SINTER PLANT DOC NO: SP/IMS/PR/10
DURGAPUR STEEL PLANT ISSUE NO: 06
SAIL DATE: 01/03/2022
PRCEDURE FOR SINTER MACHINE, GAS MIXING, SUCTION
IMPROVEMENT OF SP-1
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This is available in the system network, therefore no hard copy is issued except the Master Copy
retained by the Issuing Authority.
APPROVED BY ISSUED & CONTROLLED BY
HOD , SINTER PLANT COORDINATOR, MANAGEMENT SYSTEM
Page: 01 Rev: 00 Date: 01.04.15
SINTER PLANT DOC NO: SP/IMS/PR/10
DURGAPUR STEEL PLANT ISSUE NO: 06
SAIL DATE: 01/03/2022
1. PURPOSE : Sinter machine, Gas Mixing operation
2. RESPONSIBILITY : Shift–In Charge is responsible for
this operation and Overall
responsibility lies with the in- charge, Sinter
Plant.
3. SCOPE : This is applicable for igniting top surface of sinter
bed and making sinter in Sinter M/C in SP1.
4. REFERENCE : DSP/ MANUAL (QMS & EMS)
5 .Details of procedure
Pre-checks before Starting Empty Machine-
a. Ensure that industrial water pump is running.
b. Ensure that all quick shutoff valves of gas lines are CLOSE.
c. Ensure that any one of the igniter blowers is running and minimum air
pressure (250 mmwg) is available.
d. Ensure that all the belt weigh feeders are READY.
e. Ensure that all the drives of Group 8,11,9 and 10 are READY.
f. Ensure that water seals are BROKEN.
g. Ensure that manual valves and control valves of gas lines are CLOSE.
2. Gas Mixing-
After lighting up of the Ignition furnace with coke oven gas open the BF Gas
manual gate valve, Control valve and set the mixing ratio at RA=1.0/1.5
BF Gas flow=450-500 Nm3/hr.
CO Gas flow=300-500 Nm3/hr.
Mixed Gas flow=700-900 Nm3/hr.
Combustion air flow=2000-2500 Nm3/hr in Zone1
(2.5 to 3.0 times of Mixed gas flow)
Zone-1 Temp. =750 -1050 degree centigrade.
Moisture in SMD=7% approx.
Percentage of Return Fines in the Raw Mix=20-40%
Return Fines level should not be more than 40-60 % in any of the machines.
Page: 02 Rev: 00 Date: 01.04.15
STEPS TO START EMPTY MACHINE-
SINTER PLANT DOC NO: SP/IMS/PR/10
DURGAPUR STEEL PLANT ISSUE NO: 06
SAIL DATE: 01/03/2022
a. Load the machine with the green mix up to Zone-1 of Ignition Furnace .Hearth
layer (Min 30-35mm thick) must be spread evenly on the pallet grate bars.
b. Open the bleeder gas valve of zone-1 (on the raw mix hopper platform).
Open the quick shut off valve of CO gas, manual gate valve and control valve.
c. Control furnace air flow from the control room to light up the furnace.
d. Light the igniter torch and insert into the burner hole. Slowly open the Pilot
burner’s AUDCO valve and ensure that the furnace is lighted up.
e. Open the air valve and other Gas valves of the ignition furnace.
f. Close the Bleeder gas valve.
g. Raise the temp. of the ignition furnace up to 800-900 degree centigrade then
only move the sinter machine at low speed (0.5 to 1m/min).
h. When the loaded pallets reaches at the discharge end of the machine stop the
machine for 15-20 Minutes to stabilise the process. Afterwards run the
machine and slowly increase the speed so that burn through point place at last
but two wind boxes (Wind Box No22).
i. Hearth layer thickness must be minimum 30-35 mm and should be evenly
distributed over the pallet grate bars.
Process Control parameters.
a. Moisture control of the raw mix.
b. Coke content of the raw mix.
c. Hearth layer thickness and its distribution.
d. Machine loading control and compaction of top layer.
e. Ignition furnace temp. and pressure control and burn through point control.
f. Return fines proportion and its bunker level control.
g. Vane control of the sinter fans.
h. Sinter fan inlet temp. control.
a. Moisture Control.
This factor plays very vital role in the sintering process and should be
maintained at the optimised level. Moisture level at higher or lower side of
the optimised level affects the sintering process and bed permeability.
Moisture content at lower side causes the sinter machine bed permeability
to drop because the module formation can not take place at lower moisture
content and gets choked with finer particles.
Higher moisture content in the sinter mix also causes the drop of bed
permeability and ignition temp. of the furnace drops drastically resulting in
improper ignition of the top layer.
Page: 03 Rev: 00 Date:
b. Coke Fines Control-
SINTER PLANT DOC NO: SP/IMS/PR/10
DURGAPUR STEEL PLANT ISSUE NO: 06
SAIL DATE: 01/03/2022
The next vital parameter in the sintering process is coke fines ratio control.
This can not be done accurately until and unless moisture content is
adjusted at optimum level and crushing index of coke is 80% Min.
When moisture is optimum and in the raw mix coke content is lower the
top layer of the machine bed remains reddish and the ignition temp. of the
furnace falls(Ignition zone will appear reddish instead of white). Wind box
temp. and burn through temp. will drop drastically and results in the
formation of weak sinter.
High coke in the raw mix causes the choking of bed and consequantly the
burn through point will shift towards the last wind box of the machine
which if machine speed is not lowered /stopped will cause burning of the
conveyor belts.
So to avoid burning of the conveyor belts in the disposal area, machine
must be stopped to achieve burn through point in the machine itself.
c. Control Of Hearth Layer Thickness And its Distribution
Hearth layer thickness is controlled by the speed of the hearth layer drum
feeder and flapper plate with counter weight. Uniformity of hearth layer
thickness is very vital factor in the sintering process. Size of the hearth layer
is 10mm to 25mm and thickness of hearth layer over the pallet grates is 25-
30 mm.
Two main functions of hearth layer are
i. Protects the grate bars from excessive heating and bending.
ii. Protects the fine dust particles to pass through in the wind main thus
improves the sinter fan impeller life.
d. Machine Loading Control and Compaction of Top layer of the Sinter
Machine Bed.
After hearth layer is distributed the pallet is now filled up with raw mix
drum feeder. Speed of the drum feeder varies according to set point given
by the operator in the angle of repose controller. Set point is given in such a
way that the bigger particles roll down and forms the bottom layer and
finer particles forms the top layer of the bed. This improves the bed
permeability.
Page: 04 Rev: 00 Date:
SINTER PLANT DOC NO: SP/IMS/PR/10
DURGAPUR STEEL PLANT ISSUE NO: 06
SAIL DATE: 01/03/2022
If segregation plate is overloaded with raw mix proper segregation will not
take place and coarse particles will come at the top layer thus bed
permeability reduces.
After segregation top layer of the bed is made compact with the help of
compaction roller.
Material loosening is also provided to improve the permeability of the raw
mix bed. This is installed just before the segregation plate.
e. Ignition Furnace temperature and Pressure Control.
In the sintering process ignition of the sinter mix bed plays very vital role.
For proper ignition of the bed the following factors are mostly responsible:
i. Moisture control of the raw mix.
ii. Coke content of the raw mix.
iii. Calorific value of the mixed gas i.e CO and BF gas ratio.(normally 1:1.5
ratio is maintained.
iv. Mixed gas to compaction Air ratio
Zone1---1:2.5-3.0 temperature=750-1050 degree centigrade
To maintain the furnace temp., Temperature set point is given and
accordingly mixed gas and air flow comes to maintain that temperature.
Furnace pressure is controlled by dampers provided in the first four wind
boxes which come below the ignition furnace. First two wind boxes comes
under zone1 and last two comes under zone2.Furnace pressure is
maintained slightly positive than the atmospheric pressure. So that outside
cold air can not enter inside the furnace.
All dampers must be operated once in a shift and should be kept in the
condition mentioned below:
1st damper 10%open
2nd damper 25%open
3rd damper 50%open
4th damper 100%open
Page: 05 Rev: 00 Date: 01.04.15
SINTER PLANT DOC NO: SP/IMS/PR/10
DURGAPUR STEEL PLANT ISSUE NO: 06
SAIL DATE: 01/03/2022
f. Burn Through point Control and Return fines Bunker Level Control :
Burn Through point is a location in the machine bed where all the coke has
been burnt out and peak wind box temp is attained. This should be
maintained at 23rd wind box, if it is shifted towards last wind box,
immediately reduce machine speed and check the following parameters
i. Moisture content of the raw mix
ii. Coke content of the raw mix.
iii. Any rat hole on the machine bed.
iv. Gas and air flow ratio.
Rat-hole pallets must be replaced by O.K pallets at the earliest opportunity.
Otherwise this will cause increase in return fines bunker level, decrease in
production rate and productivity. Because the near by area of the rat hole
will be unsintered and will generate more return fines. So to avoid this
immediate action should be taken by the shift in-charge.
Return fines bunker level should be maintained at 45-50% each in both
machines. If the level increases check the process and increase the return
fines ratio in the raw mix to control the level of return fines.
DEFINITION: Return fines is that fraction of Product sinter having LOI zero
and which is not suitable as an input material to Blast Furnace.
g. Sinter Fan Inlet Temperature and vane Control
The control of sinter fan vane is a very vital activity to improve the
productivity of the machine.
Sinter fan inlet temperature is the average temp. of the gases which are
generated in the sintering process and air which is sucked through the bed.
This must be maintained above 70 degree centigrade (Min).when air
becomes hotter the volume of air sucked through the bed will more hence
machine will run at higher speed.
When machine stops vane should be closed to maintain the process stability
otherwise through sinter area of the bed becomes more permeable which
acts as a natural damper.
Page: 06 Rev: 00 Date:
SINTER PLANT DOC NO: SP/IMS/PR/10
DURGAPUR STEEL PLANT ISSUE NO: 06
SAIL DATE: 01/03/2022
6. Energy Control Measures :
i) Sinter Machine
Sl. Action Procedure Action for Impact on energy
No Deviation Consumption
01. Ignition Temperature. Maintain furnace 01. Check BF to CO Decrease in
temperature between gas ratio to gaseous fuel
750-1050 achieve CV consumption and
02. Air to gas ratio improvement in
between 2.5 to 3. yield.
03. Keep segregation
plate clean
02. Waste gas Maintain the 01. Adjust machine Lower the
temperature. temperature above speed. exhauster power
70⁰C. 02. Adjust moisture consumption.
Maintain BTP above in raw mix.
250⁰C. 03. Check thickness
of hearth layer.
04. Clean
segregation
plate.
05. Adjust solid fuel
addition.
03. Uniform ignition of 01. All burner nozzles 01. Burner nozzles to 01. Lowers the
top layer. to be kept fully be cleaned gaseous fuel
clean. during consumption
02. Maintain ignition shutdowns. 02. Improvement in
temperature of 02. Adjust air to gas yield.
furnace between ratio and
750-1050⁰C. maintain CV.
03. Ensure cleanliness 03. Clean of
of segregation segregation
plate, MLD bar & plate, MLD bar &
Leveler plate. Leveler plate.
Page: 07 Rev: 00 Date:
SINTER PLANT DOC NO: SP/IMS/PR/10
DURGAPUR STEEL PLANT ISSUE NO: 06
SAIL DATE: 01/03/2022
ii) Gas mixing :
Sl. Action Procedure Action for Impact on energy
No Deviation Consumption
01. Ignition Temperature. Maintain furnace 04. Check BF to CO Decrease in
temperature between gas ratio to gaseous fuel
750-1050 achieve CV consumption and
05. Air to gas ratio improvement in
between 2.5 to 3. yield.
06. Keep segregation
plate clean
02. Waste gas Maintain the 06. Adjust machine Lower the
temperature. temperature above speed. exhauster power
70⁰C. 07. Adjust moisture consumption.
Maintain BTP above in raw mix.
250⁰C. 08. Check thickness
of hearth layer.
09. Clean
segregation
plate.
10. Adjust solid fuel
addition.
03. Uniform ignition of 04. All burner nozzles 04. Burner nozzles to 03. Lowers the
top layer. to be kept fully be cleaned gaseous fuel
clean. during consumption
05. Maintain ignition shutdowns. 04. Improvement in
temperature of 05. Adjust air to gas yield.
furnace between ratio and
750-1050⁰C. maintain CV.
06. Ensure cleanliness 06. Clean of
of segregation segregation
plate, MLD bar & plate, MLD bar &
Leveler plate. Leveler plate.
Page: 08 Rev: 00 Date:
7. Safety measures:
SINTER PLANT DOC NO: SP/IMS/PR/10
DURGAPUR STEEL PLANT ISSUE NO: 06
SAIL DATE: 01/03/2022
a. Personal safety:
a. Use of PPEs i.e. safety boots, safety helmet, hand gloves, dust mask, ear
plug in noise prone area and well fitted cloths.
b. Not to touch moving parts of any machinery.
c. Use of designated walk ways and stair-cases. Not to take any short cut
route.
d. Cleanliness of conveyor gallery, stair cases and aisles.
e. Getting clearance from control and also checking physically as far as
possible before starting any conveyor belt or any equipment,
f. Not to start the machine if any danger tag is found hanging.
g. Not to throw any material down below the area at height without specific
instruction while cleaning conveyors or machine floor.
h. Ensuring railing in platform at height.
i. Ensuring no gas leakage in gas line.
b. Equipment safety:
a. Checking of any abnormal sound
b. Checking of any abnormal vibration.
c. Checking of any abnormal temperature by touching covers.
d. Checking of tightness of coupling and base bolts.
e. Ensuring Emergency Stop Switch is working properly.
f. Ensuring gearbox oil levels are maintained.
g. Ensuring overhead lamps and hand lamps are available in working area.
h. Ensuring no water leakage in water line.
c. EMERGENCY OPERATION DURING FIRE AND GAS LEAKAGE:
In case of fire the Fire Brigade to be informed and also higher authority to
be informed. The fire fighting pump in the pump house to be made on and
hose pipes with landed valves at different places to be connected.
In case of gas leakage, gas control to be informed and also higher authority
to be informed to take necessary actions. All the gas valves to be closed and
the ignition to be STOPPED.
Page: 09 Rev: 00 Date:
