DIRECT REDUCTION PLANT

WELCOMES
CONTINUAL IMPROVEMENT AND DEVELOPMENT PROJECT

1. STOP ENTRY OF FALSE AIR

IN DIRECT CONTACT WITH
FINISHED DRI.

2.TO ELIMINATE AIR

POLLUTION AT COOLER
DISCHARGE AREA.
CONTINUAL IMPROVEMENT AND DEVELOPMENT PROJECT

3.TO INCREASE LIFE CYCLE OF

CONVEYOR BELT BC 26 FROM
300 TO 450 DAYS.

4. TO USE UN-BURNT CARBON

FINES IN TO ABC CHAMBER TO
INCREASE STEAM GENERATION
 TEAM MEMBERS

Organisation Name :- SUNFLAG Iron And Steel Co. Ltd

Bhandara Road

Department :- DRP
HOD & Facilator :- M S Vas
Group Leader :- P.L.NAKHALE
A.P Sadhu
Team Members C.Hatwar
S.Roy
U.W.Jagnade
S..S.Waghmare
 PROBLEMS BEFORE MODIFICATION

THERE WERE VARIOUS PROBLEMS AT COOLER

DISCHARGE AREA.
Sr. No Probabale Causes of Problem

1 The finished DRI is comming in direct contact with air and there is
always chance of re-oxidation of DRI. Hence GRADE of DRI reduces.
Air is getting polluted due to dust is coming from cooler discharge area.
2
This dust is un-burnt coal fines.
One person is always required at cooler area to adjust damper position.
3
Operator is continuously required to adjust the flow of material.

Belt conveyor BC26 is a long belt of length 410 meter. The average belt
4 life is 300 days. But belt is getting damaged due to hot material is coming
in direct contact with belt. Hence, belt life is getting less than 300 days.
BEFORE MODIFICATION PHOTO
 PROJECT PLAN

Phase Responsibility Target date Status

Process observation & data M S VAS
analysis May 2016

Action Plan P. NAKHALE

A . SADHU
C. HATWAR

Decision on corrective M.S Vas

actions P . NAKHALE
A. SADHU
Implementation and U.W.JAGNADE
checking of effectiveness S.S.WAGHMARE
/standardisation
 REVIEW BY HEAD OF DEPARTMENT FROM
APR-2016-JULY-2016

Month May-16 June-16 July16 August-

16
Project is in Yes Yes Yes Yes
progress
If Yes,state the In-house Preparation Mounting of BC-26A
progress designed & monting load cell. & belt
prepared of weighing commissioni installati
for hopper . ng of on
weighing weighing
hopper. system

If No,state the
reason - - - -
 REVIEW BY HEAD OF DEPARTMENT AUGUST 2016 - NOV
2016
Month Sep-16 Oct-16 - Nov 16 Nov-16
Project is in Yes Yes No
progress
If Yes,state the 1. Discharge 1. PID Auto control
progress chute modified. logic prepared in
Opening of Rockwell PLC
hopper and 2.System trial
gate positioner taken found ok but
rod is still pending for
provided. extra suction line
2. Mounting connection to ABC
arragement chamber for
done for utilisation of un-
invertor & burnt carbon fines
interfacing for steam
done with generation
feeder
If No,state the Suction line
reason work is in
 REVIEW BY HEAD OF DEPARTMENT DEC 2016 - MARCH
2017

Jan-17 Mar-17
Month Dec-16 Feb-17
Project is in progress No Yes Yes Yes/No
If Yes,state the Suction line Systen is
progress work working
completed & successf
finally system uly
taken in line.

If No,state the reason Suction line

work is under
progress
 Corrective Actions Plan
Sr Problem Root Causes Corrective Action Date of
.n completi
o on

1 Stop entry of After cooler In-house designed hopper 17-Feb

false air in discharge, mterail weighing system installed and
direct is directly falling on new belt BC-226A installed to
contact with BC 26 . There is no maintain the level in side the
finished DRI. provision to restrict hopper which stops the false
the false air entry. entery of air.
2 To eliminate The DRI is directly Modified the cooler discharge 17-Feb
air pollution falling on BC 26 chute & material taken in
at cooler from a height of 2.5 weighing hopper which stops
discharge meter.Hence, dust air pollution at cooler
area. is spread up in discharge.
near by area and
air gets polluted
 Corrective Actions Plan

3 To increase life 1)Direct falling of 1)Direct falling of 17-Feb

cycle of conveyor material on cooler material avoided by
belt bc 26 from discharge belt providing auto control
300 to 450 days. BC-26. weighing hopper
2)DRI material system.
temperature 2)Now DRI material
around 120 to 180 temperature
deg.celcius maintained between
90 to 110 deg.celcius
4 To utilise the un- Direct falling of To use un-burnt 17-Feb
burnt carbon finesfinished materail carbon fines in to abc
which cause air on discharge belt chamber to increase
pollution carbon fines steam generation .
AFTER MODIFICATION (Photographs)
 BENEFITS
1) THE ENETRY OF FALSE AIR FROM COOLER
DISCHARGE END IS RESTRICTED DUE TO
INSTALLATION OF HOPPER WEIGHING SYSTEM.
THIS HAS HELPED TO AVOID RE-OXIDATION OF
FINISHED DRI. HENCE, GRADE OF DRI DOES NOT
REDUCE DUE TO ENETRY OF FALSE AIR.

2) THE AIR POLLUTION AT COOLER DISCHARGE

END IS REDUCED .

3) NOW COOLER DISCHARGE OUTPUT IS KNOW TO

OPERATOR , WHICH HELPS TO KNOW THE THE
CONDITION OF COOLER ( LIKE JAMMING ETC).
4) MANUAL CONTROL OF COOLER DISCHARGE
DAMPER IS CONVERTED TOAUTO CONTROL.
HENCE, ONE MANPOWER IS NOT
CONTINUOUSLY REQUIRED TO OPERATE GATE
DAMPER
5)NOW ,BELT BC 26 ( LENGTH-410 METER ) IS
INCREASED FROM 300 DAYS TO 450 DAYS (I.E
INCREASED BY 150 DAYS OR ORE THAN THAT) .
THE BELT COST IS RS 10 LACS.
6) UN- BURNT CARBOB FINES IN FORM OF
DUST COLLECTED FROM DISCHARGE CHUTE
ARE TRANSFERRED TO ABC CHMABER FOR
INCREASING STEAM GENERATION.
THANKS