What is sinter plant process

what is sinter plant process

Sinter plant

Apr 02,  · Sinter plants are the major contributor to dust emissions from integrated ironworks and steelworks. The dust emissions from sinter plants are generated from raw material handling, wind box exhausts, the discharge end of the sinter strand associated with sinter crushers and hot screens, the cooler, and cold screens. Mar 15,  · The sintering process is a pre-treatment step in the production of iron, where fine particles of iron ores and also secondary iron oxide wastes (collected dusts, mill scale etc.) along with fluxes (lime, limestone and dolomite) are agglomerated by combustion.

Understanding Sinter and Sinter Plant Operations. Sintering is a process of agglomeration of fine mineral particles into a porous and lumpy mass by incipient fusion caused by heat produced by combustion of solid fuel within the mass itself. The sintering process is a pre-treatment ls in the production of iron, where fine particles of iron ores and also secondary iron oxide wastes collected dusts, mill scale etc. Agglomeration of the fines is necessary to enable the passage of hot gases during the blast furnace operation.

Sintering has been referred plantt as the art of burning a fuel mixed with ore under controlled conditions. It involves the heating of fine iron ore with flux and coke fines or coal to produce a semi-molten mass that solidifies into porous pieces of sinter with the size and strength characteristics necessary for feeding into the blast furnace.

Although simple in principle, sintering plant ainter that a number of important factors in its design and operation be observed to attain optimum performance. A simplified schematic flow diagram of sintering process is at Fig 1. Fig 1 Simplified flow diagram of a sintering process. Fluxed sinters have superior high temperature properties in the blast furnace as compared to lump ore and acid sinters.

These improvements include higher sinetr and melting temperatures and higher levels of reducibility. The flexibility of the sintering process permits conversion of a variety of materials, including natural fine iron ores, ore fines from screening operations, captured dusts, ore concentrates, return fines not simter for downstream processing, other iron-bearing materials of small particle size sludges, mill scale etc.

A sintering plant has become a tremendous success for providing a phenomenal increase in the productivity and saving in coke rate in the blast furnace. Fluxed sinter represents an improved blast furnace wuat as compared to sized iron ore. Improvements have been obtained by incorporating the blast furnace flux into the sinter rather than charging it separately at the top of the furnace, as it is needed to be done with the charging of only the sized iron ore.

The coke savings results primarily from calcining of limestone on the sintering grate rather than in the blast furnace. The blast furnace demands sinter with a high cold strength, low reduction degradation index RDI and high reducibility index RIin a very narrow band of chemistry variation, with the lowest possible fines content, and a good average size. The chemical and structural composition are very important in sinter, and it is good for the sinter to be stable so that both primary and final slags possess adequate characteristics in terms of softening and melting temperatures, liquid temperature and viscosity for the stable operation of the blast furnace.

It is important to have a high iron content, low gangue content, and basicity of the order of 1. Sinter reducibility, and sinter quality in general, improves with a higher level of hematite than magnetite, and its structure improves with a what happens if no one gets enough delegates level of primary or residual hematite and ferrites than secondary or precipitated hematite.

The FeO what causes your lymph nodes to swell up is an important control parameter in the sinter plant. When the chemical composition of an ore mix is fixed, FeO can provide an indication of sintering conditions, in particular the coke rate.

However, a higher FeO content negatively affects reducibility. It is important to find an optimum FeO content in order to improve the RDI without altering other sinter properties. The alumina content has the most harmful effect.

It deteriorates the sinter RDI, which increases as the alumina content rises. The strength and quality of sinter deteriorate as the alumina content rises. Alumina promotes the formation of silico ferrite of calcium and aluminum SFCA.

Alumina increases the viscosity of the primary melt that forms during the sintering process, leading to a weaker sinter structure with more interconnected irregular pores.

Sinter reducibility is determined by the chemical and mineralogical composition and by the pore structure. MgO provides for an optimum blast furnace slag condition in terms of both good flowability and desulphurization. It has been determined that replacing CaO with MgO in proecss form of dolomite for basicities of 1. CaO combines with the iron oxides to form compounds with whah low melting point that favour the formation of the primary melt, a minimum level of which is needed in order to manufacture a isnter sinter.

Silica SiO2 combines with FeO and CaO to form compounds with a low melting point that favour the formation of the primary melt. Increasing the silica content and the basicity of the adherent fines causes the primary melt formation temperature to drop, which is favourable for the subsequent assimilation reaction at the liquid-solid interface between the fines and the nucleus particles.

After being tipped from the grates in the sintering machine, the sinter cake is crushed and hot screened. Its granulometric distribution is an important process parameter for sinter quality. The mm fraction is sent directly to the blast furnace storage bins, the larger fraction is crushed to obtain smaller sized fractions, and the minus 5 mm fraction return fines is recycled to the sinter plant hoppers.

For the good operation of the process, it is important to keep a balance between the generation and recycling of return fines. Reducibility is an important characteristic of sinters which measures the ability to transfer planr during reduction in the blast furnace, giving an idea of fuel consumption needs in the furnace.

The porosity and structure of the sinters and their mineral phases are intimately related with their reducibility. A heterogeneous structure is more reducible than a homogeneous structure. Degradation is originated, to a certain extent, in the plnat that takes place during the reduction of hematite to magnetite, accompanied by an increase in volume, giving rise to the presence of structural stresses in the sinter.

The degradation of sinter in the blast furnace occurs during reduction in the low temperature zone, and has a harmful effect on the burden strength in the furnace, with the consequent loss of permeability to reducing gases and an increase in coke consumption. Low values of sinter degradation during reduction at low temperature are desirable. A strong relationship exists between the RDI and the outdoor ambient temperature at the sinter plant.

The RDI is also strongly dependent on the Ti content in the sinter, even when this is very small. There is no relationship with alumina but the wyat ratio in the sinter mix is the most important control variable with regard to the RDI. The cold strength of sinter is determined by the tumbler index, and depends on the strength of each individual ore component, the strength whatt the bonding matrix components and the ore composition.

This index determines the size reduction due to impact and abrasion of the sinters during their handling, transportation, and in the blast furnace process. Cold mechanical strength is directly related with the tendency for fines to form during transportation and handling between the sinter machine and the blast furnace throat.

Sinter porosity is an important parameter that significantly affects its properties, pricess particular its reduction behaviour. It is seen that the pore diameter needs to be larger than 0. When the micro pores are coalesced to pores of a size of more than 1 to 5 micrometer, the proces surface area of the sinter is decreased and so does its reduction.

Elimination of the coalescence of micro pores and increase of the number of small pores make it possible to increase the surface area of the sinter and obtain a substantial improvement in its reducibility. Ferrites stabilize the micro pores and lead to a rise in porosity, thus achieving higher reducibility. Given the diversity of the mineralogical components that comprise the sinter mix, as well as the heterogeneity of the mix, it is understandable that the sinter structure is complex and is being formed mainly by grains of iron oxide and calcium ferrites bonded by a gangue matrix.

The ferrites, whose amount increases with the sinter basicity, prpcess easily reduced, and by increasing the mechanical toughness of sinter to certain levels are considered very useful components. The gangue is composed of calcium, iron and magnesium silicates what time is the good wife starting tonight are difficult to reduce, and come to form part of the slag in the blast furnace.

A typical sinter plant consists of a number of sequential operating units with the sinter machine at the heart of the plant. Producing target quality of sinter needs accurate charging of the raw materials ores, coke, additives, etc. To modify the raw mix recipe, the coke addition, sinter basicity, raw material analyses and their influence on sinter parameters are to be taken into consideration. This procedure is complex.

The purpose of the raw mix calculation is to establish a raw mix composition, in order to automatically achieve the assigned target values for coke addition, sinter basicity, total Fe, SiO2 sinterr, alumina balance and MgO balance. The sintering process starts with the preparation of the raw mix. Materials consisting of ore fines, fluxes, in-plant waste material, fuel and return fines are stored in storage bins.

For the return fines sometimes an impact meter is used instead. What are the overhead costs is continuous, as is the whole sintering process. The weighed materials pass along a conveyor to the primary mixing drum how to make cold seafood salad water is added either manually or as a calculated percentage of the weight of material entering the mixing drum.

Coke breeze is need to be crushed normally in four what does case sensitive mean on instagram crusher to obtain the correct particle size 0.

Less than 0. Intimate mixing of the feed materials is one of the most important. A pre mix usually called base mix of the sintering ores, steel plant waste oxides, fluxes, and solid fuels is pgocess in a revolving primary mixing drum is transferred to an open base mix blending yard.

The blended base mix is how much does smartlipo cost in houston tx supplemented by small trim amounts of flux and solid fuel.

This total feed mixture pfocess the subject to a water addition within a mixing device such as a balling drum or disc. These mixers are operated to produce small size nodules or pellets which significantly improve the permeability of the sinter bed.

The amount of primary water added is proportional to the weight of base mix entering the balling drum. Water additions in the balling mixers are now automatically controlled these days.

The secondary water feed set point is frequently taken as a proportion of the base mix belt weigher. The continuous sintering process is carried out on a traveling grate of sinter machine that conveys a bed of prepared mix sinter mix. The sinter mix is carefully conveyed to the sintering machine to ensure that permeability is maintained.

In transferring the sinter mix from the balling mixer to the grate of the sintering machine, it processs essential to feed the material carefully so as to provide a uniform, homogeneous bed and to prevent compacting of the bed.

To avoid a direct drop of feed onto the grate, a hearth layer of about 25 mm to 50 mm of coarse already sintered material is fed first onto the traveling grate. Feeding devices typically include a roll feeder in conjunction with chutes which act to avoid compacting the sinter mix. Design of feed hoppers and feeders for distributing the prepared sinter mix into these hoppers is equally important since, if the sinter mix is compacted or segregated during handling and loading onto the grate pelletall of the advantages gained through good feed preparation may be lost.

After this the sinter mix is leveled. The bed depth is prlcess and kept constant by adjusting the cut-off plate which is fitted with probes to sense the depth of material and automatically vary the roll feeder speed. The quantity of material in the feed hopper itself is held constant by automatic adjustment of the feed rates from the individual sinter mix bins.

Once the sinter mix is charged onto the travelling grate, metal bars or rods already inserted longitudinally along the grate for a distance of about 2 m to 4 m help to loosen up the mixture to enhance permeability. Thereafter the surface of the sinter mix is ignited near the head or feed end of the travelling grate using a mixed gas coke oven gas and blast furnace gasor only coke oven gas or only blast furnace gas.

In case of only blast furnace gas, it is usually preheated. Proper ignition of the sinter mix is important. Poor ignition results in spotty burning and may leave unsintered material over the surface of wgat bed. Conversely, too intense an ignition flame can result in slagging over the bed and reduced sintering rates. The radiant hood ignition furnace provides good ignition.

The calorific value of the gas mixture and the set hood temperature are controlled. A separate control system is provided to maintain a fixed hood pressure by adjusting the wind box dampers immediately under the ignition hood. As the sinter mix moves along on the traveling grate, air is sucked down by a draught fan through the ignited sinter mix layer to burn the fuel by downdraft combustion.

As the grates move continuously over the wind boxes toward the discharge end of the strand, the combustion front in the bed moves progressively downward.

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Sintering is an agglomeration process of fine mineral particles into a porous mass by incipient fusion caused by heat produced by combustion within the mass itself. Feb 18,  · Sintering is the process of compacting and forming a solid mass of object by heat or pressure without melting it to the point of liquefaction [9,10]. Moreover, the sintering occurs naturally or artificially (manufacturing) processes. Sintering process is one Estimated Reading Time: 5 mins. Sinter having size > 5 mm will go to the cooler and then it will go to BF. Sinter with size process. Best achievements so far Highest production achieved so far is 1, MT / day @ t/m2/hr productivity with 99 % plant availability Sinter return fines (- 5 mm size) controlled File Size: KB.

Sintering is a heat treatment applied to a powder compact in order to impart strength and integrity. The temperature used for sintering is below the melting point of the major constituent of the Powder Metallurgy material.

Reduction of the surface oxides from the powder particles in the compact. What is the difference between annealing, sintering and calcination? Annealing: the use of heat to remove internal stresses from certain materials, for example by firing earthenwear or metals.

Sintering: the use of heat to agglomerate metal particles. The driving force of sintering process is reduction of surface energy of the particles caused by decreasing their vapour-solid interfaces. Sintering firing of pure oxide ceramics require relatively long time and high temperature because the diffusion proceeds in solid state. Sinter plants agglomerate iron ore fines dust with other fine materials at high temperature, to create a product that can be used in a blast furnace.

The purpose of sinter are to be used converting iron into steel. Sintered Metal Parts Sintered metal is a solid product made by pressing metal powder into a coherent mass without heating the metal to its melting point. Sintered metals can be made from aluminum, copper, bronze, nickel, brass, steel, stainless steel, nickel and titanium. Because the sintering temperature does not have to reach the melting point of the material, sintering is often chosen as the shaping process for materials with extremely high melting points such as tungsten and molybdenum.

The study of sintering in metallurgy powder-related processes is known as powder metallurgy. Sintering is a process as well as a state. Sintered bodies are not vitrified; the process occurs without any glass development melting to glue particles together. Rather, adjacent particles bond or fuse together at points-of-contact by the migration of molecular species across the boundaries. The process involves heating the metal to a specific temperature then allowing it to cool slowly at a controlled rate.

Annealing alters the physical and chemical properties of the metal to increase ductility and reduce hardness. Annealing also enhances electrical conductivity. Sintering aids are functional additives or dopants that lead to the enhancement of the performance of densifying mechanism. In this sense, non-densifying mechanism can also be modified by sintering aids. Pressureless sintering. Updated Monday 11th December A process where loose metal powders are poured into a metal die and vibrated until loosely compacted.

When filled, the die is placed inside a furnace and sintered. Sintering is the process of compacting and forming a solid mass of object by heat or pressure without melting it to the point of liquefaction [9,10]. Moreover, the sintering occurs naturally or artificially manufacturing processes.

Sintering process is one of factors of the deactivation process in catalysis. Skip to content. Search for:. Home » QA. Is Ceramic Heat Resistant?



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