Iron

To Tailing Thickener
Fines Closed ckt
Bin grinding
Hydro clone
Wet
Screen

Primary Ball Secondary Ball

Mill Mill

Primary Sump
Secondary Sump

Concentrated Thickener
Flush Water
Tank Holding Tank

Pressure Filter

Filtrate
Tank
Ball
Ball MillMill
Circuit
Filter Cake Conveyor to Stock Pile
Circuit –
 FEEDING & GREEN BALL FORMATION CIRCUIT
1 2 3 4 5 6 7 8 9 10

WF WF WF WF WF WF WF WF WF WF

Belt Conveyor:

Mixer
1 2 3 Bel
t Con Belt
vey Con
or: veyo
r:
VF VF VF

1 2 3

o O/S ize Ro ll e r Screen)

Belt Conveyor: (T
MATERIAL FLOW FROM O/SIZE SCREEN TO GRATE TO KILN TO COOLER TO PRODUCT STOCKYARD

O/Si
ze R
Scre oller
en
-16mm Green Balls

yor
Be l t Conve
Wide

een
o l l er Scr
R
d er Size 8-16mm Green Balls
Un

DD-1 DD-2 PH-1 PH-2

KILN
TO B.C.- ALONG WITH BELT & SCRAPPER CONVEYORS
O/SIZE RETURN.

Product C
Product t onveyor
o Screen
Stockyard

Annular Cooler Blowers

Product Fines:
(+3mm) FINES (-3MM)
(-3mm)
 Process Gas Flow Diagram –Grate Kiln

Furnace Oil
& Coal
P.H.-2 P.H.-1 D.D.-2 D.D.-2

KILN

C.B. Blower
E.S.P.

HAF-1 ID Fan
Gas Temp
Profile:
P.H.-2 I/L- Mat. Temp
Cooler blowers 1000 C,
0 HAF-2
Profile:
D.D.-1 I/L-
Sedimentation Chamber/Dedusting Unit P.H.-1 I/L- 7000C, 30 C,
0

DD-2 DD-2 O/L- 2500C,

I/L- 450 C,
0 P.H.-1 O/L-
4500C, P.H.-2
O/L- 9000C.
 Grate Kiln Process
 The grate-kiln process has three units for meeting radically
different thermal conditions.
 Drying, pre-heating and oxidation are carried out in a
traveling grate while pellets are fired in a rotary kiln. Hot
pellets are cooled in a rotary cooler.
 Hot air from the rotary kiln is used in the grate for drying and
preheating. The hot air from the cooler is recirculated in the
rotary kiln, and Traveling Grate.
 Heat supply for various reactors can be regulated very easily
because of three units being separate.
 Pellets Produced have more uniform properties because
Induration takes place in the Rotary kiln exposing each pellet
to uniform heat.
 TEMPERATURE AND PRESSURE GUIDELINES

Pelletizing Process - This is an oxidation process with high temperature and

negative pressure .The source of heat is coal , fuel oil and flue gases coming from
cooler. Here three fans ( hot air fan-1, fan-2 & ID fan ) are sucking flue gases and are
controlled to maintain temperature and pressure at various zones.

TRAVELLING GRATE

900°c 500°c 300°c 150°c

COAL BURNER FLAME
1000°C to 1350°C To To To To
1100°c 700°c 500°c 300°c
3
1
2 PH -2 PH -1 DD -2 DD -1

Annular cooler
Cooler -1 zone- 1000 – 1100°C
2 zone- 300 – 500°C
Fuel
3 zone- 90 – 105°C
Oil
 TRAVELLING GRATE FLUE GAS FLOW

ID FAN

HAF-1

DUCT FROM
D.D-1 D.D-2 PH-1 PH-2 COOLER-II
ZONE

HOT GAS FLOW

HAF-2
Grate-Kiln

Grate :-

The travelling grate consists of three main parts :

The movable Grate, the stationary wind boxes below and the stationary hood
above. The Grate consists of an endless chain of grate plates which are
connected with the wind boxes in a gas-tight manner. The process gases are
passed through adequately dimensioned fans.

12
Rotary Kiln :-

In the Rotary kiln, the pellets are brought from their relative position of rest on
the travelling grate into a rolling movement. They roll spirally in a very thin layer
towards the discharge end. The pellets are uniformly heated by radiation heat of
the hot kiln wall and hot gases thus leaving the kiln as indurate pellets.

13
PROCESS FLOW-CHART

14