Blast furnace operation

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BLAST FURNACE

JNIL, SPD, SILTARA, RAIPUR

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OPERATION


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A blast furnace is a type t ype of metallurgical furnace used for smelting of iron ores to producing generally iron iron . The earth crust contains about 5% iron. iron. However,it is present as a compound compound mostly mostly as iron oxide. Iron is extracted as metallic iron from the oxide ores o res of iron by reduction with a reducing agent. the principal agent that is used is a naturally occurring carbon in the form of coke or coal (pulverised coal). The most abundant oxide ores of iron is hematite (Fe2o3) and magnetite is used .but hematite is used mainly in our country iron oxide also contain oxide minerals of some other elements such as aluminium, silicon Mn and P. Sinter is also used in blast furnace. It is the prepared burden which is occurred by the sintering process .this is agglomeration agglomerat ion process which utilises the fines of iron , fluxes and coke. 80 to 90 % of sinter is charged in our JNIL blast furnace.

BLAST FURNACE OPERATING DATA : Number of furnace – furnace – 01 01 Useful volume – volume – 680 680 cub.met. Working volume – volume – 560 560 Throat diameter – diameter – 5.10 5.10 No. Of tuyers – tuyers – 16 16 Tuyer diameter – diameter – 110 110 mm Tap hole – hole – single single Slag notch refractory lining – lining – micropour micropour carbon block Top charging system – system – bell bell less top No. Of stoves – stoves – 03 03 Cooling system – system – stave stave Hot blast volume – volume – 1,05,000Nm3/hr. 1,05,000Nm3/hr. Hot blast pressure – pressure – 1.9Kg/cm2 1.9Kg/cm2 Furnace top pressure – pressure – 0.88Kg/cm2 0.88Kg/cm2


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INPUT – BLAST BLAST FURNACE Raw material : Iron ore &sinter-(size 10 to 30) Flux, limestone, dolo, & quartz-( size10 to 30mm) Mn ore – ore – ( ( size10 to 30mm) Coke – Coke – (size (size 25 to 80mm) Hot blast air – air – (Temp. (Temp. 980Deg.C) PCI – PCI – ( ( as injection)

OUTPUT - BLAST FURNACE Hot metal Steel melting Shop Pig Casting Machine Blast furnace Gas – Gas – Power Plant Rolling Mill Sinter Plant Slag granulated – granulated – Cement Plant


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HOT METAL ANALYSIS Si% = 0.5 TO 0.8 Mn% = 0 to 0.6 S% = 0.06 max.

FOUNDRY GRADE :-

BASIC GRADE :-

FROM FURNACE / BY ADD. OF Fe-Si; Fe-S i;

Si% =0.5 to 0.8

Si% = 2.0 to 2.5

Mn% = 0.5max.

Mn% = 0.5 to 1.0

S% = 0.06max. 0.06max.

S% = 0.06max.

GAS ANALYSIS CO% = 25 Co2% = 17 H2% = 2.5 O2% = 0.5 CV = 750 to 800 Kcal

COKE DETAILS FC% = 85.52 S % = 0.58 Ash% = 13 M10% = 4.6


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IRON ORE DETAILS Fe% = 60 to 65 Al2o3% = 2 to 3.5 Sio2% = 1.5 to 3

SLAG ANALYSIS Cao% = 32 to 34 Sio2% = 33 to 35 Al2o3% = 21 to 23 Mgo% = 10.5 to 11.05

Cao

Mgo

Sio2

Al2o3

Fe

Mn

Limestone

48.50

1.70

4.0

0.90

0.46

-------

Dolomite

28.0

18.50

4.0

0.90

0.46

-------

Quartzite

--------

--------

96.0

1.42

--------

--------

Mn ore

---------

---------

-------

--------

28.20

26.70

Fe ore

---------

---------

1.56

--------

66.0

--------

Sinter

8.50

2.20

4.5

2.8

58.0

--------


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INPUT< ----------------------------------------------------------------------->OUTPUT I I I I I I I

PROCESS

The blast furnace process is based on counter current principle. The input and output are of modern blast furnace practice pract ice .the furnace is refractory refracto ry lined and is filled with material from the stock rod level down to bottom. Solid raw material material at room temperature temperature or preheated furnace temp. At beginning beginning the process are charged from the top of the furnace furnace . Preheated air above 950 to 980 deg.C is blown through tuyer pipe inserted in to the furnace wall along with injection of pulverised coal. The hig hest temp. Of the furnace is at the level of tuyere. This heat is transferd from bottom to top. That result direct and indirect reaction occurred.

PROCESS REACTION :OXIDATION OXIDATION REACTION ;-C + 1/2O


----------------

CO

C + O2

---------------

CO2

C + CO2

---------------

2CO

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REDUCTION REACTION ;-3Fe2o3 + Co ------------ 2Fe3o4 + Co2 Fe3o4 + Co ------------ 3Feo + Co2 Feo + Co ----------- Fe + Co2

DIRECT REACTION;-Feo + C ----------- Fe + Co Sio2 + 2C ---------- Si + 2Co Mno + C ----------- Mn + Co H2o + C ---------- H2 + Co

INDIRECT REACTION;-Feo + Co ---------- Fe + Co2

THE FURNACE INTERIOR IS BROADLY DIVIDED IN TO;-   

STACK, where wall slops outward going downwards. BELLY, the cylindrical portion below the stack. BOSH, below the belly and sloping inwards going downward. HEARTH, below the bosh and tuyere region re gion and the cylindrical portion.

Stack : This zone extends from the stock s tock line down to the metal level . it is the zone in which the burden is completely solid. The charge gets heated from 200 deg. C at the stock line level to nearly 1100 to 1200 deg. C by the line it descents to the bottom of the stack.


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Bosh : -The charge materials materials being to soften and fuse fuse as they come down down in to bottom of the stack. The The next lower zone is called the bosh in which meeting of the burden, except that of core takes place. The gangue gangue & flux combine to form two slag. TUYERE OR COMBUSTION ZONE:-By the time the charge descends in to the area near the tuyere , except the central column of coke , the entire change in molten . the oxygen of the blast burns coke to CO and several combustion zone. One in front of each tuyere, tuyere, exist in the tuyere zone .thus, there is a runway or raceway. In front of each tuyere which is first horizontal and then smoothly changes it,s direction to vertical while expanding over the entire cross section of the furnace. In our furnace there are 16 tuyeres, No. Of tuyeres = Hearth Hearth dia. * 2 +2 COOLERS:-In our blast furnace having material of tuyeres are, 1 to 4 row

cast iron coolers

5 to 9 row

Cu. Coolers

10 to 15 row

cast iron coolers

HEARTH:-Although most of the coke burns at the tuyere level , small s mall fraction fraction descends even in to the hearth where it dissolve in the metal to its near saturation .the intir charge is molten and sends to stratify in to slag and a nd metal layer in the hearth from where these are tapped separately.


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PULVERISED COAL INJECTION PCI (pulverised coal injection) is the fine powder of non – coaking coaking coal . this coal is injected in a blast furnace . Because the reason is is that , by using using PCI we can decrease the rate of coke consumption in a blast furnace. PCI RATE:-7 T per hour RAW COAL BUNKER:-Raw coal are stored in to it , the capacity of bunker has 80 T. DRAG CHAIN CONVEYER (DCC):-Drag chain conveyer this is the t he type of conveyor. But the DCC is differ from belt conveyor because at the bottom of the raw material hopper becomes heavy material load load by far DCC is used otherwise slipping slipping is occurred and can not transferred. MILL:-Mill is used for milling the raw coal coa l at the temp. Is 80 to 84deg, C. Temperature is provided provided for the wet material material ( coal) has become become dried because this condition coal is well pulverised . Three rollers are held in to a mill for the milling purpose.rollers are rotate through the centre axis of roller table. SCREW CONVEYOR:-In a PCI two numbers of screw conveyors conve yors are used for the feeding in single connection from the two bag filter. PC SILO:-PC SILO is a storage tank. Hot gas generator (H.G.G).:-Hot gas generator is used for supply of hot gas in to the mill, because has maintained the mill parameter or temperature apprix,80 deg C.


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RAW MATERIAL HANDLING SYSTEM(RMHS)

Raw Material Handling System(RMHS) is the main part of integrated steel plant. This system is raw material mater ial supplied and import from the supplier or mines. Main Equipment of RMHS 

Wagon Tippler



Side Arm Charger



Stacker cum Reclaimer



LOCO



Conveyors

Wagon Tippler:Wagon Tippler is the mechanism through this the wagon material ( raw material form the mines and suppliers ) are t ippling ippling or tilting in to the hoppers. In our Jayaswal New Industries limited have one Wagon Tippler. I n a Wagon Tippler four hydraulic clamps are provided for clamping the Wagon . 58 Wagon of Iron ore 3600 T & 2600 T are required 4 hours for empting.

Side Arm Charger:Side Arm Charger is used for removing the interconnections of the each wagons. By the help of Side Arm Charger wagons has positioned in wagon on table. Side Arm Charger is worked in forward and reversed movement.

Stacker cum Reclaimer:This is a very big machine in Jayaswal Neco Industries Limited. Stacker cum Reclaimer is material handling machine or mechanism. Material to be handled:Iron ore

_

10-40mm

Coke

_

20-80mm

Quartzite

_

20-50mm


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Lime stone

_

20-50mm

Dolomite

_

20-50mm

Stock pile height

_

12meter

Travel length

_

412meter

Bucket Wheel – Wheel – By the help of bucket wheel material has Stacking St acking and reclaiming through the boom conveyor. Stacker Cum Reclaimer is travel on the t he Conveyor Conveyor no. -3.

Stock – Stock – House:House:It is alsop knows as raw material store section. When the RMHS has some problem are include that condition the raw mater ial are required for continue operating the Blast -furnace - furnace as per condition we are provide the stock house for Blast-furnace operating. Stock house are connected through the Junction House-3. Two numbers of Travelling Tipper are held in the stock house. Travelling Tipper-1 on C5 Travelling Tipper-2 on C6 Stock house have 16 th bunkers for various type of Raw Material Feeding. Bunker capacity is 30tonne to 250tonne. Weighing hopper are 12 in no. in this hopper the burden has weighted as per required. Screening System:Vibro Screens are used for the Screening purpose and required size mater ial are provide for Blast – Blast – furnace. furnace. Vibro Feeder:-

This is a feeding equipment. Which is worked on vibration, for this purpose two Vibro Cylenders are used. Pig Casting Machine:-


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

   

In a Pig Casting Machine the hot liquid iron(metal) ar e poured in to the Pig moulds, this complete process is known as casting cast ing process. The producyt of casting process is called as Pig or Pig iron. Jayaswal NECO Industries limited have two Pig casting machine. The weight of one piss or pig iron casting has 10kg per pig. 1200 pigs are producing(casting) machine with the help of a o ne belt or the pig casting machine. Total 4800 pigs are produced in pig casting machine.

Pig Storage Yard:

The casting pig are transferred through t hrough the wagon Pig Storage Yard. Where pigs are accumulate and stay by the gardes. Such as_ 

Foundary grade

Basic grade Then the pigs are loaded on trunk by the Electro magnetic crane and sopplied the customers. 



Inmotion Bridge:  

It is used for the t he reading or taking weight of the metal by the LOCO & ladle car in running condition. tn this bridge 4load cells held. This bridge has worked when the speed of loco is more the 5km/hr..


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Gas Cleaning Plant(G.C.P)

Blast furnace produce an effluent gas containing a significant proportion of carbon monoxide. Which could not be used for iron oxide reduction. The act ual CO many vary around 20-30% nearly 900kcal/m3 . the quantity of gas produced depends upon the amount of fuel burnt. For one tone to ne of coke burnt nearly 4000m3 of effluent gas may be produced. The effluent gas from the furnace cannot directly be us ed as a fuel since a substantial quantity of dust & wear in the equipment using the gas. The gas is therefore, clean before its use & in so doing the sensible heat of the gas is invariably lost. So here the chemical heat of the c leaned gas is utilized. In general cleaned is carried out in three stage_ 1. Coarse 2. Semi-fine 3. Fine cleaning There are following arrangement through which cleaning of the gas is carr ied out in the Gas Cleaninig Plant(G.C.P). The effluent gases from furnace are carr ied out of the furnace by large vert ical pipes called up takes. Up takes are four in number. Two adjacent uptake are joined together to form a single duict & the two such ducts, thus formed, are connected to from only one duct which carriea t he gas downwards into trhe duct catcher . the downcoming pipe or doct is called downcomer. A bleeder valve is a safet y device which opens automatically or is opened ,to released extre pressure developed inside the furnace and thereby eliminate the danger of explosion. DUST CATCHER;-

The dust is contained in the gas by virtue of its velocit y hence if the velocity is zero the dust particles will be eliminated e liminated from the gas.the state of zero velocity is achieved in the gas catcher by simply reversing the direction direct ion of the gas flow from vertically to vertically upward diection. The downcomer leads the gases into the dust catcher t hrough a Vertical pipe that flares out and extends nearly to the bottom of the dust catcher. The gases comes


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down vertically & suddenly changes its direction to vert ically upwards since the outlet is located nearly at the top of dust catcher, The efficient of the dust catcher cat cher is usually upto 65%. VENTURY WASHER(1&2):-

It is a vertical unit with w ith a construction where water is injected in the form of sprays to wet the gas moving downwards. The coarse cleaned gas from the dust catcher enters into the ventury washer-1, where wat er sprays at angle appoxemately 120 degree. Due to venture effect & the water wat er sprays dust particle is sett le down in the B.S.P 1. From venture-1 the cleaned & low pressure gas is fed to the venture washer-2. Where the t he same way water spray is done & the clear gas upto % is is done. B.S.P(Bottom Seal Port):-

BSP is located near the bottom of venture washer- 1 & cyclone separator, where the t he surry is accumulated & collected bottom of BSP. Cyclone Separator:-

From venture washer-2 the Blast furnace gas enter into cyclone separator and spun rapidly. The centrifugal force created by the circular flow throws the dust particles toward the wall of the cyclone. After After striking the wall, these particles fall into into a hopper located located underneath. When the gas travel upward in the cyclone separato r, strikes with mist eliminator and hence moister is gas is eliminated from the Blast furnace gas. SEPTUM VALVE:-

Septum valve is use to control the clean gases. Als o septum valve is used to maintain the top pressure. Septum valve contain five valve   

2 regulating valve(1 pneumatic+ 1 motorized) 2 shutt off valve(both are motorized) 1 valve is always open having a small diameter.

FLARE STACK:-

Flare stack is a st ack through which the blast furnace gas is fed into at mosphere.


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GAS HOLDER:-

Gas holder capicitty 40,000m3 hold or storage the blast furnace gas. Which are not comsume comsume by the plant. BOOSTER STATION:-

Booster station is used to boost Blast furnace gas t o conveyt desired place since it is used long distance like rolling mill etc.


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MECHANICAL & ELECTRICAL


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BLAST FURNACE MECHANICAL # Tap Hole Drill Machine(Hydro-pneumatic Machine(Hydro-pneumatic Equipment) Supplier- Rotamech, Kolkata Return Speed- 0.603m/s Rotation of drill bit- 395rpm Drill rod length- 4150mm Drill bit dia.- 38mm-65mm Hydraulic rated press- 100kgf/cm2 Hydraulic tank capacity- 800ltr Hydraulic oil- HLP68

2 Hydraulic operation

With two cylinder(Big & Small) Big cylinder- Rod dia- 90mm Bore dia-200mm Stroke- 800mm Small cylinder- Rod dia- 45mm Bore dia- 80mm Srtoke- 335mm 3 pneumatic operation

*forward, reverse & rotation Globe air motor & drifter *Globe air motor Make- Atlas Atlas Capco Model- RM310F *Drifter Make- Haryson Model- BBC120F


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#Mudgun Supplier- Shougang China Rated press- 20 MPa Max press- 25 MPa Hydraulic tank capacity- 800ltr Rated flow capacity- 210ml/rev. Min oil level- 600ltr Hydraulic oil-HLP68 *Operational sequence Swing, Tilt & Push Hydraulic cylindersClay pushing cylinder- Rod dia- 320mm Stroke- 1260mm Total pushing force- 1655kN Tilt cylinder- Rod dia- 45mm Bore dia- 70mm Stroke- 500mm Swing cylinder- Rod dia- 110mm Bore dia- 160mm Stroke- 1000mm

#Skip Charging system Volume – Volume – 4.5m3 4.5m3 Capacity- 9 tonne Inclination of bridge- 53 deg. *Skip Winch


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Rated elevating capacity- 7 tonne each car Elevating max speed- 2.5m/s Travel time- 54sec. Lenth of rope- 145m each No. of rope- 2 per car Dia of rope- 32mm Motor – Motor – 160kW 160kW DC drive, 1200rpm Skip winch drum dia- 1850mm Double herringbone type gear for skip winch drum Reduction of gear box- 26.92:1

# BLT(bell less top) system Burden tank consist of 4 valves 

3 Hydraulic



1 motorized

*burden receiving valve Bore dia- 80mm Rod dia- 45mm Srtoke- 370mm *Upper seal valve US1-Bore dia- 100mm Rod dia- 56mm Srtoke- 200mm US2- Bore dia- 80mm Rod dia - 45mm Srtoke - 370mm *Lower seal valve


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Bore dia- 80mm Rod dia- 45mm Srtoke- 560mm Other than burden tank it consist of 04 hydraulically operated valves *02 equalizing valve *02 pressure relief valve Equalizing valve detail: Bore dia- 80mm Rod dia- 40mm Stroke- 165mm Pressure relief valve detail: Bore dia- 100mm Rod dia- 55mm Stroke- 190mm

#BLT hydraulic system: Hydraulic tank- 1200ltr Hydraulic pump- 02 no’s Working pressure- 9.5 to 11MPa Accumulators- 05 no’s #Burden flow regulating valve: Motor – Motor – 5.5kW, 5.5kW, 1500rpm, AC servo motor #Disributor: Motor – Motor – 7.5kW, 7.5kW, 1440rpm, Induction motor #Chute: Motor - 7.5kW, 1440rpm 1440rpm,, AC servo motor motor


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#COOLING SYSTEM 1. Bottom hearth pipeline- 23 no’s 2. Row no. 1,2,3 No. of cooling plates- 28(each row) Two plates interconnection. 3. Row no. 4 No. of cooling plates- 32 No. of pipelines- 16 4. Row no. 5, 7, 8 & 9 No. of cooling plates- 28 No. of pipelines- 28 5. Row no. 6 No. of cooling plates- 28 No. of pipelines- 14 Two plates interconnection. 6. Row no. 10, 11, 12 No. of cooling plates- 28 No. of pipelines- 14 Two plates interconnection. 7. Row no. 13 & 14 No. of cooling plates- 28 No. of pipelines- 28 8. Row no. 15 No. of cooling plates- 28.

#STOVE AREA No. of stoves- 03 no’s Each stove has following valves: 1. Hot blast valve 2. Cold blast valve 3. Cold blast by pass valve


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4. Burner shut off valve 5. Gas regulating valve 6. Gas safety shut off valve 7. CA shutoff valve 8. CA regulating valve 9. Chimney valve 1 & 2 10. Chimney by pass valve 11. Branch bleeder Other than these valves in each stove there ar e three valves installed in the stove line. 1. Mixed air shutoff valve 2. Mixed air regulating valve 3. Back draft valve

# STOVE PROPER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Total height of stove Inner dia. of stove Dome shell inner dia. Dome brick work inner dia. Shell height Stove height to dia. ratio Checker chamber section area Combustion chamber section area Overall heat accumulating area of stove Checker type Overall height of checker Overall weight of checker Ceramic burner type Capacity of burner No of column Weight of each column No of grids No of beams


35.261m 7000mm 8000mm 6632mm 35800mm 5 118.79m2 118.79m2 3.14m2 19040m2 7 hole honey comb 27m 728 tone Sleeve type 32000m3/hr 18 635kg. 14 24

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#GAS CLEANING PLANT Dust catcher- Dry type



Venture 1: Type- adjustable throat venture Make- kirloskar AAF Ltd. Pressure drop- 600 to 800mmwc 800mmwc Water circulating rate- 110 m3/hr m3/hr Temp. at outlet- 60 to 70 deg.











Venture 2: Pressure drop-1600 to 2000mmwc Water circulating rate- 110 m3/hr Temp. at outlet- 50 deg. Cyclone separator: Type- centrifugal Make- kirloskar AAF Ltd. Diameter- 3650mm Height- 13300mm Pressure drop- 75mmwc Mist eliminator Type- chevron Make- kirloskar AAF Ltd. Size- 1000*600 & 1000*400 mm2 No of passes- 2 pass Pressure drop- 25mmwc Flare stack: Capacity- 90000Nm3/hr Inlet pressure- 900mmwc Overall height- 55m Type- tip burning No of pitot burner- 04 no’s Fuel for burner- LPG Gas holder


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Effective volume- 40000 m3 Operating pressure- 875mmwc-600mmwc Design pressure- 1000mmwc Design temperature- 70 deg.

STOCK HOUSE EQUIPMENT SPECIFICATION


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Weighing Hopper (WH): WH No. 01 to 03

Material Iron ore

m3 4.5

Capacity(tone) 5

04 to 08 05 to 09 06 to 07

Flux Flux Coke

0.2 1.2 4.5

3 3 5

Quadrant Gates (QG): 1. QG type A: Electrical actuator operated 1000mm stroke, 1000kg thrust QG 01, 02, 03, 10, 11, 12 – Iron Iron ore QG 04, 05, 08, 09 – Flux Flux QG 13, 14 – 14 – Intermediate Intermediate hopper 2. QG type B: Electrical actuator operated 600mm stroke, 500kg thrust QG 06, 07 – 07 – Coke Coke Vibroscreen 01 to 03 & 06 to 08 Make: International Combustion Qty: 06 no’s Wire deck size: 1390*1035 Wire mesh size: 10mm2 Feed material: I/O Feed rate: 200 TPH Separation: 10mm Motor: 11kW, 1000rpm Coupling: U coupling


Load cell Compression type 04 no’s Single ended 03 no’s Single ended 03 no’s Compression type 03 no’s

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Shaft: Carden Shaft Bulk density: 2.5 T/m3

Vibroscreen 04 & 05 Make: International Combustion Qty: 02 no’s Wire deck size: 1380*1130 Wire mesh size: 25mm2 Feed material: Coke Feed rate: 110 TPH Separation: 25mm Motor: 7.5kW Coupling: U coupling Shaft: Carden Shaft Bulk density: 0.5 T/m3

Vibrofeeders 05 to 12 Make: International Combustion Inclination angle: 10 deg Liner: 04mm thick Feed material: LS/DOLOMITE/Mn ore/Qtz. Bulk density: 1.6/1.65/2.0/2.5 T/m3 Feed size: 20 - 50 mm Feed rate: 260 TPH Feed rate variation – variation – 10% 10% - 100%


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WAGON TIPPLER Type of wagon tippler – tippler – Hydraside Hydraside Gross weight of wagon to be handled – handled – 110 110 tonne Max angle of rotation of tippler – tippler – 155° 155° No. of load cell provided: provided: 06 no’s No. of top clamp – clamp – 4 4 no’s Drive Unit: Hydraulic motor powered through power pack mounted outside of the tippler rotating body. Gear box: Planetary Tippler drive motor: 90kW, 1440rpm Type of wagon clamping: Hydraulic

SIDE ARM CHARGER Motor for power pack- 45kW, 1450rpm Charger drive type: Planetary gear box (1:77) Arm drive: Hydraulic cylinder 02 no’s

STACKER CUM RECLAIMER 

Materials to be handled Iron ore = 10 – 10 – 30 30 mm Coke = 20 – 20 – 80 80 mm Qtz = 20 – 20 – 50 50 mm Limestone = 20 – 20 – 50 50 mm Dolomite = 20 – 20 – 50 50 mm



Stockpile height – height – 12 12 m Travel length – length – 412 412 m



Capacity



While stacking


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I/O – I/O – 1500TPH 1500TPH Coke- 450 TPH Mn ore, Qtz, LS, Dolomite Dolomite – – 1500 1500 TPH 





While reclaiming I/O – I/O – 650 650 TPH Coke – Coke – 130 130 TPH Mn ore – ore – 500 500 TPH Qtz, LS, Dolomite - 400 TPH Drive details: Motor: 06 no’s, 7.5kW, 1500rpm AC variable frequency control



Coupling: Flexible brake coupling



Gear box: Vertical gear unit



Brake: Thrust operated jaw brake



Bucket Wheel: Type: cell less No. of bucket: 08 no’s no’s Bucket capacity: 250 ltrs. No. of discharge/min.: 28 RPM: 3.5 Motor: 45kW, 1500rpm, AC SCIM reversible Gear box: Planetary gear box (410:1)



Boom Conveyor: Belt width: 1400rpm Belt speed: 1.75 m/s Conveyor length: 33.407m Motor: 75kW, 1500rpm, AC SCIM reversible Gear box: Bevel helical triple reduction reduct ion gear, 28:1 Brake: DC electromagnetic brake 400Ø



Slewing mechanism: Slewing speed at centre of bucket wheel: 08 – 08 – 32 32 mtr/min Slewing angle: ±105° Motor: 02 no’s, 10kW, 150 – 1500rpm, 1500rpm, continuously variable DC drive Lifting mechanism for boom




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Type: hydraulic No. of cylinder: 02 Speed: 03 m/min. Type of cylinder: differential double acting cylinder 

BELT CONVEYOR DETAILS: Conveyors Conveyors Belt Length (m) 36 C1 299 C2 1249 C3 400 C4/C4A 400 C5/C6 95 C7/C8 54 C9A 63 C9B 142 C11/C11A 145 C12 165 BF1

Belt Speed (m/s) 1.75

Motor (kW)

Belt Size (mm)

30

1400

1.75

200

1400

1.75

280

1400

1.75

90

900/800

1.75

75

900

1.25

22

1000

0.5

11

650

0.5

5.5

650

0.5

11

650

0.5

30

500

0.75

7.5

500

PCI (PULVERIZED COAL INJECTION) EQUIPMENTS: 

ID FAN: Flow rate: 43900 – 43900 – 53000 53000 m3/ln Pressure: 2256 – 2256 – 2432 2432 Pa Working temp: 150 – 150 – 300°C 300°C RPM: 0 – 0 – 1480 1480



CA BLOWER: Flow rate: 3963 – 3963 – 4792 4792 m3/ln Pressure: 4256 – 4256 – 4662 4662 Pa Working temp: 20°C RPM: 2900



COAL MILL:


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Capacity: 15.1 TPH Diff. pressure: 5 – 5 – 6 6 kPa Inlet flow rate: 40000 m3/ln m3/ln Max inlet size: 50 mm Inlet temp.: 300°C Outlet temp.: 80 - 100°C Inlet moisture: <12% 

BAG FILTER: Flow rate: 40000 m3/ln Inlet temp.: <120°C Filtering speed: 0.41m/min Filtering area: 1610 m2 Density inlet: <1000 g/m3 Density outlet: <50 g/m3



PC BUNKER: Volume of tank: 140 m3 Weight level limit: 90T max 20T min



COAL BUNKER: Volume of tank: 130 m3 Weight level limit: 90T max 20T min



BELT CONVEYOR: NO. 01 & 02 Breadth: 650mm Speed: 1.25 m/s Quality: 120TPH Length: 86.4m & 84.82m.

ELECTRICAL OF BLAST FURNACE ;


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1.

SLD OF BLAST FURNACE

2.

SLD OF STACKER CUM RECLAIMER

3.

SLD OF WAGON TRIPPLER


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EOT CRANES – ELECTRIC OVERHEAD TRAVELLING CRANE are used for transporting transporting raw material,laddle material,laddle etc from one place to another. Components1. Current collector – It It is mainly ma inly used for power supply from down shop line to crane. As crane is movable,


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current collector is used which is fixed with respect to crane but movable with respect to dsl. 2. Switch fuse unit- It is used in power panel to prevent from short circuit.

3. Overloading relay- it is used in power panel to prevent the motor from overloading. 4. Miniature circuit circuit breaker and contactor

5. Transformer- A step down transformer is used in power panel. It reduces 44o V to 110 V. 6. Motor 7. Break 8. Limit switch 9. Timer 10.



Resistance box

Safety equipments for EOT cranes – 1.

Counter weight limit switch - it is

present in the main hoist. When main hoist raise


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to maximum limit of height, it touch the counter weight limit switch and entire power supply of crane is cut-off.

2.

Rotary gear limit switch- it has coupling

with the rope drum. There is the th e limit to revolve the drum in both direction d irection,, when the rotation exceed for the limitd value, then power supply is cit off.

3.

End limit switch – it is used for both long

travel and cross travel maximum limit, when crane touch the limit switch, power supply cut off.

4.

corner limit switch- it is situated as the

master panel. If there any fault is found in the crane then supply is cutoff by this switch.


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INSTRUMENTATION


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INSTRUMENTS IN AGLANCE AT JNIL BLAST FURNACE

Instrumentation is used to measure many parameters (physical values). These parameters include: 1. Temperature 2. Pressure, either differential or static 3. 3. Flow 4. Level 5. Weight

consists of Thermocouple Theory : A thermocouple, shown in Figure 1, consists two wires of dissimilar metals joined together at one end, called the measurement (“hot”) junction. The other end, where the wires are not joined, is connected to the signal conditioning circuitry traces, typically made of copper. This junction between the thermocouple metals and the copper traces is called the reference (“cold”) junction.


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Figure 1. Thermocouple. The voltage produced at the reference junction depends on the temperatures at both the measurement junction and the reference junction. Since the thermocouple is a differential device rather than an absolute temperature measurement device, the reference junction temperature must be known to get an accurate absolute temperature reading. This process is known as reference junction compensation (cold junction compensation.) Thermocouples have become the industry-standard method for cost-effective measurement of a wide range of temperatures with reasonable accuracy. They are used in a variety of applications up to approximately +2500°C in boilers, water heaters, ovens, and aircraft engines—to name just a few. The most popular thermocouple is the type K , consisting of Chromel ® and and Alumel ® (trademarked nickel alloys containing chromium, chromium, and aluminum, aluminum, manganese, and silicon, respectively), with a measurement range Type K (Chromel (Chromel / Alumel)

Type K is the 'general purpose' purpose ' thermocouple. It is low cost and, owing to its popularity, it is is available in a wide wide variety of probes. Thermocouples are available in the -200°C to +1200°C range. Sensitivity is approx 41uV/°C. Use type K unless you have a good reason not to Type S (Platinum S (Platinum / Rhodium)

Suited for high temperature measurements measurements up to 1600°C. Low sensitivity (10uV/vC) and high cost makes them unsuitable for general purpose use. Due to its high stability type S is used as the standard of calibration for the melting point of gold (1064.43°C). (1064.43°C). Type J (Iron J (Iron / Constantan)

Limited range (-40 to +750°C) makes type J less popular than type K. The main application is with old equipment that cannot accept 'modern' thermocouples. J types should not be used above 760°C as an abrupt magnetic transformation will cause permanent decalibration.

What are Rtds?


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Resistance Temperature Detectors or RTDs for short, are wire wound and thin film devices that measure temperature because of o f the physical principle of the positive temperature coefficient coefficient of electrical resistance of metals. metals. The hotter they become, the larger or higher the value of their electrical resistance. They, in the case of Platinum Plat inum known variously as PRTs and PRT100s, are the most popular RTD type, nearly linear over o ver a wide range of temperatures and a nd some small enough to have response times of a fraction of a second. They are among the most precise temperature sensors available with resolution and measurement uncertenties or ±0.1 °C or better possible in special desions. Usually they are provided encapsulated in probes for temperature sensing and measurement with an external indicator, controller or trans mitter, or enclosed inside other devices where they measure temperature as a part of the device's function, such as a temperature controller or precision thermostat. The Advantages of RTDs

The advantages of RTDs include stable output for long period of time, ease of recalibration and accurate readings over relatively narrow temperature spans. Their disadvantages, compared to the thermocouples, are: smaller s maller overall temperature range, higher initial cost and less rugged in high vibration environments. They are active devices requiring an a n electrical current to produce a voltage drop across the sensor that can be then measured by a calibrated read-out read -out device

Platinum RTD Output Equation

ASTM Standards E 1137 for Industrial Platinum Resistance Thermometers specifies that the resistance-temperature relationship for


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such devices for the range 0 °C to 650°C, to within the tolerances given below, will be described by the equation: R(t) = R(0)[1 + At +Bt^2] Where: t = temperature (to ITS-90) (to ITS-90),, °C, R(t) = resistance at temperature t, R(0) = resistance at 0°C A = 3.9083 * 10^-3(°C), and, B = -5.775 * 10^-7(°C^2).

LOOP DIAGRAM


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Thermocouple/RTD

mV/ohm

Temperature Transmitter

4-20 mA

DCS


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PRESSURE MEASUREMENTS

DEFINITION OF PRESSURE Absolute pressure The pressure is referenced referenced to zero absolute pressure and has units units of psia. Absolute pressure can only have a positive value.

Gauge pressure The pressure is referenced to atmospheric pressure and by convention co nvention is measured in the positive direction, i.e. 7 psig.

Vacuum pressure The pressure is is referenced to atmospheric atmospheric pressure and by convention convention is measured in the negative direction, i.e. -50 mm Hg.

DP TRANSMITTERS


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•

DP i.e Differential pressure transmitters are used for the measurement of flow and level.

Supply: 24v dc Output: 4-20 mA

Types of Flow meters 1. Magnetic Flow meters 2. Vortex Flow meters 3. Ultrasonic Flow meters 4. Coriolis Mass Flow meters 5. DP type flow meter

Types of level measurem measurement ent 1. Radar 2. Ultrasonic 3. Capacitance


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4. Differential pressure 5. Conductive 6. RF Admittance Level Switches

Principles of Radar Level Sensor

The antenna on a radar level gauge generates millions of very short 1 Nano second microwave pulses pulses every second. Each pulse is directed and transmitted to and reflected from a product surface. The elapsed time period between transmission and reception reception of the signal at the the speed of light is measured and calculated as a distance. This continuous stream of


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pulses gives real time level level information updated and is evaluated evaluated many times a second. Radar level sensors work with safe, low emitted power in the c (4 to 8 GHz) and k-band (18 to 26.5 GHz)frequency range. The proven ECHOFOX signal processing selects the correct level echo reliably. Adjustment by filling and emptying the vessel is not necessary, it can ca n normally be done with simple input of vessel dimensions. dimensions.

Principles of Conductive level Sensor


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Principles of Loadcell


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Application Application of loadcell loadcell



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Opacity Meter Opacity meter is used for t he measurement of opacity and dust concentration within the flue gas.


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2. Measurement Principle

Consider the two identical transceiver units positioned at either s ide of the flue(or duct), unit 1 and unit 2. The transmi trans missivity ssivity of light from unit 1 to unit 2 (unit 1transmitting) can be represented by the equation : t12 = K1 (D21/D11) where : K1 = gain constant to produce t = 1 (100% transmissivity, clean air condition) D11 = the detector output at unit 1 (internal reference level) D21 = the detector output at unit 2

The transmissivity of light from unit 2 to unit 1 (unit 2 transmitting) tra nsmitting) can also be represented by the equation equatio n :

t21 = K2 (D12/D22) (D12/D22 )

where : K2 = gain gain constant to produce produce t = 1,

D12 = the detector output

at unit unit D22 = the detector output output at unit 2 (internal reference reference level)

Control valve 

Control valves are used to control the process


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Parameters such as flow, flow, pressure, temperature, temperature, level. level.

It works under force balance principle. 

Control valve accessories include:



AFR-air filter regulator



I/p- current to pressure



Positioner.



Control valves are of two types:



Air to close



Air to open


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Flow diagram of control valve

Instrument air (5-6 kg /cm2)

AFR

I/P (0.2 -1 kg/cm2)

(1.5kg /cm2)

Positioner

AFR (2-3 kg/cm2)

I to P converter •

•

•

I to P converts an analog signal (4 to 20 mA) to a proportional linear pneumatic output (.2 to 1 kg/cm2). Its force balance principle is a coil suspended in a magnetic field on a flexible mount. At the lower end of the coil is a flapper valve that operates operates against a precision ground nozzle to create a backpressure on the servo diaphragm of a booster relay. The input current flows in the coil and produces a force between the coil and the flapper valve, which controls the servo pressure and the output pressure.

Positioner


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•

Positioner consist of air supply port , signal input port, out put port.When positioner get input signal signal ,it compare with stem position and output is generated and signal boosted sufficiently to operate the valve . It uses force balance system.

•

•


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I/O’s defined in DCS •

DI signals – Signals Coming from swicthes,sensors,etc swicthes,sensors,etc DI FIM card -32 channels are used.

•

DO signals - Signals given given to drives,shut drives,shut off valves valves etc. etc. DO FIM card-32 channels are used.

•

AI Signals – Signals coming from transmitters,etc transmitters,etc AI FIM card – 16 channels are used.

•

AO signals – Signals given to control valves,regulating power cylinders,etc AO FIM card – 8 channels are used.


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