DRI(OPERATION)

INTRODUCTION: Sponge iron is a metallic product produced through direct reduction(DR) of iron ore/pellet in the solid state using non-coking coal in a rotary kiln. The process of sponge iron making aims to remove oxygen from iron ore. The departing oxygen causes micro pores in the ore body making it porous. The final product, when observed under a microscope, resembles a honeycomb structure looking spongy in texture . DRI is a good substitute for steel scrap for producing steel in EAF, BOF etc, which result a rapid growth of the sponge Iron Industry. The quality of sponge iron is primarily ascertained by the percentage of metallization (removal of oxygen). Sponge iron manufacture is highly sensitive to raw material characteristics.

RAW MATERIAL :1. Iron ore : 2. Coal : 3. Dolomite :

1. Iron ore : Hematite ore (Fe2O3) Fe :- 70% Magnetite ore (Fe3O4) Fe :- 72% Lemonite ore (Fe2O3+H2O)Fe :- 50-60% Siderite ore (FeCO3) Fe :- 40% CHEMICAL COMPOSITION : Fe(T) :- 65% Al2O3 :-5%max Phosphorous :-0.05%max LOI :- 1-2%max Moisture :-1%max

PHYSICAL COMPOSITION : Required size :- 5-18mm +18mm :- 1%max +15mm :- 20%max -5mm :- 5%max

2. COAL(Non coking coal) : Anthrasite coal Bituminous coal CHEMICAL COMPOSITION : FC :- 40-42% VM :- 25-30%

 Ash :- 30-37% Moisture :- 7-11% PHYSICAL COMPOSITION : Required size :- 5-18mm +18mm :- 1%max +15mm :- 20%max -3mm :- 5%max

3. DOLOMITE (CaCO3.MgCO3) : Dolomite is used for the desulphurization. Low silica dolomite is used. CHEMICAL COMPOSITION : CaO :- 30%min MgO :- 20%min LOI :- 45% SiO2 :-3%max R2O3 :- 2%

PHYSICAL COMPOSITION : Required size :- 2-8mm +8mm :- 8%max -1mm :- 10%max

4. DRI CHEMISTRY :Reaction C + O2 = CO2 CO2 + C = 2CO C + CO2 = 2CO C + 1/2O2 =CO Fe2O3 + CO =Fe3O4+CO2 Fe3O4 +CO =Feo+CO2 FeO + CO = Fe + CO2 Delta H at kcal +25.42 +41.22 +41.22 -94.05 -12.85 +8.76 -6.85

5. DRI OUTPUT COMPOSITION: Fe(T) :- +88% Fe(M):- +81% MTZ :- +90% Gangue:- 6%max P :- 0.05% S :- 0.03%max C :- 0.25% Non mag :- below 1% 6. FINAL PRODUCT:Sponge iron 7. BY PRODUCT:-

Char Dolochar Steam Fly ash

PHYSICAL REQUIREMENT OF IRON ORE: Shatter index Tumbler index Reducibility Porosity Thermal degradation index Size of ore TECHNICAL SPECIFICATION OF COAL: Chemistry of coal Moisture in coal Reactivity Decripitation behavior Calorific value Caking index Ash softening temp. CONTROL OF PROCESS PARAMETRS:In the operation of rotary kiln for direct reduction the important process parameter which required close monitoring and control are as follows Feed rate of raw material.

Temperature profile. Air profile. Kiln revolution(rpm). Gas pressure in kiln. Cooler discharge temperature. Coal injection. Mean particle size. Retantion time.

INDICATIONS TO HAVE A KILN SHUTDOWN 1. Low Output. 2. High back flow material. 3. High pressures in the kiln. 4. High load of kiln. 5. Huge amount of accretion. 6. Hot spots on the kiln shell.

KILN DISCRIPTION:-(350 TPD) Kiln length = 76 m Kiln dia.(shell) = 4.28 m Kiln speed = 0.36- 0.55 rpm (Design rpm=0.76) Kiln dia.(effective) = 3.82 m Kiln inlet temp. = 7500 8000C Kiln outlet temp. = 10000 10200C Kiln inlet pressure = 0.5 0.6 mbar Kiln outlet pressure = 0.2 0.3 mbar Inclination of Kiln = 2.5% = 1.4130 Rotary cooler rpm = 1.3 rpm Rotary cooler inlet temp. = 10000C Shell air fan(SAF) = 8 Nos. (2900rpm) Castable thickness(Kiln) = 230mm Castable material = LC 80 (Low cement) Gas temp. Kiln inlet = 9000C Gas temp. Kiln outlet = 11000 11500C Boiler inlet temp. = 9500C Boiler outlet temp. = 1800C Cooler discharge temp. = below 1000c

MECHANICAL
Whole DRI consists of 2 nos. Kilns , 350 TPD & 500TPd . Most of the equipments are similar in both plant except some key equipments including kiln & cooler & their accessories & Drive system .

REPAIRING
The spares that had got defect has been replaced by new or spare one available in department . And then the defected spare has been prepared with new replaced parts & being assembled as spare ready for future replacement on any defects .

PREVENTIVE MAINTENANCE
In preventive maintenance system we use to check is to carry out scheduled lubrication of equipments or bearing .

SHUTDOWN PLANNING
By taking jobs planned for shutdown in register & jobs from slippage from previous shutdown list the new job list for shutdown is been prepared & the planning of manpower tools tackles, machinery equipments to be replaced .

BREAKDOWN MAINTENANCE
Due to improper lubrication or maintenance or disoperation of equipments the breakdown of equipments occurs , this also implies the improper checks over equipments or overlooking of the conditional monitoring parameters . Always but obviously the breakdown of any equipment cost more than its preventive

maintenance since DRI is a constant process the keen observation is required over the equipment & change over a standby machine scheduled to the maintained keeping in mind the Breakdown losses to equipment & production losses pertain to that .

KILN
In Kiln tyre used is 4.support roller is 8 .Shell air tube is made up of stainless steel . The grease-680 is used in lubricating in slip seal . Here the lubrication is done by Force lubrication system . Here a cooler is used to cool the lubricating oil .The GS-100 is used in main drive & EP-2 is used in support roller for lubrication . The oil used in FLS is oil-320 for all gear box . The break used in kiln is thrusters break . Two pinions are used in kiln but one pinion is used in cooler . The fan used in shell air tube is known as swiller . Air tube length is 2.5 mtr . Lobe compressor is used to provide pressure for coal injection . The pressure of Lobe compressor is 0.7bar & provide high volume . The screw compressor is used for purging system of Bag filter & to provide pressure to pneumatic cylinder . The cylinder in one carriage mounted is 4 . So the total cylinder is 40 . The pressure of screw compressor is 7kg/sq cm .

COOLER
In Cooler Girth gear is mounted which rotates the cooler . Pinion is connected to Girth gear & pinion is connected to gear box & gear box is connected to motor . The number of teeth on girth gear is 132 7 on pinion is 32 . Here pin bush coupling is used . Gear box type is helical type gear box & bearing used is Spherical Roller Bearing . The tyre is covered to cooler which rotates . Number of

tyre is two . The tyre when rotates slides to supporting roller . Number of supporting roller is 4 which supports the rotary cooler . There is also a thrust roller is mounted for providing movement of cooler . At support roller bearing used is Tapper Roller Bearing type & coupling is Gear coupling . In coal injection & wet scrapper chain drive is used for power transmission .

DIFFERENT BASIS MAINTENANCE TECHNIQUES

Some of very basic methods of maintenance applied in shop are :Lifting Technique The proper handling procedure for the lifting of material , machines are very necessary . Some of the common important tools used for techniques are :(a) Cranes (b) Winches (c) Slings , Steels Ropes , D-Shakles , U-Clamps (d) Hydraulic (e) Wedges (f) Pulley & Rope Ways (g) Turn buckles Shifting Techniques

For shifting if materials also proper procedure is followed & some of the common machines used in industry for above tasks are:(a) Cranes (b) Trolleys (c) Fork lifts Fitting Technique The fitting technique is very important in any shop as most of the tasks need accuracy (mostly fitting of shafts , bearing & housings , blower etc) . some of important tools used in this technique . (a) Pulleys (Hydraulics & mechanical) (b) Cutting tools for heating (c) Hammering Dismantling Technique In this maintenance of any equipment the dismantling is very important technique as it is very essential to dismantle the job safely to be reused & common methods used in this techniques are:(a) Pulley (b) Cutting Tools (c) Hammering Tools Cleaning Method

For proper maintenance of the equipments the cleanliness is very essential during disassembling & assembly of same . As any of the jute thread or the fine dust may cause the failure of the part . Some of the commonly used cleaning agents used during the technique are :(a) Diesel (b) Kerosene (c) Rustoline (d) CTC Welding Technique The Technique has very vital role in industry as the metal to metal joining process is very critical process . The important types are :(a) Gas Welding (b) Arc Welding Arc Welding are also two types such as :(a) Consumable Electrodes (b) Non- Consumable Electrodes The different welding positions are :(a)Horizontal (b) Vertical (c) Overhead

Sealing Technique It is also very important to ensure that the proper sealing of assembly & some of leak-proofed equipments are like gear boxes , fans , blowers & other fire & heat protect equipments used in industry . The sealing agent used for sealing purpose are :(a) Gasket sealants (like Lucite 510 & Lucite 574) (b) M-Seal (c) Metallic & Non-Metallic Gaskets (d) Glass Wool (e) Asbestos ropes & Graphite ropes (f) Ceramic blanket & Asbestos clothes (g) Rubber/Silicon rubber seal .

Equipments & Their Specification

Equipment Name Lobe Compressor 350TPD Cap-3000Cu M/Hr Speed-1070rpm Motor-110Kw, 1500 rpm Coal Injector Cap-12TPH Speed-20-25rpm 3.7kw, 1425rpm Bestech Engg. Work CB Fan Cap-12000Cu M/Hr 45kw, 1460rpm 500TPD 3000Cu M/Hr 1070rpm 110Kw, 1500rpm 15TPH 20-25rpm 3.7kw, 1425rpm Evergreen Work 14000Cu M/Hr 55kw,1460rpm

Scientillant Project Pvt. Ltd Sealing Air Fan Cap-4000Cu M/Hr 3.7kw, 1440 rpm SPPL

SPPL 7000Cu M/Hr 9.3kw, 1440 rpm SPPL

Cooling Air Fan

Cap-7000Cu M/Hr 9.3kw, 1440 rpm SPPL Cap-10500Cu M/Hr 30kw, 1460 rpm

7000Cu M/Hr 9.3kw, 1440 rpm SPPL 15000Cu M/Hr 30kw, 1460 rpm 9000Cu M/Hr 18.5Kw, 2900 rpm SPPL 30000Cu M/Hr 90kw,988rpm ACI 458mm 408mm 5Mtr HK-40 M/s Jindal Casting 380mm 320mm 2830mm HK-40 M/s Super Casting 102mm 80mm L-3Mtr

ABC Fan

Shell Air Fan

Cap-8000Cu M/Hr 15Kw, 2900 rpm SPPL

Deducting Fan

Cap-30000Cu M/Hr 90kw, 988rpm Able Corporation India

Feed Tube

OD-458mm ID-408mm Length-5Mtr Material-HK-40 M/s Jindal Casting

Air Injection Tube

OD-380mm ID-320mm Length-2580mm Material-HK-40 M/s Super Casting

Coal Throw Pipe

OD-94mm ID-72mm L-3Mtr

Material-HK-40 M/s Nitin Casting Wet Scrapper Cap- 5 TPH Speed-0.03 m/sec 7.5 KW, 960rpm M/S Enviro Abbrasive Cooling Tower Size -2*300m^3/hr 22KW, 1460 rpm M/S Paharpur CT Screw Compressor Cap 374CFM @7.5bar 55KW, 2965 rpm Bag filter with fan Cap-2*20000m^3/hr 30KW, 2965 rpm Cap-1*10000m^3/hr 15KW, 295rpm ID Fan - (ESP) Cap- 237000 m^3/hr 250KW, 988 rpm M/S Algappa Engg ABC Water Pump Cap- 10m^3/hr@40mHd 7.5kw, 2900rpm M/S Mathar & Platt Cold Well Pump Cap- 320 m^3/hr 22kw, 1470rpm M/S KSB Pumps Magnetic Separator (Lumps) 50 TPH, 1500 w belt-type 3.7kw, 1450 rpm 2200 Gauss, Strontium Ferrite

HK-40 M/s Nitin Casting Cap- 7.5 TPH Speed-0.3 m/sec 11KW,975 rpm M/S Enviro Abbrasive Size -2*300m^3/hr 22KW, 1460 rpm M/S Paltech CT 374CFM @7.5bar 55KW, 2965 rpm 60000m^3/hr 132KW, 1500 rpm M/S Ecomak Environmental 237000 m^3/hr 250KW, 988 rpm M/S Algappa Engg 10m^3/hr@40mHd 30kw, 1470 rpm M/S KSB Pumps 400 m^3/hr 22kw, 1475rpm M/S KSB Pumps 50 TPH, OD 900*1600 5.5kw, 1450rpm 2200 Gauss

M/S Electro Zavod Weigh Feeder Dolomite 2 TPH, 2-6mm, 650 BW 1.5kw, 1450rpm Iron Ore 25 TPH, 4-20mm, 650 BW 1.5kw, 1450rpm Feed Coal 16 TPH, 4-20mm, 800 BW 1.5kw, 1450rpm Coarse Coal 10 TPH, 4-20mm, 800 BW 1.5kw, 1450rpm Fines Coal 10 TPH, 0-4 mm, 800 BW 1.5kw, 1450rpm Kiln Shell Cooler Shell Kiln Main drive 4300*76 Mtr length 3200*45 mtr length 150kw,1000rpm,DC 1:180hellical G/Box Elecon 132T:17TG/Gear Pinion Cooler Main drive 90kw,1485rpm,AC 1:160hellical G/Box Elecon 116T:17TG/Gear Pinion Kiln Aux. Drive 15kw,1455rpm 1:35.5 hellical G/Box Elecon Primary Coal Crusher(Toothed double roll 150mm to -60mm) Cap-150tph@120rpm 650mm*1200mm L 37kw,1470rpm M/S Ecoman

M/S Electro Zavod

2 TPH, 2-6mm, 650 BW 1.5kw, 1450rpm 35 TPH, 4-20mm, 650 BW 1.5kw, 1450rpm 35 TPH, 4-20mm, 800 BW 1.5kw, 1450rpm 12 TPH, 4-20mm, 800 BW 1.5kw, 1450rpm 12 TPH, 0-4 mm, 800 BW 1.5kw, 1450rpm 4800*80 mtr length 36 00*50 mtr length 250kw,1000rpm,DC 1:210hellicaG/Box Ele. 136T/21TG/Gear Pinion 160kw,1485rpm,AC 1:140hellical G/Box Ele. 104T:19TG/Gear Pinion 18.5kw,1455rpm 1:35.5 hellical G/Box El.

150tph@120rpm 650mm*1200mm L 37kw,1470rpm M/S Ecoman

Secondary Coal Crusher(Toothed double roll 60mm to -20mm) Cap-150tph@120rpm 650mm*2500mm L 55kw,1475rpm M/S Ecoman Iron Ore Screen(Circular Motion Double Deck) 150tph,Amp-6-8mm,17deg 18&4mm,11kw,975rpm M/S Electro Zavod 150tph,Amp-6-8mm,17deg 18&4mm,11kw,975rpm M/S Electro Zavod Cap-150tph@120rpm 650mm*2500mm L 55kw,1475rpm M/S Ecoman

Primary Coal Screen(Circular Motion Double Deck) 150tph,Amp-6-8mm,17deg 60&4mm,11kw,975rpm M/S Electro Zavod 150tph,Amp-6-8mm,17deg 18&4mm,11kw,975rpm M/S Electro Zavod

Secondary Coal Screen(Circular or Linear Motion Double Deck) 100tph,Amp-6-8mm,16deg 60&4mm,11kw,975rpm M/S NECO Day bin Coal Screen(Circular Motion Single Deck) 150tph,Amp-6-8mm,16deg 4mm,11kw,975rpm M/S Electro Zavod Product Screen(Circular or Linear Motion Double Deck) 75tph,Amp-7.5mm,15deg 20&4mm,2*3.8kw,950rpm M/S Electromag Hydraulic Power pack(Stack Cap) 100tph,Amp-6-8mm,17deg 18&4mm,11kw,975rpm M/S Electro Zavod 150tph,Amp-6-8mm,15deg 4mm,2*15kw,975rpm M/S Electro Zavod 150tph,Amp-6-8mm,12deg 18&4mm,2*5.3kw,975rpm M/S Electromag

400ltr,14Lpm,1440rpm M/S Denison Hydraulics Hydraulic Power pack(Hyd. Thruster/T-Chut) 400ltr,14Lpm,1440rpm

400ltr,14Lpm,1440rpm M/S Denison Hydraulics

400ltr,6/14Lpm,1440rpm

DRI
ELECTRICAL & INSTRUMENTS

There are two incoming sources for DRI 350 / DRI 500, TPD from AIL and CIAL power plant.

Two sources for DRI 350 is - From AIL power plant - Emergency power supply form CIAL Power Plant.

Single line diagram of DRI 350 TPD is

No. of MCC panels in DRI 350 TPD - MCC 1 - MLDB BULK FEEDER - AIL P/P EMERGENCY - CAPACITOR BANK 1 - PH MCC - PDB 1 & 2 - DEDUSTING FAN - MLDB - ESP MCC

DEDUSTING FAN 2 ID FAN MCC 2 RMP MCC CAPACITOR BANK 2

Rapper control - This rapper system is connected to the top of the ESP used for the rapping of the electrodes. - In DIR 500 total 42 rappers one operated in matrix form. - In operate on the principle of magnetic impulse gravity impact (MIGI) - When the power supply is given the hammer goes to up and after removing supply this hammer goes down due to gravitation impact and stress the ESP electrodes.

- When the supply given to coil it consist an electro magnet and attract the hammer. After few minutes it goes off and hammer removed which stress the electrode insulation and remove dust particles on the electrodes.

ESP- ESP stands for electrostatic for electrostatic precipitator which is used to remove the dust particles in the gas before removing in atmosphere. - There are 3 HVDC transformer is connected at the top of the ESP. - Basically this is the type of rectifarmer which is step up type. - Rectifier improves the GIP VDH . And then rectified it before feeding electrodes.

Rectifarmer rating 54.74KVA Rated o/p Rated I/P 78 KV 440 v +_ 10% 44kv

Presently o/p VDC -

Drive- there are two drive system in DRI.

1. AC drive system 2. DC drive system 1) AC drive systemsystem is used. Mainly for Due to the motor speed regulation this drive

Lobe compressor Shell air fans C.B. fans (55kv)

(110kv)

- Cooler main drive - ID fan. 2) DC drive system This type systems is used where the high
torque is required basically kiln master motor & kiln slave motor is operated with DC drive. SCR control system is used to provide input supply for the master / slave motor.

Transformer & protectionA. Buchholze relay B. Oil temperature indicator C. Winding temp indicator D.Explosive vent E. Conservator tank F. Tap setting G. Breathers (silica gel)

a) Buchholze relay This is gas operated relay. When

any lighting is happen inside the transformer then gas generated. Which pass through this Buchholze relay . when the gas is more than set pt. It starts the alarm and trip the breaker.

b) Oil temprature indicator- This indicator is

mounted with RTD is inside the transformer oil. when the oil temp goes upto the set point it starts the alarm and trip the breaker.

c) Winding temp indicator- This also used for

transformer protection is similler to oil temp indicator.

d) Explosive vent-when are explosions is happen inside

the transformer these vent operated for removing the gas.

e) Conservator tank-this is the oil tank which is used

for providing convent oil in the transformer.

f) Tap setting-when the required o/p is not as required

then this tap is set and required o/p is taken at the o/p.

g) Breather (silica gel)-transformer takes atmospheric

air this air goes inside through breather gel. this absorbers the moisture, present on the air.

Instrument section:
Process parameter in industry: -temp -pressure -flow -level -weight Temp measurement: To use the temp measurement in sinter plant RTD and thermocouple is uesd. i) RTD(resistance temp detector): RTDs are wire wound and thin film devices that measure temperature because of the physical principle of the positive temperature coefficient of electrical resistance of metals. The hotter they become, the larger or higher the value of their electrical resistance. R(t) = R(0)[1 + At +Bt^2],where A,B temp. Coef. Of resistance R(0) resistance of conductor at 0C . Advantages of RTDs Stable and linear output for long period of time. Ease of recalibration. Accurate readings over relatively narrow temperature spans. Disadvantages Compared to the thermocouples, are:

Smaller overall temperature range. Higher initial cost .

Less rugged in high vibration environments Mostly pt-100 RTD( range-650-700c) in ESP inlet and outlet ,bellows and blast furnace gas pipe line. 2) thermocouples: A thermocouple is a device consisting of two different conductors usually metal alloys that produce a voltage proportional to temperature difference. Principle :Seeback Effect

Types of thermocouple : Types of thermocouple J type K type R type S type range 0-900C 0-1270C 0-1600C 0-1600C Materials content Fe-Constantan Chromel-Alumel Pt-PtRh 10% Pt-PtRh 13%

Thermocouples are used in ignition furnace and preheater. R type is used in furnace-1 and S type is used in furnace-2. Weight measurement: For the weight measurement in industry we use weigh feeder with load cell. Load cell operate with the principle of strain gauge . when the force is applied on strain gauge ,its resistance varies which is measured by the wheat stone bridge and calculate the weight in terms of change in resistance of strain gauge.

Types of load cell: Compression Type load cell Single ended shear beam type load cell Double ended shear beam S Type

Application of loadcell:

Compression type load cell is used in weight bridge and hopper and weight house. Weight feeder:

Main idler is mounted with the load cell with the bend rod. Support idler is used for protection for main idler. Weight calculated as:

TPH= weight speed of belt= kg/m m/sec =kg/sec =1000T/3600 sec Speed measurement: To calculate the speed of belt and motor tachometer and belt scale is used. Belt scale is the device which directly calculate the weight of material in TPH which is set by the operator. Tacho meter is a device which directly operates on the principle of induction and measure the speed of motor. Generally tacho meter is mounted on each weight feeder. Moisture sensor: Moisture sensor is used to sense the moisture present on the material. 3 sets moisture sensors are used in sinter plant: i) On coke feeder weigh bridge 1017 ii) On balling drum-1 iii) On balling drum-2 The moisture level is maintained 9-11% in proportioning building on coke weigh feeder. And 7-9% maintained in balling drum. Flow measurement: For liquid flow measurement in sinter plant( balling drum pipe line) electromagnetic flow meter is used. Vibration measurement: To measure vibration of equipment 2 vibro motor is used. Vibro motor is used in ID fan bearing system. Level sensor: Capacitive type level sensors are used in sinter to measure the level of materials.

Control valves: In sinter plant balling drum to control the flow of water supply ,air to open shut off valve and butter fly valve is used. To control the flue gas flow also shut off valve and control valves are used. Principle: Control valves are used to control the process Parameters such as flow,pressure,temperature, 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

Input/Outputs defined in DCS: DI signals Signals Coming from switches, sensors etc. DI FIM card -32 channels are used. DO signals - Signals given to drives,shut off valves etc. DO FIM card-32 channels are used. AI Signals Signals coming from 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.