Mill Reject Handling system

 Over view
 Introduction
 Mill rejection type
 Our plant mill rejection
 Aux rejection system
 MRHS Compressor tech data / line up/ operation.
 Local line up
 Local isolation
 Start permissive / Inter lock and Protection
 Sequence of operation mode
1) Time mode
2) Probe mode
3) Manual mode
Over view
Introduction

 The function of mill Reject handling system (MRHS) is to automatically Discharge

through scrapper chamber due to mill rotation the iron pyrite and non-grind-able
material from coal mill through an outlet connection to the reject conveying system

 Mill rejects will be led to respective pyrite hopper through mill rejects outlet spout and
thereafter, it is further discharged to the transport vessel. Pneumatic conveying
system has been envisaged for conveying of rejects from the transport vessel to mill
reject silo
Mill rejection type

 Drag Chain conveying System

 Pneumatic conveying system

Our plant rejection type.

 Pneumatic conveying system

Mill rejection auxiliary system

 MRHS Compressor
 Conveying air receiver tank
 Instrument air receiver tank.
Drag Chain conveying System
Pneumatic conveying system
P&ID
MRHS TECH DATA
Equipment Value
Pyrite hopper 55 cft
Conveying Air receiver (2nos) 6 m3
Instrument Air receiver (1no.) 2 m3
Dome seal cooling water flow Pr 1.5 -2.0 bar flow 4.5m3/ hr

Bunker capacity 22m3

Conveying Vessel (Model 6/8/5)

First digit (6) Capacity of conveying vessel (6 cft)
Second digit (8) Size of inlet valve (8”)
Third digit (5) Size of conveying pipe (5”)
Mill Reject Handling system compressor
Mill reject compressor
Make Elgi
Type Screw
Model EG 75-8
Quantity 2 nos.
Rated I/P Power Kw
Air flow 14.78 m³/min
Air pressure 7 Bar
Operating Pressure 5.0 – 5.8 KSC

Mill Rejection compressor Motor

Make ABB
Model  
Type SQIM
Quantity 2 nos.
Rated speed 1479 rpm
Rated power 90 KW
Rated current 155 A
Rated parameters  
Efficiency 95.2 %
Insulation class F
Protection IP 55
 
 
Start permissive
Description Condition
System ON in Local Control Panel  
Vessel Pressure low <0.3 KSC
Conveying header Pressure adequate >5.5 KSC
Dome Seal Pressure adequate (Pressure switch) >5.5 KSC
Probe override Probe mode not selected
Cooling water pressure adequate (Pressure Switch) >6.0 KSC
Bunker 01/02 ok Bag filter ON (AND) Bunker level not High
Instrument air Pressure adequate 6.0 KSC
Line Purge Not persisting

Inter lock and protection

MRH system changes from Auto to Manual if any of the following protection
acts
Description Condition
Bunker fault Bag filter OFF (OR) Bunker level high
Dome fault Not closed(Close Feedback)
Dome seal fault Seal pressure not OK
Conveying Air fault Pr < 5.0 KSC
Line Block HPS > 4.0 KSC
KGV-1 fault Open / Close FB not OK
Quenching SOV Hopper temperature high (>90ºC)
Local line up
 Ensure all PTW closed condition.
 Ensure hopper man hole door closed condition.
 Dome Seal CW Supply and Return valve Open Condition
 Ensure the Instrumentation air valve in local control panel open condition
 Instrument Receiver Line up and ensure air pressure >6 kg/cm2
 Ensure Vessel pressure is zero
 Ensure KGV 4 valve open condition.
 Check Conveying air valve open condition
 Check Conveying compressor running and receiver pressure>5 kg/cm2
 Ensure both Conveying air receiver tank drain SOV line up done
 Instrument air Receiver tank lineup done. Drain to be done periodically to
remove condensate
 Pyrite hopper fire quenching SOV Spray valve up stream and down stream valve
open condition. Bypass closed condition( in emergency condition only. Currently
both valve closed condition) sov will open hopper temp >90c
 Rejection bunker bottom SECTOR gate closed condition instrument air miv open
condition.
 Bag filter instrument air miv open condition. Before start bag filter should be on
Local isolation
 Ensure Mill is in stopped condition.
 Ensure vessel pressure is 0 kg/cm2
 Change MRH system from Auto to Manual.
 Close Pyrite hopper inlet KGV-1.
 Open Pyrite hopper to atmospheric rejection KGV-2 & KGV-3 and ensure hopper is emptied and close
KGV-2 & KGV-3.
 Close Pyrite hopper outlet manually operated KGV-4.
 Close instrument air ball valve
 In Local control Panel switch the selector switch to Stop.
 Close Conveying line MIV of the specific MRH system.
 Close DMCW cooling water inlet and outlet MIV.
 Close quenching line MIV.
Sequence of Operation in Timer mode:

 
 Once all permissive are satisfied change required MRH system (I,II,III,IV,V,VI)
from Manual to Auto. Start the sequence one by one.
 Vessel Inlet Dome valve will open and Pyrite Hopper I/L KGV-1 close.
 Filling Timer (T-1) starts for 10sec once the KGV-1 close limit acts and Dome
valve opened.
 After completion of T1 Dome valve gets closed. Completion of filling is ensured
after getting dome valve close FB and seal pressure healthy. KGV-1 opens.
 Blow valve opens and conveying Time (T2) starts for 60 sec.
 Simultaneously pyrite hopper quenching water SOV opens for 2sec.
 Throughout conveying timer (T-2) if the vessel pressure maintains normal (<3.0
KSC) conveying cycle is completed. Sequentially cycle gap timer (T-3) starts for 15
sec. On completion of cycle gap timer sequentially next MRH system starts as per
set timer T-1, T-2, T-3 & T-4.
 During conveying if vessel pressure persist above Intermediate Pressure (IPS set
pressure-3.0 KSC) , line block timer will be initiated (T-4) for 200 sec.
 Conveying continues till line block timer (T-4) to clear the blockage if any.
 During line block timer if High Pressure Switch (HPS) acts (HPS set pressure- 4.0
KSC) and persists till completion of T-4 line block is declared and that MRH system
changes from Auto to manual.
 On completion of timer T-4 sequentially next MRH system starts the same above
said cycle.
 Pyrite hopper to atmospheric rejection valves KGV-2 opens with respect to the
timer T-4 of 15 min.
Timer Mode
Following table shows the normal time setting for the sequential operation in Timer
Mode (which can be adjusted as per rejection of individual mills requirement

Description Duration (Sec)

Filling Time (T1) 10
Conveying Time (T2) 60
Cycle Gap Time (T3) 15
Line Block Time (T4) 200
KGV-2 Timer (T5) 900
Sequence of Operation in Probe Mode

 Once all permissive are satisfied change required MRH system

(I,II,III,IV,V,VI) from Manual to Auto. Start the sequence one by one.
 In probe mode of operation, whenever pyrite hopper level High switch
acts, the auto sequence of that specific MRH system conveying starts.
 Vessel Inlet Dome valve will open and Pyrite Hopper I/L KGV-1 close.
 Filling Timer (T-1) starts for 10sec once the KGV-1 close limit acts and
Dome valve opened.
 After completion of T1 Dome valve gets closed. Completion of filling is
ensured after getting dome valve close FB and seal pressure healthy.
KGV-1 opens.
 Blow valve opens and conveying Time (T2) starts for 60 sec.
 Simultaneously pyrite hopper quenching water SOV opens for 2sec.
 Throughout conveying timer (T-2) if the vessel pressure maintains normal (<3.0
KSC) conveying cycle is completed. Sequentially cycle gap timer (T-3) starts for
15 sec. On completion of cycle gap timer sequentially next MRH system starts as
per set timer T-1, T-2, T-3 and T-4.
 During conveying if vessel pressure persist above Intermediate Pressure (IPS set
pressure-3.0 KSC) , line block timer will be initiated (T-4) for 200 sec.
 Conveying continues till line block timer (T-4) to clear the blockage if any.
 During line block timer if High Pressure Switch (HPS) acts (HPS set pressure- 4.0
KSC) and persists till completion of T-4 line block is declared and that MRH
system changes from Auto to manual.
 On completion of timer T-4 sequentially next MRH system starts the same above
said cycle.
 Pyrite hopper to atmospheric rejection valves KGV-2 opens with respect to the
timer T-4 of 15 min.
Manual Operation of MRH system

 Check the Pyrite Hopper I/L valve KGV-1 is open of Mills which are in service.
 If the Material is oversize then open the Pyrite Hopper discharge valve KGV-2
for removing oversized material.
 If the level of Oversize material attained low, close the KGV-2 valve.
 Open the Pyrite Hopper discharge valve KGV-3.
 After removal of material, close the Pyrite Hopper discharge valve KGV-3
Unloading of rejection bunker.
 Ensure tractor placed on bunker chute bottom
 Check the bunker level.
 Open the bunker bottom gate.
 Check the level of tractor send to rejection yard.
 same will follow until bunker will empty.