15 days Industrial Training Report File

On Sinter & LDP (10/03/2017-24/03/2017)

Submitted To Submitted By

Mr. UC Mishra Shani Kumar Singh

General Manager Roll No-1344948

Sinter & LDP Branch-Mechanical

Jindal Steel and Power Ltd,Raigarh Semester-8th

College-CGC-COE,Mohali

Signature-
 Acknowledgement
It is matter of great pleasure and privilege for me to present this report of 15 days
industrial training in Sinter & LDP Plant. Though this report, I would like to thank numerous
people whose consistent support and guidance is standing pillar in architecture of this
report.

To begin with, my sincere thanks to Ateet Namdeo, AGM-HR & ES of Jindal Steel and
Power Ltd for providing me an opportunity to get acquainted with various activities of
different Plant. I express my thanks to Mr. UC Mishra, General Manager of Sinter & LDP
Plant for extending co-operation to enable me to get acquainted with the various activities
of their department.

I would like to express my sincere gratitude to my guide Mr. Kuljeet Singh. I was
privileged to experience a sustained enthusiastic and involved interest from his side.

I would like to express my sincere thanks towards members of Maintenance, Operation

department for making me a deep knowledge about various activities of Sinter & LDP plant.

Shani Kumar Singh

 INDEX

1. Introduction of Jindal Steel & Power Limited

2. Facilities at Raigarh Plant Include
3. Introduction of LDP Plant
4. Process & Layout of LDP Plant
5. Major Equipments or Station of LDP Plant
 Bunker
 Vibro Feeder
 Screen
 Bucket
 PFR kiln
 Product handling System
 Waste Gas Fan
 BF Gas Booster
6. Introduction of Sinter Plant
7. Process & Layout of Sinter Plant
8. Major Equipments or Station of Sinter Plant
 Sinter Machine
 Sinter Cooler
 Mixing and Nodulising Drum
 Sinter Breaker
 Double Roll Crusher
 Waste Gas Fan
 Electrostatic Precipitator
 Dedusting Fan
 Sinter Furnce
 Feed Hopper Bin
 Introduction of Jindal Steel & Power Limited

 JSPL is an industrial powerhouse with a dominant presence in steel, power, mining

and infrastructure sectors.
 Turnover of approx. US$ 3.3 billion, JSPL is a part of about US$18 billion diversified
Jindal Group conglomerate.
 In terms of tonnage, it is the third largest steel producer in India.
 The company manufactures and sells sponge iron, mild steel slabs, Ferro chrome,
iron ore, mild steel, structural, hot rolled plates and coils.
 JSPL operates the largest coal-based sponge iron plant in the world and has an
installed capacity of 3 MTPA (million tons per annum) of steel at Raigarh in
Chhattisgarh.
 JSPL has been rated as the second highest value creator in the world by the Boston
Consulting Group.
 The 11th fastest growing company in India by Business World and has figured in the
Forbes Asia list of Fab 50 Companies.
 In Oman (Middle East), the company has set up a US $ 500 million,1.5 MTPA gas-
based hot briquetted Iron(HBI) plant. It has now added a 2MTPA integrated Steel
Plant.
 Alongside contributing to India’s growth story the company is driving an ambitious
global expansion plan in Africa, Australia and Indonesia.
 It deploys its resources to improve infrastructure, education, health, water,
sanitation, environment and so on in the areas it operates in. It has won several
awards for its innovative business and social practices.
 Facilities at Raigarh Plant Include

 DRI Plant-4nos. of 500TPD (0.72 Million TPA) and 6nos. of 300TPD rotary kilns (0.72
Million TPA)
 DRI Plant-4nos. of 500TPD (0.72 million TPA) and 6nos. of 300TPD rotary kilns (0.72
million TPA)
 0.8 million TPA Coke Oven Plant
 2.5 million TPA sinter Plant
 1.25 million TPA and 0.42 million TPA Blast Furnace
 2.0 million TPA and 1.25 million TPA steel melting shop
 2 Vacuum degassing Unit
 RH degassing Unit
 1 No. Single strand slab Caster
 1 No. of 6-strand billet-cum-round Caster and 1 No. 6 Strand billet caster
 2 No of 4-strand combi-caster
 Rail and Universal beam Mill(RUBM) (0.75 million TPA)
 Plate-cum-coil MILL(1.0 million TPA)
 Submerged arc furnace(SAF)(0.03 million TPA)
 Oxygen Plant 37683 Nm^3 per hour
 Lime and Dolomite Calcination Plants(0.4165 million TPA)
 358 MW Captive Power Plant(CPP)
 0.7 million TPA medium and light structure mill
 Introduction of LDP Plant

Calcination or calcining is a thermal treatment process to bring about a thermal

decomposition. The process takes place below the melting point of the product. The name
calcination is derived from the Latin word ‘Calcinare’ which mean to burn lime. Limestone is
a naturally occurring mineral. It exists nearly all over the world. The chemical composition of
this mineral varies greatly from region to region as well as between different deposits in the
same region. Therefore, the end product from each natural deposit is different. Typically
limestone is composed of calcium carbonate (CaCO3), magnesium carbonate (MgCO3), silica
(SiO2), alumina (Al2O3), iron (Fe), sulphur (S) and other trace elements.
Limestone is one of the most basic raw materials employed in the steel industry and is used
both in iron making and steel making processes. Lime (CaO) is one of the oldest chemicals
known to man and the process of lime production is one of the oldest chemical industries.
Quicklime was produced in US as early as 1635 in Rhode Island. Technical progress which
was non existing in centuries past, has rapidly advanced the lime industry during the last
fifty years in the area of process methods and design.

Calcined dolomite is also known as dolime or doloma. When dolomite is heated at a high
temperature then it loses its reactivity and the product is known as burnt dolomite. Burnt
dolomite is a refractory material and is used in the manufacture of basic refractories.

Various uses of lime and dolomitic lime in the steel plant include its use in the production of
basic sinter, as a desulphurizing agent, as a slag forming material to remove impurities in
basic oxygen furnace (BOF) and in electric arc furnace (EAF), in secondary steel making,
neutralizing of waste acid liquors, and in the treatment of water. A growing use of lime is in
the treatment of stack (flue) gases. Lime absorbs and neutralizes sulphur oxides of these
gases.

In sinter plant finely divided lime/dolomitic lime is usually added to the sinter mix to assist
in the binding of the material and to improve sinter machine productivity while assisting in
the production of stronger sinter.

Both high calcium and dolomitic lime enjoys its most extensive use as a flux in refining of
the steel in BOF and EAF. Lime is particularly effective in removing phosphorus, sulphur,
and silica, and, to a lesser extent, manganese. Lime also has important uses in secondary
refining of steel and in the manufacture of steel products.

Process & Layout of LDP Plant

Calcination reactions usually take place at or above the thermal decomposition

temperature. This temperature is usually defined as the temperature at which the standard
Gibbs free energy is equal to zero. In case of limestone calcination, a decomposition
process, the chemical reaction for decomposition of the limestone is

CaCO3= CaO + CO2 (g)

Calcination of calcium carbonate is a highly endothermic reaction, requiring 755 M Cal of

heat input to produce a ton of lime. The reaction begins when the temperature is above the
dissociation temperature of the carbonates in the limestone. This typically is between 850
deg C and 1340 deg C. Once the reaction starts the temperature must be maintained above
the dissociation temperature, and carbon dioxide evolved in the reaction must be removed.
Dissociation of the calcium carbonate proceeds gradually from the outer surface of the
particle inward, and a porous layer of calcium oxide, the desired product, remains. The
following factors affect the calcination.

Crystalline structure affects the rate of calcination, internal strength of limestone and
resultant crystal size of lime after calcination. The smaller crystals agglomerate during
calcination and forms larger crystals which in turn cause shrinkage and volume reduction.

Bunker

Vibro Feeder

Screen

Weighing Hopper

Trap

Bucket

Charging Hopper

Kiln Furnace

Discharge Table

Disharge Trap

Disharge Hoppper

Disharge Vibrofeeder

Product Handling System

Dolomite is also known as dolime or doloma. When dolomite is heated at a high

temperature then it loses its reactivity and the product is known as burnt dolomite. Burnt
dolomite is a refractory material and is used in the manufacture of basic refractories.

Various uses of lime and dolomitic lime in the steel plant include its use in the production of
basic sinter, as a desulphurizing agent, as a slag forming material to remove impurities in
basic oxygen furnace (BOF) and in electric arc furnace (EAF), in secondary steel making,
neutralizing of waste acid liquors, and in the treatment of water. A growing use of lime is in
the treatment of stack (flue) gases. Lime absorbs and neutralizes sulphur oxides of these
gases.

In sinter plant finely divided lime/dolomitic lime is usually added to the sinter mix to assist
in the binding of the material and to improve sinter machine productivity while assisting in
the production of stronger sinter.

Major Equipments used in LDP Plant

Bunker

Proper automatic feeding of bulk material into sorting and feeding units for further
processing. Depending on the objects to be fed and the technical requirements to be met,
for this purpose bunker is used.

Bunker
Dolomite 1(No of Bunker)
Lime stone 2(No of Bunker)

Vibro Feeder

A vibratory feeder is an instrument that uses vibration to "feed" material to a process or

machine. Vibratory feeders use both vibration and gravity to move material. Gravity is used
to determine the direction, either down, or down and to a side, and then vibration is used to
move the material. They are mainly used to transport a large number of smaller objects.
A belt weigher are used only to measure the material flow rate but weigh feeder can
measure the flow material and also control or regulate the flow rate by varying the belt
conveyor speed.

Screen

A screen filter is a type of filter using a rigid or flexible screen to separate sand and other
fine particles out of water for irrigation or industrial applications.[1] These are generally not
recommended for filtering out organic matter such as algae, since these types of
contaminants can be extruded into spaghetti-like strings through the filter if enough
pressure drop occurs across the filter surface.

It’s purpose is to filter the below size particle from the raw material.Further that below size
raw material transferd to the hopper with the help of Conveyor.

Charging Bucket

Charging Bucket is used for transfer the raw material like dolomite & Sinter to the charging
Hopper.For this purpose a bucket is used which is drive through rope and motor
arrangement or rail is supported on the rail by means of support rail.

PFR Kiln

A PFR kiln (parallel flow regenerative shaft kiln) consists of two vertical shafts and a
connecting crossover channel. Both shafts work with each other. While one calcines the
product, the other preheats the stone. In the burning shaft the lime is calcined in parallel

flow. The hot combustion gases are then transferred through the crossover channel to the
non-burning shaft where they preheat the limestone in counter flow in the upper area of
the shaft. The flow direction of the gases is reversed at regular intervals. This allows the
regenerative preheating of the stone to take place (the stone in the preheating zone of the
kiln acts as heat exchanger) and thus for the maximum use of the heat contained in the kiln
gases.

The principle of calcination in parallel flow is ideal for the production of high-reactive
quicklime. A PFR kiln from Maerz processes up to 800 tons of burnt lime per day. Gaseous,
liquid or pulverised solid fuels as well as different combinations of these may be used.
Depending on the required output and grain size of the limestone to be processed.

Product Handling System

Product of LDP Plant is lime and dolo which is discharge after cooling in PFR Kiln to the
discharge table there after with the help of vibrofeeder the product is discharge to the Belt
Conveyor through which the product is supplied to the desired station or Plant. For
Conveyor Drive there is a motor which drives the drive Pulley.
Waste Gas Fan ID Fan

Waste gas ID Fan is used kiln to suck the waste gases from the furnace or we can say that
the continuous flow of flue gases inside the kiln is maintained. ID fan is used to extract the
air from Kiln post combustion via (Electrostatic Precipitator if present) to exhaust through
the chimney.

BF Gas Booster

Gas pressure boosters pump low pressure gas up to higher levels as required by
downstream equipment. The discharge pressure is the sum of the incoming supply pressure
and the pressure added by the booster. Blast furnace gas coming from the Blast furnace
need to increase the pressure and to maintain the the flow according to the the
requirements for this pupose Gas Booster is used.

BF Gas Booster
 Introduction of Sinter Plant

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 final product, a
sinter, is a small, irregular nodule of iron mixed with small amounts of other minerals. The
process, called sintering, causes the constituent materials to fuse to make a single porous
mass with little change in the chemical properties of the ingredients. The purpose of sinter
are to be used converting iron into steel.

The purpose of the sinter plant is to process fine grained raw materials into a coarse grained
iron ore sinter, ready to be charged to the blast furnace. Sintering of fine particles into a
porous clinker – sinter – is necessary to improve the permeability of the burden, making
reduction easier. A high quality sinter has high reducability, which reduces the intensity of
blast furnace operations and reduces coke demand.

In the sintering process a blend of different ores, ferrous containig materials – such as flue
dust – and fine coke particles (known as coke breeze) is deposited on a large travelling
grate. The coke at the top of the blend is ignited by gas burners, that can be fueled by coke
oven gas, blast furnace gas, or natural gas. As the grate moves, air is sucked from the top
through the mixture, enabling combustion through the entire layer and complete sintering –
where the temperatures may reach 1300 – 1480 oC. At the end of the strand, the material is
cooled by air and finished sinter is size-screened.

Sinter Plant
 Process and Layout of Sinter Plant

During mining operation of Iron ore,big boulders are crushed to smaller size suitable for
blast furnace charging. During this operation approximately 60%fines is generated which
contains Fe but can not be charged in the blast furnace due to the size constraint

In view of the above it has become essential to agglomerate the fines to a desired size which
can be charged in the blast furnace. Sintering is the most favorable agglomeration process
which can be used for the agglomeration of fines into a porous mass by incipient fusion.

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.

After compaction, neighbouring powder particles are held together by cold welds, which
give the compact sufficient “green strength” to be handled. At sintering temperature,
diffusion processes cause necks to form and grow at these contact points.

There are two necessary precursors before this “solid state sintering” mechanism can take
place:-

 Removal of the pressing lubricant by evaporation and burning of the vapours

 Reduction of the surface oxides from the powder particles in the compact.
These steps and the sintering process itself are generally achieved in a single, continuous
furnace by judicious choice and zoning of the furnace atmosphere and by using an
appropriate temperature profile throughout the furnace.

Chemical Reactions

Fe2O3 + CaO 2Fe2O3CaO at 1200°C

2Fe2O3.CaO + Al2O3.SiO2 Fe2O3CaO.Al2O3.SiO2 (SFCA)

 Major Equipments or Station of Sinter Plant

Sinter Machine

Sinter Machine is used to 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 final product, a
sinter, is a small, irregular nodule of iron mixed with small amounts of other minerals. The
process, called sintering, causes the constituent materials to fuse to make a single porous
mass with little change in the chemical properties of the ingredients. The purpose of sinter
are to be used converting iron into steel.

Pallet cars are one of the important components of a sinter machine. Sinters are made by
igniting the surface of the raw material fed into the pallet car while suction from the
underside forces air downward. Sinter grate bars are used to make this possible. Because
technology to expand the width of the pallet cars has been adopted, only minimal
retrofitting is required to increase the production volume of the sintered ore.

Sinter Cooler

Sinter Cooler is used to cool down the temperature of the agglomerated ores ie is sinter.
Sinter cooler has a special arrangement in which sinter is discharged through chute of sinter
machine at discharge end. Sinter machine is circulaer chamber in which is rotaed in circular
path with the help of motor gear arrangement made diagonally at the end f sinter machine.
There is FD fan or we can say blower to provide air supply to the chamber.

Sinter Cooler

Cooling of hot sinter is accomplished into a Cooling Bin, of special design, by blowing up air
through the bed of crushed sinter to be cooled down. The necessary cooling air is delivered
by the blower system connected to the metallic bin. An alternative for the Cooling Bin is a
Metallic Cooling Conveyor, which cools down the crushed sinter while conveying same to
the screening station.

Mixing & Nodulising Drum

Mixing and nodulizing of the raw mix is performed in a drum specially developed for this
purpose. Nodulizing of the raw mix is achieved by special lifters. Filling degree and retention
time of the raw mix in the drum ensure an optimum mixing and nodulizing effect. According
to the plant configuration required the mixing drum can be of the continuous or batching
type. The supervisory station automatically controls water addition in the Mixing and
Nodulizing Drum.

Mixing & Noduliding Drum

Sinter Breaker

Sinter Breaker is used to break the bulky agglomerated sinter at the end of discharge of
sinter machine. Sinter breaker is a rotary structure on which spikes are made and this
structure is rotated the end of sonter discharge where with the help of spikes bulky
agglomerated piece are break down.
 Sinter Breaker

Double Roll Crusher

Double Roll Crushers can be used for primary and secondary crushing. The Double Roll
Crusher is generally regarded as a 4:1 feed to product ratio crusher; however in some
instances, dependent upon material friability and hardness, it is possible to achieve a 6:1
crushing ratio.

The feed material should enter the centre of the gap between the two rolls and spread
across the full roll width for maximum efficiency and this ensures a uniform product size
distribution.

Waste Gas Fan

waste gas fan (ID Fan, Backward curved) in the Sinter plant to handle the waste gas passing
through the sinter bed and ESP.

Waste Gas Fan

Waste gas fan is basically id fan which purpose is to create pressure gradient so that the
waste gas is suked from the sinter machine and transferred through the sinter bed to ESP
and further in the atmosphere through the chimney.

Electrostatic Precipitator

An electrostatic precipitator (ESP) is a filtration device that removes fine particles, like dust
and smoke, from a flowing gas using the force of an induced electrostatic charge minimally
impeding the flow of gases through the unit.

In contrast to wet scrubbers which apply energy directly to the flowing fluid medium, an ESP
applies energy only to the particulate matter being collected and therefore is very efficient
in its consumption of energy.

The waste gas coming from sinter machine through sinter bed is filter in the ESP where
approx 99 % of dust particles are removed and further the the clean waste gas is removed in
the atmosphere.

Electrostatic Precipitator

Dedusting Fan

De-Dusting Fan is used to collect the large quantities of dust generated in the sintering
process that can then be recycled as a process input. Dust generated during material
handling is collected with the help of dedusting fan and the dust particle separated from
dust and that dust particle used as raw material in the Sinter Plant.
Sinter Furnace

This flame from the burner nozzle hits the raw material sent to pallet cars by the feeder and
ignites the fuel (coke) within the raw material.Equipped with high efficiency burners
developed for sinter machine ignition furnaces, the straight-directionality of the nozzles
allow the flames to reach the raw material surface at a fast speed, thereby increasing
thermal conductivity and igniting the raw material quickly and reliably.
A lifting device is installed within the furnace in order to ensure that the burner flames hit
the raw material surface accurately.
The spacing of the burners has been reduced in order to enable even ignition of the raw
material surface.The furnace temperature and the amounts of the coke oven gas and
combustible air is monitored and automatically controlled by the control panel.

Feed Hopper Bin

There are similar series of over head bunker and conveyors to feed the sinter machine at a
time. Series contains 19 bunkers . These Bin are used to store the raw Materials and
discharged the conveyor through weigh feeder. Materials stored in the bunkers in following
are listed below table :

Raw Material No of Hopper

Iron Ore 4
Lime 1
Dolo 1
Return Fines 2
Coles 2
ESP Dust 1
Solid Waste 3
Calcined Lime 2
Spare 1