Raw Material Presentation

(1)

It is a Iron Ore

Palletizing Plant at

sohar –

Sultanate of Oman Sultanate of Oman

Capacity: 2*4.5MTPA

13636 T/Day

568.16 T/Hr

Technology: Technology: Grate Kiln {formerly Grate Kiln {formerly known as Allis-Chalmers known as Allis-Chalmers

Kiln} Kiln} Brief: Pellets are Brief: Pellets are transforms of Mineral transforms of Mineral resources of superior resources of superior

quality fe

quality feed as ed as rawraw materials to D.R.I & Blast materials to D.R.I & Blast

Furnace process Furnace process For Steel making…… For Steel making……

Raw Material: Raw Material: Iron ore, Iron ore, Limestone, Limestone, Anthracite & Anthracite & Bentonite. Bentonite. Fuel: Natural Gas Fuel: Natural Gas

(2)

V

Vaallee’’ss IIn

nd

du

ussttrriiaall E

Em

mp

piirree

Vale Oman Vale Oman Palletizing Plant Palletizing Plant

(3)

Iron Ore Fines Utilization….. Via

(4)



Analyze Process

capability



Stimulate Process

Performance



Prepare Process

Plan

(5)

We

are

here

(6)

V

Vaallee O

Om

maan

n P

Paalllleettiizziin

ng

g Co

Com

mp

plleex

x::--Process

Process

Control

Dept.

(7)

Thickener

Vale Oman Process Flow Chart

Fuel Fuel

Drying

_Grinding

Feed Feed Iron Ore Iron Ore Additives Additives Chips/Chunks Chips/Chunks Bentonite Bentonite Mixing Mixing P P H H 2 2 P P H H 1 1 T T P P H H D D D D 1 1 D D D D 2 2 Rotary Kiln Rotary Kiln

Traveling

Grate

Roller Roller Feeder Feeder Balling Balling Annular Annular Cooler Cooler

(8)

CONTENTS:-Define :

Define :

Process Control

Glossary of Terms & Methods of preparation:

(Sampling)

Raw Material Handling:

( Sampling of Iron ore

( Sampling of Iron ore , Lime stone, Anthracite)

, Lime stone, Anthracite)

Grinding Area:

( Sampling of feed to

( Sampling of feed to mill & mill discharge feed)

mill & mill discharge feed)

Mixing & Blending Area:

( Sampling of Mixed

( Sampling of Mixed material & Bentonite )

material & Bentonite )

Thickener Area:

(Sampling of slurry )

Balling Area:

(Sampling of Green Ball )

Traveling Grate Area:

( Sampling of Feed to T.G , Discharge material of T.G

Measurement of Temperature, Differentia

Measurement of Temperature, Differential Pressures and Process

l Pressures and Process Gas flow)

Gas flow)

Rotary Kiln & Annular cooler Area:

( Measurement of Kiln Feed end,

Middle, Discharge Temperatures, Gas Flow ,

Stack sam

Stack sampling

pling & Sam

& Sampling of finishe

pling of finished product)

d product)

Product Coating Area :

( Sampling of coating material )

Health & Safety Information:

(9)

Define : Process Control :

Define : Process Control :The Fundamental philosophy associated with the economic production of The Fundamental philosophy associated with the economic production of Pellets must be based on defect PREVENTION rather then defect DETECTION. This approach Pellets must be based on defect PREVENTION rather then defect DETECTION. This approach requires a system of PROCESS CONTROL, which can only be effectively implemented through requires a system of PROCESS CONTROL, which can only be effectively implemented through STATISTICAL TECHNIQUES. Decisions to modify or adjust processes must be based on statistical STATISTICAL TECHNIQUES. Decisions to modify or adjust processes must be based on statistical evidence, such as control chart data. Relia

evidence, such as control chart data. Reliance on INSPECTION fornce on INSPECTION for quality control is both ineffectivquality control is both ineffectivee and inefficient. and inefficient. Process : Process :

The combination

of machine and

equipment, people,

resources,

methods and mill

environment that

produce a given

result.

Control : Control :

To guide with in

boundaries or to

make something

behave the way

you want it to.

Hold on specifics

as well.

(10)

Glossary of Terms & Methods of preparation:

(Sampling)

TERMINOLOGY USED IN SAMPLING AND SAMPLE PREPARATION

Lot:

The quantity of Raw material/ Finis

The quantity of Raw material/ Finished Products indicated to be

hed Products indicated to be of the same category and offered

of the same category and offered

for inspection at one time. A lot may consist of the

for inspection at one time. A lot may consist of the whole or a pa

whole or a part of the quantity ordered for.

rt of the quantity ordered for.

Sub-lot:

The quantity of ore/pellets in each of the pa

The quantity of ore/pellets in each of the parts into which a lot is divided for the purpose

rts into which a lot is divided for the purpose of

of

sampling.

Increment:

The quantity of ore/pellets obtained by a sampling device at o

The quantity of ore/pellets obtained by a sampling device at o ne time from a lot or sub-lot.

ne time from a lot or sub-lot.

Unit Sample:

The quantity of ore/pellets collected at one time from the conve

The quantity of ore/pellets collected at one time from the conve yor (Unit sample is larger

yor (Unit sample is larger

than the increment).

Gross sample:

The total quantity of ore/pellets consisting of all increments or unit samples taken from

a sub-lot.

Size sample:

The sample taken for t

The sample taken for the determination of the size

he determination of the size distribution

distribution of the lot or s

of the lot or sub-lot.

ub-lot.

Moisture sample:

The sample taken for the determination of moisture content of the

The sample taken for the determination of moisture content of the lot or sub-lot.

lot or sub-lot.

Laboratory sample:

The quantity of ore/pe

The quantity of ore/pellets obtained by reducing a

llets obtained by reducing a gross sample

gross sample following a

following a

specified procedure for determining chemical composition of a lot or sub-lot.

Composite sample (For the lot):

The quantity obtained by mixing together propo

The quantity obtained by mixing together proportional quantities of

rtional quantities of

ore/pellets representing the mass of each sub-lot which a

ore/pellets representing the mass of each sub-lot which a lot has been divided.

lot has been divided.

Sampler:

Sampler:Person responsible for performing the Person responsible for performing the sampling operations.sampling operations. Sampling method:

Sampling method:That part of the sampling procedure dealing with the That part of the sampling procedure dealing with the method prescribed for withdrawinmethod prescribed for withdrawingg samples.

(11)

Random sample:

Sample in which the different fractions of the

Sample in which the different fractions of the material have

material have

an equal probability of being

an equal probability of being represen

represented.

ted.

Representative sample:

Sample obtained according to a sampling procedure

designed to ensure that the different parts of a

designed to ensure that the different parts of a batch or the different properties

batch or the different properties

of a

of a non-unifor

non-uniform material are

m material are proportiona

proportionately represented.

tely represented.

Sampling plan:

Description of the

Description of the location, number of

location, number of units and/or quantity of

units and/or quantity of material

material

that should be

that should be collected, and associated acceptance criteria.

collected, and associated acceptance criteria.

Sampling procedure:

The complete sampling operations to be

The complete sampling operations to be performed on a defined

performed on a defined

material for a specific purpose. A detailed written description of the

material for a specific purpose. A detailed written description of the sampling procedure

sampling procedure

is provided in the

is provided in the sampling protocol

sampling protocol ..

Sampling record:

Written record of the sampling operations carried out on

Written record of the sampling operations carried out on a particular

a particular

material for a defined purpose. The sampling

material for a defined purpose. The sampling record should contain the batch number,

record should contain the batch number,

date and place of sampling, reference to the sampling protocol used, a description of the

containers and of the

containers and of the materials

materials

sampled, notes on possible

sampled, notes on possible abnormalities, together with any other relevant observations,

abnormalities, together with any other relevant observations,

and the name and signature of the inspector.

(12)

Need for Sampling:

Introduction

Introduction:: According to ISO/IEC 10725, “sampling”According to ISO/IEC 10725, “sampling” is defined as “a procedure wheris defined as “a procedure whereby a part of eby a part of a

a substance, matsubstance, material or product is takerial or product is taken to provide for testing or caen to provide for testing or calibration a reprlibration a representativeesentative sample of sample of the whole.

the whole.

Sampling may also be required by the appropriate specification for

Sampling may also be required by the appropriate specification for which the substance, materiwhich the substance, material oral or product is to be tested

product is to be tested.”.” In other words, thIn other words, the goal ofe goal of sampling is to select ansampling is to select and obtain a test portion od obtain a test portion of thef the material in some manner, such that the

material in some manner, such that the sub-sample is represensub-sample is representative of the larger amount of material.tative of the larger amount of material. Sampling is often a major source of error and if a truly representative sample of the batch is

Sampling is often a major source of error and if a truly representative sample of the batch is not obtained, then the

not obtained, then the subsequent analysis will give a wrong figure. subsequent analysis will give a wrong figure. It is the It is the aim thereforeaim therefore to develop correct sampling protocols, considered to be

to develop correct sampling protocols, considered to be an essential requirement foran essential requirement for obtaining valid results within Prospect.

obtaining valid results within Prospect.

100% Inspection of Process Output is an 100% Inspection of Process Output is an unsatisfactory method to determine product unsatisfactory method to determine product quality. It is costly ,has no relationship quality. It is costly ,has no relationship to future quality, and is impossible in to future quality, and is impossible in many cases.

many cases.

Sampling reduces the cost to measure Sampling reduces the cost to measure

Product quality and can be used to predict Product quality and can be used to predict Future product quality when used in Future product quality when used in Conjunction with control charts. Conjunction with control charts.

Samples must be taken so that their Samples must be taken so that their results are representative of actual results are representative of actual process quality .In other words, they must be process quality .In other words, they must be taken So that the results are unbiased. taken So that the results are unbiased.

(13)

SAMPLING:

The methods of collecting increments or unit samples from a lot

may be classified into following types or a combination of below

mentioned.

Sampling from conveyors.

Shipment sampling.

Stockpile sampling.

Sampling during production.

Automatic samplers.

Sectional sampling.

Trench sampling.

(14)

I

I r

r o

o n

n

O

r

r e

e

P

Pe

elllle

e t

tss

•• Sampling from conveyors:Sampling from conveyors: When ore/pellets is moved on conveyors, one of the most reliable When ore/pellets is moved on conveyors, one of the most reliable methodsmethods of manual sampling is stopped belt method. Whenever it is

of manual sampling is stopped belt method. Whenever it is practicable to stop the conveyor beltpracticable to stop the conveyor belt periodically, a large quantity of iron ores know

periodically, a large quantity of iron ores known as unit samplen as unit sample may be drawn by stopping the belt. Themay be drawn by stopping the belt. The sample shall be collected from the full

sample shall be collected from the full width and thickness of the ore/pellet stream over a width and thickness of the ore/pellet stream over a suitable lengthsuitable length of the conveyor. In case it is not possible to stop the conveyor

of the conveyor. In case it is not possible to stop the conveyor the sample shall be taken from a specifiedthe sample shall be taken from a specified place on a

place on a conveyor or at a specified transfer point of conveyor or at a specified transfer point of conveyor.conveyor.

•• Shipment sampling:Shipment sampling:In order to get gross sample, the ore/pellets shall In order to get gross sample, the ore/pellets shall be sampled as far as possiblebe sampled as far as possible when in motion. That is

when in motion. That is from the conveyor during loading or immedfrom the conveyor during loading or immediate discharge during unloading atiate discharge during unloading at regular interval.

regular interval.

•• Stockpile sampling:Stockpile sampling:The ore/pellets from stockpiles shall be carried out as The ore/pellets from stockpiles shall be carried out as far as possible, when theyfar as possible, when they are in motion, that

are in motion, that is, during the formation of the stock piles or is, during the formation of the stock piles or during the shifting of the stockpiles toduring the shifting of the stockpiles to the other places. Sampling from the stationary stockpile shall not be

the other places. Sampling from the stationary stockpile shall not be conducted, as this would introduceconducted, as this would introduce significant bias in

significant bias in sampling.sampling.

•• Sampling during production:Sampling during production: The ore/pellets shall be collected as The ore/pellets shall be collected as per stopped belt method from theper stopped belt method from the conveyor or at the convenient discharge point of the conveyor.

(15)

Trench sampling:

Trench sampling: Along a randomly chosen line on the ore surface

Along a randomly chosen line on the ore surface of the sub-lot, a

of the sub-lot, a

trench shall be dug, right down to the ground level leaving about 0.3 meter

walking space at t

walking space at the ground level. From t

he ground level. From the trenches so dug, the

he trenches so dug, the required num

required number

ber

of increment shall be collected with the help of

of increment shall be collected with the help of suitable sampling scoop

suitable sampling scoop, at

, at

various poi

various points randomly spread ov

nts randomly spread over the two exposed si

er the two exposed sides of the

des of the trenches. In

trenches. In

case of large stockpiles, in addition to the

case of large stockpiles, in addition to the trench, the sides of the piles may

trench, the sides of the piles may also

also

be opened to expose the ore down to th

be opened to expose the ore down to the bottom, at places where the trench

e bottom, at places where the trench does

does

not expose the ore inside.

Automatic samplers:

In Grinding Section & Product pellet area, the automatic

samplers have been provided. By

samplers have been provided. By simple button pressing at the req

simple button pressing at the required interval

uired interval

the sample will be collected.

Sectional Sampling:

4 unit samples in the case of fines and calibrated ores and at least

8 unit samples in the case of sized ore and lumps are to be collected from each

sub-lot. For this purpose, the requisite number of points shall be chosen at

random on the entire surface of the

random on the entire surface of the stockpiles. At each of the selected points, a

stockpiles. At each of the selected points, a

circle of suitable diameter (minimum three times the

circle of suitable diameter (minimum three times the largest particle size) shall

largest particle size) shall

be marked. The material over the

be marked. The material over the area of this circle

area of this circle and along entire height of the

and along entire height of the

stockpile from top to bottom shall be collected in stages. This can

stockpile from top to bottom shall be collected in stages. This can be done by

be done by

taking initial

taking initially ores up

ly ores up to a depth of 50 cm

to a depth of 50 cm and covering the hole so formed by a

and covering the hole so formed by a

plate for removing t

plate for removing the ores lying on t

he ores lying on the sides of the hole. Then

he sides of the hole. Then after removing

after removing

the plate further depth can be reached in the same manner and the ores can be

collected from the freshly formed hole.

(16)

SA

MP

LE

PR

EP

AR

AT

IO

N

•• Before analyzing any raw material for Physical/Chemical/Metallurgical properties it is very important to mention here about the sampling andBefore analyzing any raw material for Physical/Chemical/Metallurgical properties it is very important to mention here about the sampling and sample preparation. The sample should be collected which is a well representative of the total raw material ready for dispatch and well prepared sample preparation. The sample should be collected which is a well representative of the total raw material ready for dispatch and well prepared before analysis. In order to collect representative sample for correct analysis, sampling and sample preparation is a very important tool for before analysis. In order to collect representative sample for correct analysis, sampling and sample preparation is a very important tool for preparing a sample for analysis.

preparing a sample for analysis.

•• The primary object of sampling of any material is to draw an inference about the quality of the lot on the basis of information derived from theThe primary object of sampling of any material is to draw an inference about the quality of the lot on the basis of information derived from the sample. If the consignment is of uniform nature the inference so

sample. If the consignment is of uniform nature the inference so drawn is almost precise, which gives an accurate estimate of the quality, drawn is almost precise, which gives an accurate estimate of the quality, butbut when the material is heterogeneous in nature as is often the case with any raw material, the method by which a sample obtained becomes critical when the material is heterogeneous in nature as is often the case with any raw material, the method by which a sample obtained becomes critical in inferring about the quality of the consignment.

in inferring about the quality of the consignment.

•• The efficiency of sampling largely depends on the degree of homogeneity of the material and size of the sample. In case of heterogeneous material,The efficiency of sampling largely depends on the degree of homogeneity of the material and size of the sample. In case of heterogeneous material, the size of the sample should be more for accurate estimate of the quality.

the size of the sample should be more for accurate estimate of the quality.

•• Preparation of a final sample for physical, chemical and metallurgical properties is an important aspect, because the sample prepared inPreparation of a final sample for physical, chemical and metallurgical properties is an important aspect, because the sample prepared in accordance with the below mentioned procedure will fetch accurate analysis otherwise erratic results.

accordance with the below mentioned procedure will fetch accurate analysis otherwise erratic results. ••

•• There are different methods of sample preparation.There are different methods of sample preparation. •• Riffle dividerRiffle divider

•• Coning and quartering.Coning and quartering.

•• Reduction by Riffle divider:Reduction by Riffle divider: The final sample shall be well mixed and poured into tThe final sample shall be well mixed and poured into the riffle. This process shall be repeated using different sizes of he riffle. This process shall be repeated using different sizes of riffles according to the size of the ore.

riffles according to the size of the ore.

•• RIFFLE SAMPLE DIVIDER : IS : 1607, IS RIFFLE SAMPLE DIVIDER : IS : 1607, IS : 2720.: 2720.

•• Efficient sampling out of bulk materials/deposits is the most important for getting the true idea about the bulk material. The volume of Efficient sampling out of bulk materials/deposits is the most important for getting the true idea about the bulk material. The volume of material to be tested is us

material to be tested is usually quite huge ually quite huge and it requires reduction in and it requires reduction in volume in a methovolume in a methodical manner. Thedical manner. The RifflerRiffler Sampler (sample divider) helpsSampler (sample divider) helps to reduce the bulk while maintaining the character of the

to reduce the bulk while maintaining the character of the material and thus it is a helpful, light and handy device for samplingmaterial and thus it is a helpful, light and handy device for sampling work. Thework. The standard units are made of GI sheet and mounted on rigid steel frame and supplied with three pans and one scoop.

standard units are made of GI sheet and mounted on rigid steel frame and supplied with three pans and one scoop.

(17)

•• Coning and Quartering method:Coning and Quartering method: The ore shall be well mixed and The ore shall be well mixed and then scooped into a cone sthen scooped into a cone shapedhaped pile. Carepile. Care shall be taken to drop each scoopful exactly over the same spot as otherwise the central axis of the cone will be shall be taken to drop each scoopful exactly over the same spot as otherwise the central axis of the cone will be slackened and an uneven distribution of lumps and fines will result.

slackened and an uneven distribution of lumps and fines will result.

•• After After the conthe cone is fe is formedormed, it sha, it shall be fll be flattenlattened by ped by pressressing ting the top he top of the cof the cone witone with the smh the smooth sooth surfurface of thace of the scooe scoop.p. Then it is cut into quarters by two lines which intersect at right angles at the center of the cone.

Then it is cut into quarters by two lines which intersect at right angles at the center of the cone.

•• The bThe bulk oulk of the sf the samample is rple is redueduced bced by rejey rejecticting anng any two dy two diagiagonaonally oplly opposposite quite quartartersers

Coning

(18)

Proce

(19)

Process control:

Process control: Instruments for

Instruments for Monitoring

Monitoring Temperatures ,

Temperatures ,

Differential Pressures , Gas Flows

&

Level Sensors

T

H

E

R

M

O

C

O

U

P

L

E

S

F

L

O

W

M

E

T

E

R

S

P P R R E E S S S S U U R R E E G G A A U U G G E E S S B B E E D D L L E E V V E E L L S S E E N N S S O O R R S S

(20)

Raw Material Handling systems:

( Sampling of Iron ore , Lime stone, Anthracite)

•• In genIn general, eral, for afor any indny industrustry a rigy a right amoht amount ount of inpuf input is nect is necessaessary to ry to prodproduce an euce an effeffective octive outpuutput as yiet as yield. Ild. In our pn our pelletellet plant we are getting the iron ore fines as the input from Brazil

plant we are getting the iron ore fines as the input from Brazil through shipmthrough shipment, we need an handling system for ent, we need an handling system for transporting of the raw material from Port area to

transporting of the raw material from Port area to our plant, and hence we our plant, and hence we are making use of equipments likeare making use of equipments like Stackers, Reclaimers & Conveyors for serving the

Stackers, Reclaimers & Conveyors for serving the purpospurpose.e.

•• Raw material unloading from shipRaw material unloading from ship

VESSAL CAPACITY: 4 .0 LAKHS TONS VESSAL CAPACITY: 4 .0 LAKHS TONS UN LOADER CAPACITY : 10,000 T/H UN LOADER CAPACITY : 10,000 T/H

(21)

Unloaded Iron ore stocked near Jetty area

(Iron Ore Stockpile)

Stacker Stacker & & Reclaimer Reclaimer Capacity:10,000T/Hr Capacity:10,000T/Hr Iron ore Iron ore Piles Piles near near Jetty Jetty Of Of Capacity: Capacity: 946.000T 946.000T Iron ore Iron ore Stockpile Stockpile capacity: capacity: 766.000T 766.000T

(22)

Limestone

&

Anthracite

Stockpiles

Limestone

Stockpile Stockpile Capacity:6.000T Capacity:6.000T

Anthracite

Stockpile Stockpile Capacity:15.000T Capacity:15.000T

(23)

Process Control Sampling Plan:

•• Vale Oman has Raw material’s Storage capaVale Oman has Raw material’s Storage capacity of 1712.000T( Iron ore),wherecity of 1712.000T( Iron ore),where sampling is challengisampling is challenging task to meet theng task to meet the Homogen

Homogeneity of the eity of the sample. Process Control Dept. aims to sample. Process Control Dept. aims to execute such a difficult task execute such a difficult task where there is a where there is a higherhigher degree of confidence in the source then sample.

degree of confidence in the source then sample. •• TwTwo to typypes es of of samsamplplining eg errrrorors as are re popossssibiblele::

a)

a)Segregation errorsSegregation errors

This occurs when particles are

This occurs when particles are exposed to gravitational, rotational, vibratory or exposed to gravitational, rotational, vibratory or aeration operations (or other types of mechanical motion), usually resulting in fine aeration operations (or other types of mechanical motion), usually resulting in fine particles migrating to the bottom and larger particles being concentrated at the top. particles migrating to the bottom and larger particles being concentrated at the top.

This type of error is thus dependent upon the previous history of the powder and This type of error is thus dependent upon the previous history of the powder and

usually occurs with free or easily flowin

usually occurs with free or easily flowing powders,g powders, having a significant range of having a significant range of particle size. This type of error can be minimized by suitable mixing and building up particle size. This type of error can be minimized by suitable mixing and building up the sample from a large number of increments.

the sample from a large number of increments.

b)

b)Statistical errorsStatistical errors This is type of error

This is type of error is caused by observing a sample instead of is caused by observing a sample instead of thethe whole lot. Although this type of error cannot be

whole lot. Although this type of error cannot be prevented, it isprevented, it is likely that the size of

likely that the size of statistical errors can generally be controlled by taking astatistical errors can generally be controlled by taking a large enough random sample from the entire lot. large enough random sample from the entire lot.

(24)

Process Sampling at Stockpiles

Random

sampling

of entire

area

We need to trench We need to trench the entire the pile , the entire the pile ,

so as to have so as to have uniformity & uniformity & homogenization in homogenization in sampling sampling 10 Mtrs 10 Mtrs Top Layer Top Layer Middle Layer Middle Layer Bottom Layer Bottom Layer Dividing the Dividing the Entire Mass in to Entire Mass in to Layers a Layers a Composite sample Composite sample has to be drawn. has to be drawn.

(25)

Stocked Raw materials are transported

through conveyors in to Plant Storage

Bins:-Continuous visual Monitoring Continuous visual Monitoring

has to be followed has to be followed so, as to identify contaminations so, as to identify contaminations

(26)

Random Sampling of raw materials on

conveyors:-Sampled Raw materials are tested for moisture (M%) ; Size Distribution with the support of Quality control Sampled Raw materials are tested for moisture (M%) ; Size Distribution with the support of Quality control Depts. If there are any abnormalities, we can control at initial

Depts. If there are any abnormalities, we can control at initial stages……stages…………Later raw materia……Later raw materials are stored inls are stored in to Day Bins to meet the rated capacity of plant/day. Samples to be taken from Weigh feeders:

(27)

Hot Gas

Generator

Ball Mill

Capacity:424TPH

Grinding Area:

( Sampling of Feed to Mill &

( Sampling of Feed to Mill & Mill discharge feed)

Mill discharge feed)

The term H.G.G refers to Hot Gas Generator used to remove moisture from the mixed raw material (Iron ore, Lime The term H.G.G refers to Hot Gas Generator used to remove moisture from the mixed raw material (Iron ore, Lime stone, Anthracite) before it enters grinding mill , Grinding refers to the size reduction of a material by tumbling it in a stone, Anthracite) before it enters grinding mill , Grinding refers to the size reduction of a material by tumbling it in a revolving cylinder. There are two types of grinding processes (1) Vertical and (2) Horizontal. But we are using

revolving cylinder. There are two types of grinding processes (1) Vertical and (2) Horizontal. But we are using Horizontal

Horizontal grinding process. This occurs when the ore grinding process. This occurs when the ore and a grinding media and a grinding media are tumbled together. The grinding mediaare tumbled together. The grinding media used are Hi-Chrome Steel balls. These balls are of different diameters distributed through out the Ball Mill.

used are Hi-Chrome Steel balls. These balls are of different diameters distributed through out the Ball Mill.

The media method of size reduction depends primarily on impact or compression fracture of the ore caused by the The media method of size reduction depends primarily on impact or compression fracture of the ore caused by the impact action of heavier steel balls. Such impacts caused by the

impact action of heavier steel balls. Such impacts caused by the impacts or point-to-point contaimpacts or point-to-point contacts occur between thects occur between the ore and the balls or between the balls and the mill shell liners. It is important that the balls are large enough so that as ore and the balls or between the balls and the mill shell liners. It is important that the balls are large enough so that as many points of contacts as possible occur and sufficient impacting action is provided which will

many points of contacts as possible occur and sufficient impacting action is provided which will result in the properresult in the proper breaking of the ore particle.

(28)

Grinding

Media

Mill

Liners

Mill

Diaphragm

•• The grinding mill liners are provided with lifters. As the The grinding mill liners are provided with lifters. As the mill cylinder is rotated the mill cylinder is rotated the lifters lift the balls to givelifters lift the balls to give them a proper cascade pattern and the energy to do breaking. The

them a proper cascade pattern and the energy to do breaking. The cascade pattern is determincascade pattern is determined by theed by the rotating speed of the mill cylinder and the

rotating speed of the mill cylinder and the mill diameter. The energy consumed in grinding is thereforemill diameter. The energy consumed in grinding is therefore proportiona

proportional to the weight of media, the diameter and rotationall to the weight of media, the diameter and rotational speed of the mill.speed of the mill.

•• The size of the ball mThe size of the ball media is determined edia is determined by the size of by the size of the incoming feed particles. Larger sized ore requirethe incoming feed particles. Larger sized ore requires as a larger ball size for

larger ball size for good impact efficiency. As the ore is good impact efficiency. As the ore is gradually reduced size, the media itself wears out andgradually reduced size, the media itself wears out and the balls are reduced in

the balls are reduced in size. These smaller balls are also size. These smaller balls are also necessary, as these balls are still adequate in size necessary, as these balls are still adequate in size toto cause fracture because many more points of contact occur and many more balls are present per unit volume. cause fracture because many more points of contact occur and many more balls are present per unit volume. It is imperative to add bigger size balls for two reasons.

It is imperative to add bigger size balls for two reasons.

•• To keep up the number of bigger size balls to break the large ore particles.To keep up the number of bigger size balls to break the large ore particles.

•• To maintain the required number of balls in To maintain the required number of balls in the mill to provide the the mill to provide the power required for grinding. The mediapower required for grinding. The media should be added as and when required as the balls are continuously being worn away.

should be added as and when required as the balls are continuously being worn away.

•• Another mechanism of size reduction that occurs in the mill together with impact grinding is abrasiveAnother mechanism of size reduction that occurs in the mill together with impact grinding is abrasive grinding or attrition grindin

grinding or attrition grinding or grinding by rubbing as the oreg or grinding by rubbing as the ore particles and media slide and rub againparticles and media slide and rub against eachst each other as the ball mill rotates.

(29)

Dimensions

D=6.6M

L=12M

•• The patterns, which generally exist, are:The patterns, which generally exist, are:

--•• Cascade PatternCascade Pattern – – Here the lifters lifts the balls giving theHere the lifters lifts the balls giving them the proper cascadm the proper cascading energy for ing energy for breaking up the ore initially.

breaking up the ore initially.

•• Impact PatternImpact Pattern-- Once the balls lifted up and after attaiOnce the balls lifted up and after attaining a definite height it falls dning a definite height it falls down onown on the ore creating fractures. More the intensity of

the ore creating fractures. More the intensity of the balls finer be the the balls finer be the size reduction.size reduction.

•• Attrition PatternAttrition Pattern – – This takes place along with the impaThis takes place along with the impact grinding, here dct grinding, here due to rubbing /ue to rubbing / sliding of the ore particles and

sliding of the ore particles and the media against each other, size reduction takes the media against each other, size reduction takes place on theplace on the mill rotation.

mill rotation.

•• ThThe de disischchararge ge of of ththe be balall ml milill l papasssseed td thrhrouough gh ththe Se SEPEPOL OL aa DyDynanammic ic sesepapararatotor tr too

separate the fine particles from coarse particles, it

separate the fine particles from coarse particles, it acts as a acts as a classifier. Theclassifier. The

separated coarse particles are recirculated to mill for regrinding. separated coarse particles are recirculated to mill for regrinding.

(30)

Make

-Polysius

Polysius

• •

•• CRITICAL SPEED OF BALL MILLS:CRITICAL SPEED OF BALL MILLS:CRITICAL SPEED OF BALL MILLS:CRITICAL SPEED OF BALL MILLS: ---

-•

•

•• ØØØCRITICAL SPEED: ØCRITICAL SPEED: CRITICAL SPEED: IT IS THE LOWEST RPM WCRITICAL SPEED: IT IS THE LOWEST RPM WHICH WILL CAUSE AN IT IS THE LOWEST RPM IT IS THE LOWEST RPM WHICH WILL CAUSE AN WHICH WILL CAUSE AN HICH WILL CAUSE AN INFINIINFINI TELY SMALLINFINIINFINITELY SMALLTELY SMALLTELY SMALL PARTICLE ON THE SHELL LINER TO CENTRIFUGE.

PARTICLE ON THE SHELL LINER TO CENTRIFUGE.

PARTICLE ON THE SHELL LINER TO CENTRIFUGE. PARTICLE ON THE SHELL LINER TO CENTRIFUGE. •

•

•• ØØØØBALL MILLS ARE NORMALLY OPERATED AT 70BALL MILLS ARE NORMALLY OPERATED AT 70BALL MILLS ARE NORMALLY OPERATED AT 70 – BALL MILLS ARE NORMALLY OPERATED AT 70 – – 75% CRITICAL SPEED. – 75% CRITICAL SPEED.75% CRITICAL SPEED.75% CRITICAL SPEED.

•

•• ØØØØCRITICAL SPEED: [RPM] = 76.63 /CRITICAL SPEED: [RPM] = 76.63 /CRITICAL SPEED: [RPM] = 76.63 / √CRITICAL SPEED: [RPM] = 76.63 / √√ D√DDD Where D is the

Where D is the Internal Diameter of mill in feet, Internal Diameter of mill in feet, measumeasu

Where D is the Internal Diameter of

Where D is the Internal Diameter of mill in feet, mill in feet, measumeasu red inside shell linersred inside shell linersred inside shell linersred inside shell liners •• Types of circuits used in the Mills: -Types of circuits used in the Mills:

-•• Single MillSingle Mill

•• Primary as Single MillPrimary as Single Mill •• Primary as Twin CircuitPrimary as Twin Circuit •• Single as Twin circuitSingle as Twin circuit •• Types of Grinding Media:Types of Grinding Media: •• Steel BallsSteel Balls

•• RodsRods •• PebblesPebbles

•• Types of Grinding Mills :Types of Grinding Mills : •• Rod MillsRod Mills

•• Ball MillsBall Mills •• Pebble MillsPebble Mills

(31)

Sampling of Feed Sampling of Feed

to Ball Mill for to Ball Mill for Moisture% & Size Moisture% & Size

Distribution Distribution

Live load test to be Live load test to be

carried on carried on AL2111.01/2112.01/2113. AL2111.01/2112.01/2113. 01 01 Sampling of Mill Sampling of Mill discharge for discharge for Moisture%, Blain Moisture%, Blain .No, Size fractions .No, Size fractions

Fig:-001

Process Sampling At Ball Mill Area

(32)

Automatic Sampler: Apart from manual sampling

Automatic Sampler: Apart from manual sampling as showed in fig:-001,

as showed in fig:-001,

Automatic sampling un

Automatic sampling units are also facilitated in V

its are also facilitated in Vale Pellet Plant

ale Pellet Plant for sampling

for sampling

purpose in Grinding Area.

A sample is extracted when a hollow tube with a A sample is extracted when a hollow tube with a longitudinal slot rotates into position against the longitudinal slot rotates into position against the material flow.

material flow. The sample The sample falls directly thfalls directly through the tuberough the tube and into a sample bottle.

and into a sample bottle.

This is specially designed to extract dry, non-sticky, This is specially designed to extract dry, non-sticky, bulk solid powders on a continuous or intermittent bulk solid powders on a continuous or intermittent basis from air assisted conveyors

basis from air assisted conveyors

Air Slide Sampler

Dimensions: Dimensions:

W x H x D/mm = 340 x 660 x 240 W x H x D/mm = 340 x 660 x 240 Sample collecting container volume = 51 Sample collecting container volume = 51

(33)

Paddles

Intensive Intensive Mixer Mixer Make:Lodige Make:Lodige capacity: 650 capacity: 650 T/Hr T/Hr Length:5 Mtr Length:5 Mtr Dia:1.85Mtr Dia:1.85Mtr

Mixing & Blending Area:

( Sampling of Mixed material & Bentonite )

••

Mi

Mixer i

xer is pro

s provi

vided fo

ded for mix

r mixing o

ing of iro

f iron ore c

n ore conc

oncent

entrat

rate & bent

e & bentoni

onite

te on co

on cont

ntinu

inuou

ous bas

s basis.

is.

••

Plou

Ploughsh

ghshare sh

are shovel

ovels rot

s rotate in

ate in speci

special ar

al arrangem

rangement a

ent alon

long the

g the hori

horizonta

zontal sha

l shaft in

ft inside

side a hori

a horizont

zontal,

al,

cylindrica

cylindrical

l mixing drum. The size, number, positioning, geometric shape and peripheral

mixing drum. The size, number, positioning, geometric shape and peripheral speed of the

speed of the

mixing elements are coordinated for three-dimensional movement of the components inside the

mixing drum. The resultant turbulence, with constant, total product

mixing drum. The resultant turbulence, with constant, total product mobility caused by the mixing

mobility caused by the mixing

elements, prevents the formation of dead or static zones and

elements, prevents the formation of dead or static zones and results in gentle, precision mixing

results in gentle, precision mixing

within the shortest possible time.

••

Mix

Mixing

ing eleme

elements li

nts lift p

ft produ

roduct du

ct during r

ring radial

adial move

movement

ment from t

from the wa

he wall o

ll of the

f the drum

drum ther

thereby p

eby preven

reventing

ting

particles from becoming squashed between the wall

particles from becoming squashed between the wall and the

and the shovel. The hurling and whirling

shovel. The hurling and whirling

process is, therefore, highly suitable for

process is, therefore, highly suitable for mixing processes in which the co

mixing processes in which the components have widely

mponents have widely

differing bu

(34)

Feed Rate of Feed Rate of

WF’s-AL3112.01,02 AL3112.01,02 Bentonite Bentonite Sampling for Sampling for Moisture% Moisture% Grind% & Grind% & Swelling Index Swelling Index

Sampling at Mixer Discharge

for Moisture% , LOI &

Chemical analysis.

Process Sampling

(35)

Thickener Area:

(Sampling of slurry )

Diameter:

Diameter: 30 m²area

30 m²area ThickenerThickener

Arms Arms

•• ThickThickeninening is a prg is a process ocess of redof reducing ucing the lithe liquid cquid contenontent and t and therethereby incby increasireasing the sng the soliolid densd density witity within thin the sluhe slurry.rry. The mechanism is all based on the settling rate. The settling is

The mechanism is all based on the settling rate. The settling is even controlled by the rotation of the rake arms. Theeven controlled by the rotation of the rake arms. The rotation of the rake arms makes the

rotation of the rake arms makes the denser particles to be dragged to denser particles to be dragged to the central portion and the light particles movethe central portion and the light particles move to the periphery. Almost clear water is taken as the overflow.

to the periphery. Almost clear water is taken as the overflow. Thickener is essentially a conical tank like structure.Thickener is essentially a conical tank like structure. It has a central shaft at the axis of the conical tank.

It has a central shaft at the axis of the conical tank. The rakeThe rake arms are attached to a sprockarms are attached to a sprocket that rotates about theet that rotates about the central shaft. There are four arms, two long and two short, all 90°

central shaft. There are four arms, two long and two short, all 90° apart. The longer arms are responsibapart. The longer arms are responsible for thele for the settling action. The shorter arms mainly deal with

settling action. The shorter arms mainly deal with the central portion. But the central area the central portion. But the central area is a denser portionis a denser portion subjecting more torque on the arms

subjecting more torque on the arms. The shorter arms handle such. The shorter arms handle such denser matter reducing the torque on longer denser matter reducing the torque on longer arms.

(36)

Process sampling at Thickener area

Random Snap-cuts of slurry

samples has to collected

diff.intervals to have uniformity in

sample

Slurry Sampling

at Thickener

under flow for

Density & % of

solids checking as

per ISO:2591

(37)

CBBS extracts a rep

CBBS extracts a representative sresentative sample from ample from the falling flow the falling flow of material off of material off a belt conveyor.a belt conveyor. It’sIt’s carriage-mou

carriage-mounted cutter traverses through the nted cutter traverses through the material flow, collecting the product material flow, collecting the product sample assample as it goes, before discharging it into a

it goes, before discharging it into a hopper positioned outside the material flowhopper positioned outside the material flow

CBBS –

CBBS – Cross BelCross Belt Bucket St Bucket Sampler ampler Mounting may be in chutes, hoppers, at belt-end or head

Mounting may be in chutes, hoppers, at belt-end or head chutes. When activated, a slotted sample tube chutes. When activated, a slotted sample tube entersenters the product stream with the slot

the product stream with the slot facing down. While full y extended, the sample tube rotates facing down. While full y extended, the sample tube rotates 270 degrees,270 degrees, taking a representative sample through the product stream. The sample tube then retracts out

taking a representative sample through the product stream. The sample tube then retracts out of the productof the product stream, into the sampler housing and deposits the sample into the

stream, into the sampler housing and deposits the sample into the discharge. The sample tube can be drivendischarge. The sample tube can be driven pneumatically or hydraulically.

pneumatically or hydraulically.

In our process Cross Belt Samplers are provided at conveyor

In our process Cross Belt Samplers are provided at conveyor TR.3113.01TR.3113.01 && TR.3123.01TR.3123.01-Mixing &-Mixing & Blending Area to Balling Feed. Sample will be collected at

-Blending Area to Balling Feed. Sample will be collected at - CT.3113.01CT.3113.01. Capacity :. Capacity : 2.5kgs2.5kgs & & feed feed raterate of conveyor:

of conveyor: 900Tph900Tph.Samples are collected in a .Samples are collected in a box later carried to Quality Lab box later carried to Quality Lab manually.manually.

Automatic Sampling System –ISO-3082(2000)

(38)

Agglomeration: Agglomeration:

As the Mixed Material is fed to the As the Mixed Material is fed to the Balling disc, it gets lifted upwards due to

Balling disc, it gets lifted upwards due to the rotation of the rotation of the disc. The material gets lifted up as

the disc. The material gets lifted up as long as the frictionlong as the friction between the ore particles and the disc bed is more than between the ore particles and the disc bed is more than the gravitational force. Once the gravitation force on the the gravitational force. Once the gravitation force on the ore particles is more than the frictional force, the particles ore particles is more than the frictional force, the particles roll down. As the particles roll down, they agglomerate. roll down. As the particles roll down, they agglomerate. The agglomeration of

The agglomeration of the particles the particles continues as continues as long aslong as the rolling movement is sustained, resulting in formation the rolling movement is sustained, resulting in formation of the balls.

of the balls.

Technical details of Balling Discs Technical details of Balling Discs::

The palletizing discs consist of a flat circular base with a wall The palletizing discs consist of a flat circular base with a wall perpendicular to the plane of the base along the circumferences. perpendicular to the plane of the base along the circumferences. Scrapers are provided on the base and side wall for deflecting Scrapers are provided on the base and side wall for deflecting the material. The disc is inclined at angle greater than the angle the material. The disc is inclined at angle greater than the angle of response of the feed material and is rotated in this plane with of response of the feed material and is rotated in this plane with a variable speed drive. The scrapers are fixed 1 position and do a variable speed drive. The scrapers are fixed 1 position and do not rotate with the disc.

not rotate with the disc.

•

•Inside Diameter: 7500 mmInside Diameter: 7500 mm

•

•RotatRotation Spion Speed: 5 eed: 5 --10 rpm10 rpm

•

•Feeding CFeeding Capacitapacity: 150 y: 150 ––180 TP180 TPHH

Palletizing Disc Area: (Sampling of Green Ball )

(39)

M

Meecch

haan

niissm

m o

off B

Baallll F

Fo

orrm

maattiio

on

n::

liquid bridges liquid bridges rolling up

rolling up

powd powder er seedseed

spraying spraying binder droplet binder droplet drying/solidifying drying/solidifying solid bridges solid bridges Green pellet Green pellet G Granuleranule „ „ snowball“-structure snowball“-structure

Spheronizing of Wet Granules Spheronizing of Wet Granules

Powder layering Powder layering Factors effecting

Factors effecting Balling:-Inclination of Balling Disc Inclination of Balling Disc Disc Speed Disc Speed Feed Rate Feed Rate Moisture content Moisture content Sidewall height Sidewall height

Surface Area of the Particle Surface Area of the Particle

Principle of

Principle of Agglomerati

Agglomeration

on

Spheronizing

Green pellet Green pellet

(40)

Process Sampling at Palletizing Discs Area

Green Ball Drop test Green Ball Drop test

G.C.S –

G.C.S –Green compression Green compression strengthstrength

Green Ball Sampling for Moisture % , Size fraction , Drop. No , G.C.S

Checking of Ball Checking of Ball formation formation in discs in discs BL-3131.01-BL-3131.01-0707

(41)

Traveling Grate Area

:

( Sampling of Feed to T.G ,

Discharge material of T.G, Measurement of

Discharge material of T.G, Measurement of Temperature, Differential

Temperature, Differential

Pressures and Process Gas

Pressures and Process Gas flow)

flow)

Brief:

Brief: The traveling grate is used primarily to dry The traveling grate is used primarily to dry and preheat green balls for feeding into the rotary kiln,and preheat green balls for feeding into the rotary kiln, where they are indurated. The traveling grate provides the means for efficient

where they are indurated. The traveling grate provides the means for efficient heat transfer with high,heat transfer with high, medium and low temperature gases. These gases transfer heat by convection so intimate gas solids contact medium and low temperature gases. These gases transfer heat by convection so intimate gas solids contact is required for effective heat transfer.

is required for effective heat transfer. Dried green balls do not

Dried green balls do not have the physical properties necessary to survive direct feeding to the rotary kilnhave the physical properties necessary to survive direct feeding to the rotary kiln and must be semi-indurated. For acceptable semi-induration, it is necessary for green balls to be

and must be semi-indurated. For acceptable semi-induration, it is necessary for green balls to be substantially heated and fluxston

substantially heated and fluxstonee carbonates (if used) to be substantially calcincarbonates (if used) to be substantially calcined. Good gas-solids contacted. Good gas-solids contact is required to caus

is required to cause bonding e bonding to occur and to occur and to remove Cto remove CO2 so that calcinationO2 so that calcination of the fluxstoof the fluxstonene can proceed atcan proceed at reasonable rates. This semi-ind

reasonable rates. This semi-indurationuration or preheating is accomplished by flowinor preheating is accomplished by flowing the gases exiting theg the gases exiting the annular cooler and rotary kiln throug

annular cooler and rotary kiln through the bed of dried balls inh the bed of dried balls in the tempered preheat and preheat zonethe tempered preheat and preheat zoness respectively of the traveling grate.

(42)

Process Sampling at Traveling Grate

Checking the Bed Height, Checking the Bed Height, Sampling of feed to T.G for Sampling of feed to T.G for Moisture% & Size fraction Moisture% & Size fraction Checking Gapping of Roller

Checking Gapping of Roller Classifiers CS3131.01-07 & Classifiers CS3131.01-07 & Roller Feeder AL3131.01 Roller Feeder AL3131.01

(43)

External view of External view of Traveling Grate Traveling Grate

Internal view of Internal view of Traveling Grate Traveling Grate

Be

Bed Levd Level cel checkinheckingg

Process Measurement of Temperatures , Differential Pressures & Gas

Process Measurement of Temperatures , Differential Pressures & Gas Flows

Flows

Process Control Monitoring Process Control Monitoring of Pr

of Profile ofile Deviation……Deviation……

298.

298.90M²90M²AreaArea

L

(44)

Analyzing of Process Parameters Analyzing of Process Parameters

Temperatures Temperatures & & Differential Pressures Differential Pressures & &

Gas Flows, at Indurations Duct, Gas Flows, at Indurations Duct, Wind Boxes, Heating zones ,Stack sampling Wind Boxes, Heating zones ,Stack sampling

etc………. etc……….

(45)

Rotary Kiln & Annular cooler Area:

( Measurement of Kiln Feed

end, Middle, Discharge

Temperatures, Gas Flow & Sampling of finished product )

Rotary Kiln Rotary Kiln

The rotary kiln is a downwards-sl

The rotary kiln is a downwards-sloping cylinder from the traveling grate to the annular cooler.oping cylinder from the traveling grate to the annular cooler. The speed of rotationThe speed of rotation controls the rate of solids flow through the

controls the rate of solids flow through the rotary kiln and imparts a mixing action to rotary kiln and imparts a mixing action to the pellet burden. The mixing actionthe pellet burden. The mixing action is important because it creates a

is important because it creates a homogenehomogeneous pellet product. All of the ous pellet product. All of the pellets are exposed to the burner pellets are exposed to the burner flame for an equalflame for an equal amount of time.

amount of time.

This residence time is sufficient to uniformly indurate all pellets, thereby

This residence time is sufficient to uniformly indurate all pellets, thereby minimizing the ball-to-ball quality differencesminimizing the ball-to-ball quality differences inherent in pellets discharging from the static bed processing typical of a

inherent in pellets discharging from the static bed processing typical of a SG.SG. At the discharge end of

At the discharge end of the rotary kiln is a the rotary kiln is a single burner, which utilizes the hot recuperated (secondary) air from thesingle burner, which utilizes the hot recuperated (secondary) air from the annular cooler for combustion. The burner can be designed to fire

annular cooler for combustion. The burner can be designed to fire a single fuel or a single fuel or a combination of fuels. Oil, Natural gasa combination of fuels. Oil, Natural gas (LBG/Cok

(LBG/Coke oven gas/ BF gas/ Coree oven gas/ BF gas/ Corexx gas) or coal can bgas) or coal can be used singly or in varying mixture used singly or in varying mixtures. Becausees. Because of the single burnerof the single burner,, controlling the indura

controlling the indurationtion process is a simple temperaturprocess is a simple temperature loop. Grate-Kiln plant processing Heme loop. Grate-Kiln plant processing Hematite ore may have fewatite ore may have few additional burners in pre heating zone. This is

additional burners in pre heating zone. This is very different from a SG system that may very different from a SG system that may require up to 50 require up to 50 burners.burners.

Dia: 6.9 Mtr Dia: 6.9 Mtr Length:45Mtr Length:45Mtr

Kiln Burner flame & Red Hot Kiln Burner flame & Red Hot Pellets Discharge from Pellets Discharge from

Kiln Kiln

(46)

Process

Process control control Monitoring Monitoring KilnKiln Temperatures &

Temperatures & Pressures &Pressures & Burner Flame & Stack sampling Burner Flame & Stack sampling

(47)

Sectional view of Annular cooler

Annular Cooler Annular Cooler

The annular cooler is functionally the same as The annular cooler is functionally the same as thethe traveling grate except for

traveling grate except for its annular configuration. Hotits annular configuration. Hot pellets discharging from the rotary kiln are distributed in pellets discharging from the rotary kiln are distributed in

the annular cooler as a level bed. Ambient air is forced the annular cooler as a level bed. Ambient air is forced upwards through the conveying elements (pallets) and upwards through the conveying elements (pallets) and the bed. Thus machine parts are not

the bed. Thus machine parts are not exposed to highexposed to high temperatures.

temperatures.

The pellets are leveled in the annular cooler to a bed The pellets are leveled in the annular cooler to a bed depth of 700 mm and conveyed over up to 4 cooling depth of 700 mm and conveyed over up to 4 cooling zones. In each cooling zone, sufficient cooling air is zones. In each cooling zone, sufficient cooling air is provided to produce the mass of air at

provided to produce the mass of air at a temperaturea temperature required by the rotary kiln and traveling grate and required by the rotary kiln and traveling grate and . The. The various cooling zones are designed in such a

various cooling zones are designed in such a way thatway that they will recover the maximum heat from the

they will recover the maximum heat from the hot pelletshot pellets and various ducts carry this hot air

and various ducts carry this hot air to rotary kiln/to rotary kiln/ traveling grate zones and Ball Mill .

traveling grate zones and Ball Mill . Cooled pellets discharge through the

Cooled pellets discharge through the cooler’s dischargecooler’s discharge hopper at a controlled rate to

hopper at a controlled rate to a product load-out system.a product load-out system.

81 81 M

M²² Ar

Area

ea

Inspection & Sampling of Product Inspection & Sampling of Product Pellet

(48)

The

TheHEAD sampling equipmentHEAD sampling equipmentsamples samples pellet pellet from the end ofrom the end of a belt conveyof a belt conveyor. This product r. This product collects accuratecollects accurate representa

representative samples when mounted on the end of tive samples when mounted on the end of a belt conveyor carrying the product. Sampler installations are designeda belt conveyor carrying the product. Sampler installations are designed per application.

per application.

When activated an electric motor drives the slotted sample cutter

When activated an electric motor drives the slotted sample cutter through the product flow to collect a through the product flow to collect a sample of the material.sample of the material. The sample is discharged via gravity to a

The sample is discharged via gravity to a sample collection point. Sample collection is initiated in rsample collection point. Sample collection is initiated in r esponse to either anesponse to either an operator’s manual command or a signal automatically generated by controller logic, usually time-based but which could also operator’s manual command or a signal automatically generated by controller logic, usually time-based but which could also be volume or quantity based.

be volume or quantity based. In our process Head

In our process Head Samplers are provided at conveyor Samplers are provided at conveyor TR.1010.12 TR.1010.12 & & TR.1010.13-TR.1010.13- Product Pellet Carrying Conveyor atProduct Pellet Carrying Conveyor at Transfer tower CT-1010.10&CT-1010.11.Capacity :

Transfer tower CT-1010.10&CT-1010.11.Capacity : 6.5kgs6.5kgs& & feed rate of feed rate of conveyor :conveyor : 750Tph750Tph.Samples are collected in a.Samples are collected in a Sampling box later carried to Quality Lab manually.

Sampling box later carried to Quality Lab manually.

Automatic Sampling System –ISO-3082(2000)

(49)

Product Coating Area :

(Sampling of coating material )

Depending on customers requirements the finished product is coated to avoid Depending on customers requirements the finished product is coated to avoid Sticking of pellets in the further reduction process. To avoid such conditions Sticking of pellets in the further reduction process. To avoid such conditions Pellets are coated with external additives like Limestone or Dolomite with Pellets are coated with external additives like Limestone or Dolomite with Bentonite acts as binder, together called as oxide coating of pellets.

Bentonite acts as binder, together called as oxide coating of pellets. Pellets are coated with a additives ratio 5:1 of Limestone to Bentonite. Pellets are coated with a additives ratio 5:1 of Limestone to Bentonite.

Role of Process control is to monitor the Process variables like: Role of Process control is to monitor the Process variables like:

Checking additives blend ration Checking additives blend ration

Flow rate ~ Tonnage Flow rate ~ Tonnage

Checking Pulp Density & % of Solids ( approx: 1.15gm/cc & 22 % Checking Pulp Density & % of Solids ( approx: 1.15gm/cc & 22 % solids)

solids)

Maintaining the Product Pellet Moisture to 1.5 % max Maintaining the Product Pellet Moisture to 1.5 % max..