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Detail of blast furnace how it works mechanical with blt design
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P a g e | 1
JNIL, SPD, SILTARA, RAIPUR
BLAST
FURNACE
P a g e | 2
JNIL, SPD, SILTARA, RAIPUR
OPERATION
P a g e | 3
JNIL, SPD, SILTARA, RAIPUR
A blast furnace is a type of metallurgical furnace used for smelting of iron ores to
producing generally iron .
The earth crust contains about 5% iron. However,it is present as a compound mostly
as iron oxide. Iron is extracted as metallic iron from the oxide ores 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 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 – 01
Useful volume – 680 cub.met.
Working volume – 560
Throat diameter – 5.10
No. Of tuyers – 16
Tuyer diameter – 110 mm
Tap hole – single
Slag notch refractory lining – micropour carbon block
Top charging system – bell less top
No. Of stoves – 03
Cooling system – stave
Hot blast volume – 1,05,000Nm3/hr.
Hot blast pressure – 1.9Kg/cm2
Furnace top pressure – 0.88Kg/cm2
P a g e | 4
JNIL, SPD, SILTARA, RAIPUR
INPUT – BLAST FURNACE
Raw material : -
Iron ore &sinter-(size 10 to 30)
Flux, limestone, dolo, & quartz-( size10 to 30mm)
Mn ore – ( size10 to 30mm)
Coke – (size 25 to 80mm)
Hot blast air – (Temp. 980Deg.C)
PCI – ( as injection)
OUTPUT - BLAST FURNACE
Hot metal -
Steel melting Shop
Pig Casting Machine
Blast furnace Gas –
Power Plant
Rolling Mill
Sinter Plant
Slag granulated –
Cement Plant
P a g e | 5
JNIL, SPD, SILTARA, RAIPUR
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; Si% =0.5 to 0.8
Si% = 2.0 to 2.5 Mn% = 0.5max.
Mn% = 0.5 to 1.0 S% = 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
P a g e | 6
JNIL, SPD, SILTARA, RAIPUR
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 --------
P a g e | 7
JNIL, SPD, SILTARA, RAIPUR
INPUT< ----------------------------------------------------------------------->OUTPUT
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PROCESS
The blast furnace process is based on counter current principle. The input and output
are of modern blast furnace practice .the furnace is refractory lined and is filled with material
from the stock rod level down to bottom.
Solid raw material at room temperature or preheated furnace temp. At beginning the
process are charged from the top of the 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 highest 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 REACTION ;--
C + 1/2O ---------------- CO
C + O2 --------------- CO2
C + CO2 --------------- 2CO
P a g e | 8
JNIL, SPD, SILTARA, RAIPUR
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 and the cylindrical portion.
Stack : -
This zone extends from the stock 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.
P a g e | 9
JNIL, SPD, SILTARA, RAIPUR
Bosh : --
The charge materials being to soften and fuse as they come down in to
bottom of the stack. The next lower zone is called the bosh in which meeting of
the burden, except that of core takes place. The 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,
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 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 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 metal
layer in the hearth from where these are tapped separately.
P a g e | 10
JNIL, SPD, SILTARA, RAIPUR
PULVERISED COAL INJECTION
PCI (pulverised coal injection) is the fine powder of non – coaking coal .
this coal is injected in a blast furnace .
Because the reason is that , by 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 type of conveyor. But the DCC is differ
from belt conveyor because at the bottom of the raw material hopper becomes
heavy material load by far DCC is used otherwise slipping is occurred and can
not transferred.
MILL:--
Mill is used for milling the raw coal at the temp. Is 80 to 84deg, C.
Temperature is provided for the wet material ( coal) has 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 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.
P a g e | 11
JNIL, SPD, SILTARA, RAIPUR
RAW MATERIAL HANDLING SYSTEM(RMHS)
Raw Material Handling System(RMHS) is the main part of integrated steel plant.
This system is raw material 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 tippling or tilting in to the hoppers.
In our Jayaswal New Industries limited have one Wagon Tippler. In 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
P a g e | 12
JNIL, SPD, SILTARA, RAIPUR
Lime stone _ 20-50mm
Dolomite _ 20-50mm
Stock pile height _ 12meter
Travel length _ 412meter
Bucket Wheel –
By the help of bucket wheel material has Stacking and reclaiming through the boom
conveyor.
Stacker Cum Reclaimer is travel on the Conveyor no. -3.
Stock –House:-
It is alsop knows as raw material store section.
When the RMHS has some problem are include that condition the raw material are
required for continue operating the Blast -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 16th 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 material are
provide for Blast –furnace.
Vibro Feeder:-
This is a feeding equipment. Which is worked on vibration, for this purpose two Vibro
Cylenders are used.
Pig Casting Machine:-
P a g e | 13
JNIL, SPD, SILTARA, RAIPUR
In a Pig Casting Machine the hot liquid iron(metal) are poured in to the Pig moulds,
this complete process is known as casting 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 one belt or the pig
casting machine.
Total 4800 pigs are produced in pig casting machine.
Pig Storage Yard:-
The casting pig are transferred through 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 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..
P a g e | 14
JNIL, SPD, SILTARA, RAIPUR
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 actual CO many vary
around 20-30% nearly 900kcal/m3 . the quantity of gas produced depends upon the
amount of fuel burnt. For one tone of coke burnt nearly 4000m3 of effluent gas may be
produced.
The effluent gas from the furnace cannot directly be used 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 cleaned 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 carried out in
the Gas Cleaninig Plant(G.C.P).
The effluent gases from furnace are carried out of the furnace by large vertical 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 the gas downwards into trhe
duct catcher . the downcoming pipe or doct is called downcomer.
A bleeder valve is a safety 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 velocity hence if the velocity is zero
the dust particles will be eliminated from the gas.the state of zero velocity is achieved in the
gas catcher by simply reversing the direction of the gas flow from vertically to vertically
upward diection.
The downcomer leads the gases into the dust catcher through a Vertical
pipe that flares out and extends nearly to the bottom of the dust catcher. The gases comes
P a g e | 15
JNIL, SPD, SILTARA, RAIPUR
down vertically & suddenly changes its direction to vertically upwards since the outlet is
located nearly at the top of dust catcher,
The efficient of the dust catcher is usually upto 65%.
VENTURY WASHER(1&2):-
It is a vertical unit with 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 water
sprays at angle appoxemately 120 degree.
Due to venture effect & the water sprays dust particle is settle down in the B.S.P 1.
From venture-1 the cleaned & low pressure gas is fed to the venture washer-2. Where the
same way water spray is done & the clear gas upto % is done.
B.S.P(Bottom Seal Port):-
BSP is located near the bottom of venture washer-1 & cyclone separator, where the 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 striking the wall, these particles fall into a hopper located underneath.
When the gas travel upward in the cyclone separator, 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. Also 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 stack through which the blast furnace gas is fed into atmosphere.
P a g e | 16
JNIL, SPD, SILTARA, RAIPUR
GAS HOLDER:-
Gas holder capicitty 40,000m3 hold or storage the blast furnace gas. Which are not comsume
by the plant.
BOOSTER STATION:-
Booster station is used to boost Blast furnace gas to conveyt desired place since it is used
long distance like rolling mill etc.
P a g e | 17
JNIL, SPD, SILTARA, RAIPUR
MECHANICAL
&
ELECTRICAL
P a g e | 18
JNIL, SPD, SILTARA, RAIPUR
BLAST FURNACE MECHANICAL
# Tap Hole Drill 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 Capco Model- RM310F
*Drifter
Make- Haryson Model- BBC120F
P a g e | 19
JNIL, SPD, SILTARA, RAIPUR
#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 cylinders-
Clay 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 – 4.5m3
Capacity- 9 tonne
Inclination of bridge- 53 deg.
*Skip Winch
P a g e | 20
JNIL, SPD, SILTARA, RAIPUR
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 – 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
P a g e | 21
JNIL, SPD, SILTARA, RAIPUR
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 – 5.5kW, 1500rpm, AC servo motor
#Disributor:
Motor – 7.5kW, 1440rpm, Induction motor
#Chute:
Motor - 7.5kW, 1440rpm, AC servo motor
P a g e | 22
JNIL, SPD, SILTARA, RAIPUR
#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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JNIL, SPD, SILTARA, RAIPUR
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 are three valves
installed in the stove line.
1. Mixed air shutoff valve
2. Mixed air regulating valve
3. Back draft valve
# STOVE PROPER
1 Total height of stove 35.261m
2 Inner dia. of stove 7000mm
3 Dome shell inner dia. 8000mm
4 Dome brick work inner dia. 6632mm
5 Shell height 35800mm
6 Stove height to dia. ratio 5
7 Checker chamber section area 118.79m2
8 Combustion chamber section area 3.14m2
9 Overall heat accumulating area of stove 19040m2
10 Checker type 7 hole honey comb
11 Overall height of checker 27m
12 Overall weight of checker 728 tone
13 Ceramic burner type Sleeve type
14 Capacity of burner 32000m3/hr
15 No of column 18
16 Weight of each column 635kg.
17 No of grids 14
18 No of beams 24
P a g e | 24
JNIL, SPD, SILTARA, RAIPUR
#GAS CLEANING PLANT
Dust catcher- Dry type
Venture 1:
Type- adjustable throat venture
Make- kirloskar AAF Ltd.
Pressure drop- 600 to 800mmwc
Water circulating rate- 110 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
P a g e | 25
JNIL, SPD, SILTARA, RAIPUR
Effective volume- 40000 m3
Operating pressure- 875mmwc-600mmwc
Design pressure- 1000mmwc
Design temperature- 70 deg.
STOCK HOUSE EQUIPMENT SPECIFICATION
P a g e | 26
JNIL, SPD, SILTARA, RAIPUR
Weighing Hopper (WH):
WH No. Material m3 Capacity(tone) Load cell
01 to 03 Iron ore 4.5 5 Compression type 04
no’s
04 to 08 Flux 0.2 3 Single ended 03 no’s
05 to 09 Flux 1.2 3 Single ended 03 no’s
06 to 07 Coke 4.5 5 Compression type 03
no’s
Quadrant Gates (QG):
1. QG type A:
Electrical actuator operated
1000mm stroke, 1000kg thrust
QG 01, 02, 03, 10, 11, 12 – Iron ore
QG 04, 05, 08, 09 – Flux
QG 13, 14 – Intermediate hopper
2. QG type B:
Electrical actuator operated
600mm stroke, 500kg thrust
QG 06, 07 – 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
P a g e | 27
JNIL, SPD, SILTARA, RAIPUR
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 – 10% - 100%
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JNIL, SPD, SILTARA, RAIPUR
WAGON TIPPLER
Type of wagon tippler – Hydraside
Gross weight of wagon to be handled – 110 tonne
Max angle of rotation of tippler – 155°
No. of load cell provided: 06 no’s
No. of top clamp – 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 – 30 mm
Coke = 20 – 80 mm
Qtz = 20 – 50 mm
Limestone = 20 – 50 mm
Dolomite = 20 – 50 mm
Stockpile height – 12 m
Travel length – 412 m
Capacity
While stacking
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JNIL, SPD, SILTARA, RAIPUR
I/O – 1500TPH
Coke- 450 TPH
Mn ore, Qtz, LS, Dolomite – 1500 TPH
While reclaiming
I/O – 650 TPH
Coke – 130 TPH
Mn ore – 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
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 gear, 28:1
Brake: DC electromagnetic brake 400Ø
Slewing mechanism:
Slewing speed at centre of bucket wheel: 08 – 32 mtr/min
Slewing angle: ±105°
Motor: 02 no’s, 10kW, 150 – 1500rpm, continuously variable DC drive
Lifting mechanism for boom
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JNIL, SPD, SILTARA, RAIPUR
Type: hydraulic
No. of cylinder: 02
Speed: 03 m/min.
Type of cylinder: differential double acting cylinder
BELT CONVEYOR DETAILS:
Conveyors Belt Length
(m)
Belt Speed
(m/s)
Motor (kW) Belt Size (mm)
C1 36 1.75 30 1400
C2 299 1.75 200 1400
C3 1249 1.75 280 1400
C4/C4A 400 1.75 90 900/800
C5/C6 400 1.75 75 900
C7/C8 95 1.25 22 1000
C9A 54 0.5 11 650
C9B 63 0.5 5.5 650
C11/C11A 142 0.5 11 650
C12 145 0.5 30 500
BF1 165 0.75 7.5 500
PCI (PULVERIZED COAL INJECTION) EQUIPMENTS:
ID FAN:
Flow rate: 43900 – 53000 m3/ln
Pressure: 2256 – 2432 Pa
Working temp: 150 – 300°C
RPM: 0 – 1480
CA BLOWER:
Flow rate: 3963 – 4792 m3/ln
Pressure: 4256 – 4662 Pa
Working temp: 20°C
RPM: 2900
COAL MILL:
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Capacity: 15.1 TPH
Diff. pressure: 5 – 6 kPa
Inlet flow rate: 40000 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 raw material,laddle etc from one place to
another.
Components-
1. Current collector – It is mainly 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 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 limit to revolve
the drum in both direction, 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
Thermocouple Theory : A thermocouple, shown in Figure 1, consists of
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 Alumel ® (trademarked nickel alloys
containing chromium, and aluminum, manganese, and silicon, respectively),
with a measurement range
Type K (Chromel / Alumel)
Type K is the 'general purpose' thermocouple. It is low cost and, owing to its
popularity, it is available in a 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 / Rhodium)
Suited for high temperature 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).
Type 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 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.
They, in the case of Platinum known variously as PRTs and PRT100s, are the
most popular RTD type, nearly linear over a wide range of temperatures and
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 transmitter, 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 overall
temperature range, higher initial cost and less rugged in high vibration
environments.
They are active devices requiring an electrical current to produce a voltage drop
across the sensor that can be then measured by a calibrated 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), °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 to zero absolute pressure and has units of psia.
Absolute pressure can only have a positive value.
Gauge pressure
The pressure is referenced to atmospheric pressure and by convention is
measured in the positive direction, i.e. 7 psig.
Vacuum pressure
The pressure is referenced to atmospheric pressure and by 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 measurement
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 every second. Each pulse is directed and
transmitted to and reflected from a product surface. The elapsed time
period between transmission and reception of the signal at the speed of
light is measured and calculated as a distance. This continuous stream of
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pulses gives real time level information updated and is 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
normally be done with simple input of vessel dimensions.
Principles of Conductive
level Sensor
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Principles of Loadcell
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Application of loadcell
Application of loadcell
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Application of loadcell
Opacity MeterOpacity meter is used for the 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 side of
the flue(or duct), unit 1 and unit 2. The transmissivity 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) can
also be represented by the
equation : t21 = K2 (D12/D22)
where : K2 = gain constant to produce t = 1, D12 = the detector output
at unit D22 = the detector output at unit 2 (internal reference level)
Control valve
Control valves are used to control the process
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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
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Flow diagram of control valve
Instrument air AFR I/P (0.2 -1 kg/cm2)
(5-6 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 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 ,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
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.