available for start-up, the ramp system
must start on the control room and indurating machine and pellet plant start
accordingly.

4.3.4 Power Failure

If the power supply fails, the entire plant operation is interrupted and all motor drives are
stopped.
To avoid damage to the mechanical equipment, a separate emergency power supply is
provided so that certain machines can be operated.
As soon as the power supply fails, the emergency power supply starts up supplying
electricity for the control panel and the intercommunication equipment. The staff in the
control room must now clarify with the electrical department, whether the power failure is
the result of a short voltage fluctuation or of a complete breakdown of the main power
supply over a considerable period:

a) If the power failure is the result of a short voltage fluctuation, the plant can be
started up again as soon as the main power supply functions again.
b) If a complete breakdown over a considerable period occurs, the appropriate
drives are started automatically or local.
c) Following drives are to be started immediately as soon emergency power is
made available.

Description
Cooling Water Pumps (automatically
after 10 sec.)

Item
G6.014
Page

Cooling Water
after 10 sec.)
Burner cooling
after 10 sec.)
Air Compressor
sec.)
Air Compressor
sec.)

Pumps

(automatically

Air Fan (automatically

(automatically after 10
(automatically after 20

G6.008
G4.041/.042
G6.020
G6.025

d) Doors are manually opened on windboxes4to14.

e) Ensure that firewater (1 of 2) is running.
f)

All indurating machine burners should be purged and removed.

4.3.5 Emergency (Diesel) Generator Failure

If the power supply fails, the entire plant operation is interrupted and all motor drives are
stopped.
To avoid damage to the mechanical equipment, a separate emergency power supply is
provided so that certain machines can be operated. If for some reason it cannot be operated,
following action should be taken on top priority.
As soon as the power supply fails, the staff in the control room must now clarify with the
electrical department, whether the power failure is the result of a short voltage fluctuation or
of a complete breakdown of the main power supply over a considerable period and ask about
status of emergency power supply. All possible action should be taken urgently to start the
diesel generator.
a) The emergency water supply on the head tank outlet valve and adjust valves position
in such a way that lintelsare getting enough water. (Steam formation at the lintel
discharge end should be avoided).The cross lintel at the beginning of the Pre-heat
and the end of firing are the most important ones. The water flow can be reduce in
UDD and second cooling in such a way that it will provide more flow to the hot section
of the furnace.
b) All indurating machine burners should be removed immediately.
c) Doors are manually opened on windboxes 6 to 14.
d) This is a TOP PRIORITY EMERGENCY, power should be restored, normal or
emergency, as soon as possible, lintel-cooling water will be available from the
emergency system for a maximum period of 1 hour if water consumption is restricted
to the minimum. If lintels run out of water, severe damage can happen to the lintels,
refractory and machine structure.

4.4 Faults during Operation.

The following directives apply to faults in the operation of plant equipment. In the case of
some faults, pellet production can be kept going, though at a reduced rate.
The plant management should decide whether to stop pellet production or to carry on at a
reduced rate. Possibilities of keeping pellet production going are listed below. The following
cases are dealt with:
1) Breakdown of vibrating feeders. G7.003 or G7.004
2) Breakdown of windboxes belt conveyor. G7.002
3) Breakdown
of
the
hearth
layer
feeding
system.
(G8.002,G8.003,G8.004,G8.001)
Page

4) Breakdown of the travelling grate. G3.007

5) Breakdown of the green pellet conveyor systemG2.050
6) Breakdown of the green pellet undersize/oversize system-- G3.105/G3.004
7) Breakdown of double deck roller screen.-- G3.003/M01,M02
8) Breakdown of the cooling air fan.-G5.002
9) Breakdown of the windbox recuperating. G5.022
10) Breakdown of the updraft drying fan. -G5.012
11) Breakdown of the windbox exhaust fan.- G5.032
12) Breakdown of the hood exhaust fan.- G5.042
13) Breakdown of the Burner Cooling air fans- G4.041/042
14) Unsatisfactory permeability of pellet charge
15) Too much charge supplied to travelling grate
16) Windbox temperature profile too high
17) Pellet temperature at travelling grate discharge too high
18) Pressure in firing hood too high
19) Breakdown of the lintel cooling water system for the travelling grate

4.4.1 Breakdown of Vibrating Feeders G8.001and G7.006.

If the vibrating feeders break down, the conveyor system keeps on running. All attempts must
be made to keep the pellets flowing in the emergency chute of the bin . If the discharge bin
G7.005 fills up and stops conveyor G7.002A and vibrating feeders G7.003 and G7.004
thetravelling grate will stop when machine discharge hopper reach 100% level reaching the
maximum level.Proceed with shutdown accordingly.

4.4.2 Breakdown for Belt Conveyor G7.001

If belt conveyor G7.001 breaks down.Production can continue, since vibrating.feederG7.003,
G7.004 and belt conveyor G7.002Ais in operation. The fault should be found as soon as
possible, because dust and spillage will collect in the hoppers above the double pendulum
valves, could result in an overload when restarting the belt conveyors, G7.001 and G7.002A.
The tail end of Conveyor G7.001 will have to be inspected before any attempt to restart it.
During stoppage, pellets from indurating machine drive station will get accumulated on the
conveyor tail end.

4.4.3 Breakdown of the Hearth Layer Feeding System

If this conveying system breaks down, no hearth/side layer gets re-circulated. If the stoppage
only lasts a few minutes (e.g. if the trip cord at belt conveyor G8003 gets pulled), there is no
problem, as bin G8005 is normally kept at 80 to 85 % bin level, which means enough
heath/side layer is available for approx. 15 minutes. If it is expected to last more than 20
minutes, it is better to go for an emergency shutdown.

4.4.4 Breakdown of the Travelling Grate.G3.007

Proceed with shutdown according to Section 4.3.1 or 4.3.2

4.4.5 Breakdown of the Green Pellet Conveyor System G2.050

Proceed with shutdown according to Section 4.3.1 or 4.3.2

4.4.6 Breakdown of the Green Pellet Undersize/Oversize System G3.105

Proceed with shutdown according to Section 4.3.1 or 4.3.2

4.4.7 Breakdown of the Double Deck Roller Screen. G3.003

Proceed with shutdown according to Section 4.3.1 or 4.3.2

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4.4.8 Breakdown of Cooling Air Fan.G5.002

If the cooling air fan breaks down, the travelling grate must be stopped immediately;
otherwise excessively hot pellets will be discharged. If the fan can be restarted immediately,
burners should be switched on low fire, otherwise if the fan is not started immediately, the
burners must be extinguished and the process fans switched off. A supply of air must be
available to cool the burners. The vent door must be opened on fan WBEG5.032 and WBR
G5.022. This is not strictly necessary, the doors of windboxes 6 to 14 can alsobe opened to
cool the grate to avoid sagging of pallet car.

4.4.9 Breakdown of Windbox Recuperating Fan G5.022.

Indurating machine is stopped. Proceed with shutdown according to section 4.3.1. or 4.3.2.
4.4.10.Breakdown of Updraft Drying Fan G5012.
Indurating machine is stopped. Proceed with shutdown according to section 4.3.1.or 4.3.2.

4.4.11.Breakdown of Windbox Exhaust Fan G5032

Indurating machine is stopped. Proceed with shutdown according to Section 4.3.1 or 4.3.2

4.4.12.Breakdown of Hood Exhaust Fan G5042

Indurating machine is stopped. Proceed with shutdown according to section 4.3..1. or 4.3.2.

4.4.10 Breakdown of Burner Cooling Air Fan G1.041, G1.042

One of the two fans is always running, one fan is a standby. If one of the fans in operation
breaks down, the shutoff damper closes and the standby fan automatically starts. The shutoff
damper opens automatically. During the same period the burners will go off due to lack of
atomizing air and the grate will stop, purging will take place automatically and the burner will
be relit. Once the temperature is back to normal the grate can be restarted.

4.4.11 Unsatisfactory Permeability of Pellet Bed

Unsatisfactory permeability is usually caused by inferior green pellets quality. The supply of
green pellets to the travelling grate should therefore be reduced, until normal conditions are
re-established. The first symptom of a decline in green pellet quality is a drop in
windboxtemperature plus increase in pressure in the windboxes of the preheating and firing
zone.

Unsatisfactory permeability can also be caused by:

a) Excessively high firing temperatures;
This may be the result of incorrect temperature set points or of faulty temperature
indication.
b) Pellets bursting in the drying zones or preheating zone;
This can occur, if the moisture is too high or the volume of green pellets is too large
and the capacity of the drying and preheating zones is therefore inadequate. In this
case, the moisture content of the green pellets or the degree of fineness in grinding
may be the cause; also the binder addition should be checked for adequate drop
number of the green pellets. Appropriate action should be taken to adjust the
operating parameters correctly.
c) Crushing of green pellet due to indurating machine low speed.
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This can occur, if the ultrasonic bed level detector is not working properly at the
machine feed end or if the travelling grate speed is controlled via volumetric mode
and/or manual mode.

4.4.12 Excessive supply of green balls to Travelling Grate

If the quality of the green pellets is normal and they still do not burn through (abrasion index
increases, compression strength decreases), this is usually caused by too much charge
getting supplied to the travelling grate. In this case , the supply of green pellets must be
reduced. A downward trend in the windbox pressure profile and high travelling grate speed
are symptoms of this situation.

4.4.13 Windbox Temperature Profile Too High

This indicates that the supply of green pellets to the travelling grate can be increased or the
gas flow rates at WBE G5.032 and WBR G5.022 fans reduced.
1) The instrumentation circuits should be checked.
2) The speed control instruments of WBE G5.032 and WBR G5.022 fans should also be
checked.

4.4.14 Pellet Temperature at Travelling Grate Discharge Too High

Belt conveyors G7.002, G7.002A, G8.002, G8.003, G8.004 have to be protected by
activating the sprinkling water system.
Possible causes:
1) Good anticipation from control room operator while playing with process parameters
will avoid any kind of hot discharge.
2) The permeability of the pellets is unsatisfactory, and action taken to correct this (as
described above) has no effect or was started too late.
3) The upper layer of pellets has burst or been crushed. Hi temperature in PHbed level
too high.
4) The cooling airflow rate is too low as a result of faults in the instrumentation or the
damper/ motor speed adjustment system on the cooling air fan, not functioning
properly.
5) Too high rate of green pellets feed to the indurating machine, when dampers on fans
WBE G5.032 and WBR G5.022 are already adjusted at the maximum efficiency level
for those fans curves. (Machine operated above actual process possible capability).

4.4.15 Firing Hood Pressure Too High

If the firing hood pressure is too high (positive), hot gases are forced through the hood seal,
and thus structural parts get overheated. CAF G5002 will stop.
Possible causes:
1) The set point for the firing hood pressure is not set correctly.G4P301,305,G4H304.
2) The speed control instruments on the cooling air fan G5002 is defective.
3) There is a fault in the instrumentation system.

4.4.16 Breakdown of Cooling Water System for the Travelling Grate

If the cooling water system for the travelling grate breaks down, the appropriate non-return
valve for the emergency water supply will open automatically. Make sure that there is really
emergency water supply. If neither water system is available, this constitutes anmajor
Page

emergency. The travelling grate must be stopped and the hood temperatures lowered,
meanwhile, the pressure in the firing hood must be negative. The water systems must be
investigated/corrected immediately (flow rate, temperature, etc.)

5. Interlocks and Alarms

5.1 Interlocks
With some exceptions there are few interlocks between equipment in this area. Generally,
the interlocks are concerned with protecting the equipment itself.

5.1.1 Travelling Grate

The travelling grate can be started and controlled either from the local panel or from the
central control room. A selector feedback from the field LCSto control room determines the
position of start/stop control for this equipment.
In sequence mode, the following conditions are required to be satisfied in order to start the
grate drive mechanism
1. Lintels cooling water flow
2. Machine lubrication system is switched on
3. Discharge hopper level is not Hi-Hi (G3L011)
4. Hearth Layer Bin level is not Lo-Lo.(G8L005)
5. Expansion limit switches not actuated (G3G101A/B)
6. No emergency pushbutton are actuated on the machine .

Grate Speed and Bed Depth

If green pellet production (after screening) increases, the grate speed increases to maintain a
preset bed height as detected by the ultrasonic probes at the feed of the
machine(G3L101,G3L102,G3L103) (loop No.-G3L106). The converse is true. The normal
setpoint for bed height will be 500mm The normal grate speed is 1.5 m/min or lower. If
production rate rises to such an extent that a grate speed reaches 1.65 m/s

Page

5.1.2.Hood exhaust fanG5.042

The hood exhaust fan can only be started if the following conditions are fulfilled:
1. The inlet dampers louvers are closed
2. The temperature of the fan bearings is belowpermissible level. 60C
3. The temperature of motor bearing is below permissible level. 60C
4. The motor winding temperature is belowpermissible level. 70C
5. No emergency button are actuated.

During normal operation the fan stops automatically when:

1.

The temperature of the fan bearings rises above permissible level 60C.
2.

The vibration level exceeds the permissible level. 130m.

During normal operation

HEF control (G5042), is controlled by the hood suction (G5P114) at -5mm to -25mm.
Inlet damper(G5G110) is at 100% open and the (VFD) controls motor speed.
If HEF (G5042) fan temperature reaches at maximum operating temperature (180C)
inlet damper(G5G110) will close to protect the fan.

At machine emergency stop, the inlet damper closes and the VFD goes to minimum speed.

5.1.3.Updraft Drying Fan G5.012, Windbox Recuperation Fan G5.022, Windbox

Exhaust Fan G5.032,
The interlocks are identical for these three fans. For themto start, the following conditions
must befulfilled:
1. The temperatures of the fan bearings must not be above permissible level 60C
2. The control dampermust be closed
3. The temperature of the motor winding must be abovethe maximum permissible level
4. The temperature of the motor bearings must be above themaximum permissible level

Windbox Exhaust Fan :

Windbox Recuperation Fan:

80m alarm, 130m shutdown

80m alarm, 130, m shutdown

Updraft Drying Fan:

80m alarm, 130m shutdown

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During normal operation the fan stops automatically when:

1. The temperature of the fan bearings rises above permissible level 60C.
2. The vibration level exceeds the permissible level. 130m.
During normal operation
1. UDDF control (G5012) ,

Controlled by the UDD pressure (G4P306) at -15mmWC.

Inlet damper(G5G111) is at 100% open and the (VFD) controls motor speed.

If
UDD
fan
(G5012)
temperature
reaches
maximum
operating
temperature(400C) the inlet damper(G5G111) will close to protect the fan.

At machine emergency stop, the inlet damper(G5G111) closes, the bleed-in damper
(G5.016) opens 100% and the VFD goes to minimum speed.
If UDD fan (G5012) main motor stops auxiliary drive(G5012M06) will start to keep it running
at minimum speed.
2. WBEF control (G5032),
Controlled by an average temperature set point of 180 OC in Wind box No. 7, 8
(G5T117).
Inlet damper(G5G113) is at 100% open and the (VFD) controls motor speed.
A Stand by signal for WBEF controls (G5032) and/or shut-off damper (G5G113),
An optional method of control is a Ratio Control of average pressure in wind box
5, 6, 7, 8 (G5P104, G5P105, G5P106, G5P107)and in wind box 10, 11, 12, 13,
14 (G5P109, G5P117, G5P118, G5P119).This option can be used but it is not

recommended by the process designer.

If WBE fan(G5032) temperature reaches maximum operating temperature

(280C) the inlet damper(G5G113) will close to protect the fan.

At machine emergency stop, the inlet damper(G5G113) closes and the VFD goes to
minimum speed.

3. WBRF control (G5022),

Controlled by an average temperature average Wind box No. 12 2 t/c, 13 1 t/c
(G5T115). If this average temperature falls below set-point, the motor speed of fan
G5022 increased until set point is restored. The normal set point for burn-through
is approximately 400OC without carbon addition and 370OC with carbon addition at a
rate of about 1.4 %.
Inlet damper(G5G112)is at 100% open and the VFD controls motor speed.
If WBR fan (G5022) temperature reaches maximum operating temperature(400C)
the inlet damper(G5G112) will close to protect the fan. The bleed-in damper opens !
00%.

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At machine emergency stop, the inletdamper(G5G112) closes and the VFD goes to
minimum speed.
At that point the bleed in damper will open at 100%.
If WBR fan (G5022) main motor stops auxiliary drive(G5022M06) will start to keep it running
at minimum speed

5.1.4.CoolingAir Fan G5.002

The cooling air Fan can only be started when the followingconditions are fulfilled:
1. The hood sealing air fan G5045 must be operating
2. The adjustable dampers must be in closed position
3. The temperatures of the motor windings must be below themaximum permissible
level
4. The temperatures of the motor bearings must be below themaximum permissible
level
5. The temperatures of the fan bearings must be below themaximum permissible level
An alarm is given in the process control centerDCS whenthe fan bearing temperature
exceeds 70OC.
During normal operation

CAF control (G5002), is controlled by the suction in the firing zone at -3mm to
-5mmWC (G4P305).

Inlet damper(G5G110) is open at 100% and the VFD is controls the motor speed.

At machine stop, the inlet damper remains fully open and the VFD goes to minimum speed.

Other loops
1. Control damper (G5H110), WBRF (G5022) to HEF (G5042) duct, for control of the dewpoint (ESP requirement) in the HEF exhaust gases (G5T123).
Controlled at around 85 C.
2. Control dampers (G4H101, G4H102), WBRF (G5022) to Preheat (spider). Controls the
temperature of the first Preheat zone at about 400C if required to lower the temperature
to prevent spalling. (G4T201, G4T202, G4T304, and G4T305).
This damper to close upon machine stop.

3. Control damper (G5H106), UDD (G5012) bleed-off UDD gases to exhaust gas chimney.
Controlled at set point of 500mmWC (G5P102).
4. Control damper (G5H101), UDDF (G5012) bleed-in for control of UDD gases
temperature in UDD wind boxes and fan protection, located in duct above the second
cooling zone. Controlled at about 400C (G4T303). To maintain Fan manufacturers
advised max operating temperature (400C).
The bleed-in Damper opens fully in case of emergency stoppage of the fan.
5. Control damper (G5H102), If the UDD(G5012) outlet temperature G5T125 is too low, at
start up for instance, it can be boosted by bleeding process gas from the outlet of the
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Wind box Recuperation Fan G5022 to the suction side of the Updraft Drying Fan by
damper.(to operate at start-up only)
6. Control damper (G5H103), WBRF (G5022) bleed-in for fan protection, located in end of
the long WBR manifold. Controlled at about 400 C (G5T124). To maintain Fan
manufacturers advised max operating temperature (400C).
This damper to open fully in case of emergency stoppage of the fan.
7. Control Damper (G5H107), HEF (G5042) bleed in damper for ESP, located at inlet.
Controlled at about 110 C temperature (G5T123). It also maintains Fan Manufacturer
recommended limit of operating temperature(120C).
This damper to open upon power failure.
8. Emergency Shut off Damper G4U101 (G4032) located at PH zone in WBRF(G5022)
duct. This will operate in case of power failure or if grate stops. Normally it is fully open,
on emergency it shuts off to prevent HEF G5042. It is pneumatically operated Fail Close
damper.
9. Expansion switches(non contact type) (G4G101A/B) on each side of the discharge end
to limit the grate expansion. If expansion exceeds to set point it will trip the grate.
10. At 20% level of Discharge bin G3011 the vibratory feeders G7003 & G7004 will start,
controlling range will be between 20-40%. HiHi level will be at 50 % level. At this level
the vibrating feeders will operate on its maximum and grate will stop.
11. Two temperaturesensors G7T101,G7T102are installed on discharge conveyor
G7002AIfthe pellet discharge temperature exceeds more than set point (105C) then the
water spray valveG7U101will open. Iftemperature does not decrease below (90C)
second water spray valve G7U102 will open to control the temperature.
12. At 40% HLSB bin G7005 level the vibro feeder G7006 will start and after that it will
adjust the speed to control the bin level. Bin level controlling range will be 40-60%.
13. At 40% HLSB bin G7005 level thevibro feeder G8001 will start. It will control the Hearth
layer bin G8005 level between 30-60% by adjusting the speed. At bin G8005 level
reaches HIHI (85%) feeding conveyor G8003,G8004 and the vibro feeder G8001 will trip
immediately.
14. There is a product overflow if HLSB bin G7005 level reaches more than 80%. If overflow
chute chokes and level goes high then discharge conveyor G7002A and vibro feeders on
discharge bin G7003,G7004 will trip immediately.

5.1.5.Associated Ancillary Systems

The following systems have association with the induration area
1. Grate feed
2. Hearth Layer
3. Dribble Conveyor
4. Double Pendulum Dust Valves (windboxes)
5. Product Handling
6. ESP Dust Handling
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7. Lintel Cooling Water

8. Burner Management System
9. Fuel Oil supply and heating
10. Burner Purging (plant air)
11. Burner Cooling Air fan.
12. Instrument Air compressor(s)
13. Plant air compressor(s)
Refer to the appropriate Process Operation & Control document

6. Alarms
N
o.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

Detection

Condition

Description

Fan bearing

>60C
>60C
>100
>100

Fan motor




Travelling grate

>90C
>60C
>xxx
Above set value
Above set value
<xxxbar
< xxx L/M
Level abnormal
<400mm
>500mm
>1.6 m/m
Below set value
>xxx A

Burners

Burners

<80C
<xxxbar
<xxxbar
<xxxbar
<xxxbar
<xxx mm

Fuel oil low temperature

Fuel oil pressure low
L P G pressure low
Plant air pressure low
Instrument air pressure low
Atomizing air pressure low

Balling bins

Balling disc feed

Balling disc motor

Green ball production

>set value x 6
<set value x 6
< set value x 6
>set value x 6
>Set value x6
<70% yield

Bin level Hi
Bin level low
Feed rate low
Feed rate Hi
Motor current high
Green production Low

>90%
Stopped

Bearing Hi Temperature D/E

ND/E
Bearing Vibrations D/E

ND/E
Motor winding temperature
Motor bearing temperature
Motor Vibrations
Motor high current
Motor winding temperature High.
Lubrication pressure low
Lintel water flow low
Lintel water emergency tank level
Bed level low
Bed level Hi
Grate speed Hi
Grate speed low
Motor current Hi
Motor torque Hi
Discharge hopper Hi level
Dust collector not operating H3.001

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N
o.

Detection

37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.

Condition

Description

Filter cake

Bentonite feeder

Limestone feeder

Carbon feeder

Dust collector (bentonite)

(limestone)

(carbon)

Ash bin
Conveyors current (all)

<set value
>set value
<set value
>set value
<set value
>set value
<set value
>set value
Stopped
Stopped
Stopped
Stopped
>set value
Side travel

Feed rate low

Feed rate Hi
Feed rate low
Feed rate Hi
Feed rate low
Feed rate Hi
Feed rate low
Feed rate Hi
Dust collector not operating

Motor current Hi
Conveyor side travel

Plant air receiver

Instrument air
Water basin

<set value
<set value
<set value

Air receiver pressure low

Water basin low level (X Section)

Product discharge
Product bin G7.005

Dust collector

>set value
>90%
< 25%
Stopped

Product discharge temperature Hi.

Product bin level Hi
Product bin low level
Dust collector not operating H4.001

7. Required Logic and Instrumentation

7.1 Bed Level and Grate Speed

Number of green bed level detectors are three in quantity.(G3L101,G3L102,G3L103)

Number of Hearth layer bed level detectors are also three in quantity.
(G3L111,G3L112,G3L113)

Range of level detectors is 0 600mm

Install Grate Speed Hi Hi alarm (setting at 1.6m/min).

Display 3-D graph of bed height (requires logging of last 15 minutes data)

7.2 Pallet Change Facility

Local panel for Pallet Change at Change-out station. Mode selection (local panel
activation) from Central Control Room Workstation.
Page

Local panel selector switch to Pallet Change stops travelling grate through DCS
(grate fault).

Fault Cleared by switching to Normal on Local Panel.

Signal may eventually be used as command for pallet change, burner control(at a
later date)

7.3 Pallet Car Identification

Add heat resistance tagging to the pallet cars and detector

Pallet cars in the machine to be identified by number on the Workstation display

7.4 Windbox Exhaust Fan Control :

temperatureof wind box 7 and wind box 8 ratioed ( i.e., G5T106 & G5T107 )to operate
wind box exhaust fan.

Add pressure tapping and PT (H1P101, H1P201) into duct between ESP-2 dust
collector and inlet of WBE Fan G5032.
END

R.C.12/01.2012

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