Proposal of 200KT PIG IRON PROJECT

Page - 1 -

200KT/Y Pig Iron Project

Technical Proposal

Project No.:

Contact: Mr. Guo ke/郭珂

Email: [email protected] Skype: guoke896884090

Mobile：+86 13299042234 Website：www.xinliyejin.com

April 2015

XI’AN XINLI METALLURGICAL EQUIPMENT ENGINEERING CO., LTD.

NO.16 C DISTRICT, XIAN PIONEERING PARK, NO. 69 JINYE RD, XI’AN HI-TECH INDUSTRIES DEVELOPMENT ZONE, XI’AN CITY, P.R.CHINA

Cell phone: 0086 132 9904 2234 Email: [email protected]

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ChapterⅠGeneral

1.1 Production scale and products solution

1.1.1 Production scale

After the completion of the project, the final product is annual output of

200,000 tons cast iron.

Annual output of the project intermediate product is annual output of

360,000 tons sintered ore.

1.1.2 Product solutions

Annual output of 200,000 tons of cast iron L10 steel

1.1.3 Main equipments

Sintering: 1 * 36m2 sintering machine;

Blast furnace iron making: 2 * 80m3;

Facilities: power supply system, water supply and drainage system,

gas system, air compressor station, dust, ventilation and air conditioning

system, test center.

1.2 Main project brief

1.2.1 Sintering

1.2.1.1 Process overview

This project adopts one set of 36m2 belt sintering machine, without

India company sintering raw material for sintering experiment condition,

referring with China similar sintering experience, 1 * 36m2 sintering machine

design adopts co-efficiency of 1.35t/m2·h and 42.6t/ set·h with an annual

output of 35.8 * 104 tons finished sintered ore sinter, the sintered ore is

R2=0.95~1.05 (this project adopts 1.05), the sintered ore size 5～100mm ,




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wherein, ＞50mm is less than 5%,＜5mm is less than 10%.

Sintering process is from fuel and flux, iron containing material

acceptance to finished sinter output; including: raw material acceptance and

transportation, fuel crushing, batching, first mixing, second mixing, material

spreading, ignition and sintering, hot ore crushing , screening, cooling and

finished product output; at the same time with draw dust and ash, silencer

and other facilities.

1.2.1.2 Iron containing raw material requirement

(1) Iron containing raw material

The iron containing raw materials for the 1 * 36m2 sintering workshop is

Indian refined ore and blast furnace groove screened retiring ore, with grain

size of 0 ~ 8mm and low chemical composition fluctuation.

(2)Fusion

Appropriate particle size of limestone, dolomite, and lime are adopted

as flux.

(3) Fuel

Solid fuel for sintering is screened power coke from the blast furnace

groove. The grain size for factory acceptance is ＜5mm, and then crushed

to particle size of 3 ~ 0mm for sintering material and anthracite can be as

supplement when the broken coke is not sufficient, factory acceptance size

should be controlled ＜25mm.

Sintering gas fuel is blast furnace gas, and as fuel for preheat stove,

blast furnace gas calorific value is 3349.4kJ/Nm3, the contact pressure at the

main sintering building is greater than 5000Pa, dust compression is under

50mg/m3

1 * 36m2 sintering all input raw materials, fuel and the physical

characteristics as shown for table 1.2-1:

Table 1.2-1 Original fuel supply and incoming conditions




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1.2.2 Iron making

1.2.2.1 Workshop consists

Iron making plant includes 2X80m3 blast furnaces, blast furnace material

bin and top feeding system, furnace gas system, hot blast stove system,

tapping field system, cast iron machine system.

The project products are annual output of 200,000 tons of iron and all

cast iron ingots. Annual water slag production: 100,000 tons of, as building

material. An annual output of 13,000 tons of gas ash is for sintering batching

by vehicle. Blast furnace gas production is 4.11 * 108Nm3, 1.9 * 108Nm3 for

the hot blast stove, and 0.38 * 108Nm3 for sintering machine, cast iron and

other user.

1.2.2.2 Iron making advanced technology

A. Blast furnace adoption of water-cooled carbon furnace hearth

with ceramic cups, long life of hearth bottom, molten iron thermal energy.

B. Top combustion hot blast stove ceramic burner, air temperature is

1100 , the dome cone ball type hot blast stove.℃

C. Blast furnace gas with dry bag dust removal, low energy

consumption, low water consumption.

Chemical composition fluctuation (%) Items

Spec.

Dry supply

(×104t/a)

Size

(mm)

Bulk density

(t/m3)

Water

(%) Fe SiO2 Alkalinity

Fine iron powder 37.94 8～0 2.2 =10 ±0.5 ±0.2 ±0.05

Returning ore 1.58 5～0 1.8 =10 — — —

Lime stone 2.36 3～0 0.55 =3

Quick lime 1.26 3～0 0.55 — — —

Fuel 2.15 40～0 0.55 =10 — — —




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1.2.2.3 Blast furnace technology index

Table 1.2-2 Blast furnace technology indexes

No Index items Unit Value

I Blast furnace

1 Blast furnace nominal capacity m3 2X80

2 Using co-efficiency tHM/m3·d 3.0

3 Coke rate Kg/t·Fe 700

4 Working rate Days 350

II Production output(per year)

1 Molten iron 104t/a 20

2 Blast water slag 104t/a 10

3 Blast furnace gas 108Nm3/a 2.21

4 Coke powder 104t/a 0.7

5 Screened sintered ore 104t/a 2.1

III Raw material and fuel consumption (per year)

1 Sintered ore 104t/a 35.8

2 Coke 104t/a 13.29

3 Coal 104t/a 2.1

1.2.3 Power supply

Each workshop installation load

No. Item 10KV start 380v start

1 Sintering workshop 1600kw 1278kw

2 Iron making workshop load 2000kw 1268kw




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Sub total 3600kw 2546kw

1.2.4 Water supply and drainage

(1) Water and supplement water amount

1) Sintering production water is 114 m3 / h, net circulating water is 85 m3 /

h, water production consumption 26 m3 / h, water circulation supplement 3 m3

/ h. Water circulation rate of cooling water system is 96.6%.

2) Blast furnace part design and production water is 2220 m3 / h, among

which net circulating water is 900 m3 / h, blast furnace water slag of turbid

circulating water is 800 m3 / h, cast iron turbidity water cycle volume is 300 m3

/ h, water circulation supplement 120 m3 / h.

1.2.5 Ventilation dust removal

The project ventilation and dust removal system include:

(1) Sintering end and finished product screen dust removal

Sintering machine tail and close to its production equipment

configuration of dust and gas are concentrated to the tail dust removal system

for processing.

(2) Fuel dust removal system

Fuel in the process of crushing, transshipment produces large amounts

of coal powder, coke powder, a dust removal system is designed for the fuel

and broken.

(3) Quick lime warehouse top dust removal system

Quick lime warehouse adopts pneumatic conveying, dedusting

ventilation facilities are installed at the top of the lime bin.

(4) Blast furnace ore tank dust removal system

Places such as blast furnace ore tank under the vibrating feeder,

vibrating screen, weighing hopper and tape the feeding have plenty of dust,

so that trough dust removal system settings of the airtight drawing fan is




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designed to prevent the spread of the dust.

(5) Blast furnace dust iron removal

Blast furnace dust removal mainly solves the smoke and dust at the

tapping process of the blast furnace iron mouth iron field, the iron blast

furnace dust removal system is set in order to effectively control the large

amount of smoke tapping process and mitigate the effects of high

temperature thermal radiation for operators, above the point of taphole is set

with a dust drawing fan.

1.2.6 Fuel gas

This project design fuel gas facilities includes blast furnace gas supply

facilities.

(1) Blast furnace gas

Blast furnace gas main users are sintering machine, hot blast stove, and

blast furnace gas is produced from the blast furnace workshop, outlet from

the net the main gas pipe.

1.2.7 Thermal

This project thermodynamic facilities design mainly includes: blast

furnace blower room, blast furnace air supply pipe, air compressor station

and compressed air pipes.

(1) The blast furnace blower room are indoor and outdoor sets, main fan

is set with blower, gas station, next to the machine line, cooling water pipe,

the fan in and out of the air pipe line; auxiliary layout is set with high and low

voltage transformer room, operation room, outdoor air filter, wind inlet and

outlet pipe and circulating pipe, and muffler, two blast furnaces adopt two sets

in operation and one set for preparation arrangement.

(2) Air compressor station

The air required in project is produced from air compressor station.

Compressed air is mainly used in open hole machine, hydraulic blocking slag




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machine, cast iron machine, blowing dust removal system and equipment,

etc.




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Chapter II Project construction technology process

2.1 Sintering process

2.1.1 Iron containing raw material requirement

2.1.1.1 Iron containing raw material

The iron containing raw materials for the 1 * 36m2 sintering workshop is

Indian refined ore and blast furnace groove screened returning ore, with grain

size of 0 ~ 8mm and low chemical composition fluctuation.

2.1.1.2 Fusion

Appropriate particle sizes of limestone, dolomite, lime are adopted as

flux.

2.1.1.3 Fue l

Solid fuel for sintering is screened power coke from the blast furnace

groove. The grain size for factory acceptance is ＜5mm, and then crushed

to particle size of 3 ~ 0mm for sintering material and anthracite can be as

supplement when the broken coke is not sufficient, factory acceptance size

should be controlled ＜25mm.

Sintering gas fuel is blast furnace gas, and as fuel for preheat stove,

blast furnace gas calorific value is 3349.4kJ/Nm3, the contact pressure at the

main sintering building is greater than 5000Pa, and the dust concentration is

less than 50mg /m3.

1 * 36m2 sintering all input raw materials, fuel and the physical

characteristics as shown for table 2.1-1:

Table 2.1-1 Original fuel supply and incoming conditions

Chemical composition fluctuation (%) Items

Spec.

Dry supply

(×104t/a)

Size

(mm)

Bulk density

(t/m3)

Water

(%) Fe SiO2 Alkalinity

Fine iron powder 37.94 8～0 2.2 =10 ±0.5 ±0.2 ±0.05




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2.1.2 Design scale, working system and the product plan

2.1.2.1 Factory design scale

This project adopts one set of 36m2 belt sintering machine, without India

company sintering raw material for sintering experiment condition, referring

with China similar sintering experience, 1 * 36m2 sintering machine design

adopts co-efficiency of 1.35t/m2·h and 42.6t/ set·h with an annual output of

35.8 * 104 tons finished sintered ore sinter, the sintered ore is R2=0.95~1.05

(this project adopts 1.05), the sintered ore size 5～100mm , wherein, ＞

50mm is less than 5%,＜5mm is less than 10%.

2.1.2.2 Working system

The system of sintering workshop work for continuous work, daily

three shifts , each shift 8 hours, calendar operation rate of 87.7%, which is

equivalent to 320 working days.

2.1.2.3 Product plan

According to the assumption of the raw material conditions and quality

requirements of blast furnace sintering, 1 x 36 m2 sintering workshop

production of finished sinter is assumed to the chemical composition shown in

the following table 2.1-4.

Table 2.1-4: Finished sintered ore chemical composition reference

Chemicals TFe P S FeO CaO SiO2 MgO Al2O3 CaO/SiO2

Content % 63.5 0.05 0.025 5.5 8.47 4.97 1.71 1.82 1.7

The physical properties of sintered ore:

Returning ore 1.58 5～0 1.8 =10 — — —

Lime stone 2.36 3～0 0.55 =3

Quick lime 1.26 3～0 0.55 — — —

Fuel 2.15 40～0 0.55 =10 — — —




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Strength of sintered ore: ISO tumbler index (+6.3mm): = 60%;

The finished sintered ore temperature =150℃.

2.1.3 Main technology brief

Sintering process is from fuel and flux, iron containing material

acceptance to finished sinter output; including: raw material acceptance and

transportation, fuel crushing, batching, first mixing, second mixing, material

spreading, ignition and sintering, hot ore crushing , screening, cooling and

finished product output; at the same time with draw dust and ash, silencer

and other facilities.

2.1.3.1 Fuel, fusion, reception and storage of iron content material

Fuel (coke powder and anthracite), fusion (limestone), iron content raw

materials (fine iron powder, returning ore) shall be received by raw material

tape machine, and unloaded through the feeding trolley tape machine

into each designated proportioning bin.

Quick lime is transported to the batching chamber by forklift into

the batching ore bin.

2.1.3.2 Fuel crushing

In order to ensure the qualified sintering fuel particle size of (0 ~

3mm), the fuel crashing design adopts one open circuit crushing process.

Fuel (broken coal or coke) in fuel intermediate bin shall be fed through

motor vibration feeder in the lower part of hopper evenly into the tape

machine, before fuel entering the crusher, iron is removed through iron

remover fixed at the top of the belt machine in order to ensure the

normal work of the crusher. Followed by the belt machine, the fuel is

transported to four roll crusher (φ750X500) crusher, crushed to the size of

0 ~ 3mm, after crushing less than 3mm is > 80% of fuel the amount.

2.1.3.3 Batching

Iron content raw material and fuel shall be batched to a certain




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proportion according to the requirements of iron making, the sintering

chemical composition and supply situation of raw materials.

In order to ensure the correct batching, ingredients of original fuel design

adopts separate centralized weight proportioning, automatic batching system

controlled by computer. Of which: raw materials batching uses the "disk

feeder + electronic belt scale (uniform)" ; fuel batching uses electronic belt

scale (self modulation) ingredients, limestone with "electronic belt scale"

way of feeding , if quick lime needed, the silencer shall be used.

Sintered ore returns to the batching chamber; dust from the head dust

removal, expand the precipitator and the step sintering machine ash pipe

falls into the water sealed groove and the wet material is added to

the mixture on by belt conveyor. The material mixing belt transports them to

the drum mixer for mixing and granulating.

2.1.3.4 Mixing and granulating

Mixing and granulating adopt two sections, mixing equipment is drum

mixing: primary mixing is mainly for the purpose of blending, water addition,

mixing time is ~2.96 min, equipment specification φ2.2 x 7 m; secondary is

mainly water adjustment to the suitable humidity for pelletizing, mixing time is

~2.96 min, equipment specificationφ2.2 x 7 m.

2.1.3.5 Material spreading

After blending pelletizing mixture is convoyed to the sintering machine

at the top of the mixing silo and spread by the circular roller feeder and seven

roller feeder. the circular roller feeder and seven roller feeder device will

spread the mixture evenly on the sintering belt. The thickness of the layers on

the sintering machine is about 520 ~ 600 mm.

2.1.3.6 Ignition and sintering

Sintering ignition adopts hot stove, using blast furnace gas ignition,

micro negative pressure ignition process, furnace hearth pressure is micro




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positive pressure.

Preheating ignition plane at the holding furnace is a fan, lower part of

furnace adopts open box cover structure, roof for the ceiling. Furnace cover

closely holds the hearth.

Due to the low calorific value of the blast furnace gas, in order to ensure

the combustion temperature and the quality of combustion, the design adopts

preheating furnace using blast furnace gas ignition combustion to preheating

air to 400 ~ 450 ℃. At the same time, ignition design high-efficiency

energy-saving hot stove is adopted in order to reduce gas consumption and

solid fuel consumption. Two rows of blast furnace gas ignition burning mouth

are set at the ignition section of the roof, the blast furnace gas and the

preheated air are mixed by the vortex inside the burner and spewing burning,

ensures good surface quality and higher ignition sinter yield.

The ignition section (along the sintering machine rotation direction) is

followed by heat preservation section in order to improve the heat

preservation effect, the roof is lower than the ignition period to guarantee the

ignition material layer can continue combustion to improve the quality of

sintering.

The ignition temperature is 1150 + 50 ℃, the ignition time 1 min,

preservation temperature 600 ~ 800 ℃, holding time 1 ~ 1.5 min.

The sintering machine adopts negative pressure drawing thick layer.

The sintering machine on the mixture after ignition is negative pressure

drawing sintering.

2.1.3.7 Main drawing head and nose dust removal system

In order to prevent environmental pollution, prolong the service life of

the equipment and reduce the waste of raw material, special exhaust blower

fan is adopted for the sintering. At the same time two stages dust removal

(expand precipitator + head filter) are set in front of the fan, the flue gas after

sintering purification by dust removal system, the concentration of flue dust

emissions < 50 mg/m3, the collected dust shall be recycled as raw material.




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Main drawing system is composed of bellows, smoke collecting ring,

horn flue, drawing pipe, expanding dust removal, the nose filter, main exhaust

fan and chimney.

Expanding dust specification is 3350×4500; the nose filter is 70 m2 four

bag dust removals. The dust from the sintering machine discharging pipe,

expanding filter and its head precipitator dust is discharged into the water seal

tank, and the water seal scraper scrapes the bottom of the channel of the

plaster together, and discharges the wet material to the to belt mixture and

then into the mixing machine room to participate in the pelletizing.

Main exhaustion drawing negative pressure is 14 KPa, air volume 3600

Nm3 / min. To reduce the noise, a silencer is set on fan outlet piping.

Sintering main chimney’s height is 60m with diameter of 2.5m (inner

diameter).

2.1.3.8 Sintering crushing

The design of sintered cake crushing equipment adopts f 1100 x 1620

single roll crusher. The sintered ore cake discharged from sintering machine

tail chute shall be crushed to less than 100 mm by roll crusher.

2.1.3.9 Hot sintered ore screen and cooling

After crushed sintered ore shall directly fall into SZR1545 hot sinter ore

vibrating sieve for screening, hot screen will screen out fine material part (less

than 5 mm hot return mine) from the hot sintered ore to ensure the

permeability of sinter cooling needs and reduce the resistance and dust

emission in the cooling machine, and can reduce powder ore into blast

furnace.

The ore from heat return under rating sieve bunker shall be storage to

the returning bin, and PZ17 speed regulation device shall batch the

ingredients to mix the disc feeder belt, and then the material shall be sent to

pelletization for new sintering cycle.

The hot sinter greater than 5 mm on the hot sieve shall be sent to blast




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belt cooler, three sets of ventilation cooling machines are set, after cooling the

sintered ore temperature shall be less than 120 . ℃

2.1.3.10 Convoy and storage of sintered ore

Sintered product ore after cooling shall go into 3# transferring station

and meet the requirement of direct transportation to the blast furnace groove

and transportation to the outside.

2.1.4 Composition and configuration of main workshops

2.1.4.1Acceptance of raw material and fuel

All the iron content materials, fuel and flux shall be accepted by raw

materials open storage field, storages, and then loaded to join the mixing

tank, lime powder directly to the mixing tank by gas transportation.

2.1.4.2 Fuel preparation system

In this design, is a fuel with the intermediate bin, fuel crushing chamber,

fuel transfer station, finished product warehouse and related belt conveyor

system.

Fuel crushing chamber is 7.5 mX7.5 m multi-storey buildings. The

chamber is divided into three platforms: + 7.50 m platform with - 1 tape head

department, tape machine with a RCY - P65 permanent magnetic iron

remover hanging above the feeding point; + 3.00 m platform layout with 4

PG -f 750 x 500 four roll fuel crusher, and hole for equipment maintenance

hoist; + / - 0.00 m surface layout land with crusher discharging tape machine.

The room maintenance equipment is set with a 5 t electric single-beam

bridge crane.

2.1.4.3 Raw material storage house, batching room and lime bin

Raw material storage house is 72 m x 11.5 m, batching room main span

is 72 m x 6.5 m , arranged with auxiliary lime warehouse 6 m * 6 m, 6 m x

10.8 m lime digestive chamber and transit , all buildings is an organic whole

design. Raw material storage house is set with three iron refinery ore




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grooves, one ore returning groove, one lime stone groove, one dolomite

groove, and the fuel groove, batching room has 12 ore bins altogether,

including: 1 # as fuel intermediate storage bin, # 2 ~ # 6 for iron concentrate

storage bin, 7 # for ore returning bin #, 8 # ~ 9 # for finished product flux ore

storage bin, 10 ~ 11 # for the finished product bin, 12 # for quick lime storage

bin.

Materials in 1 # ~# 9 storage bin shall be grasped by bridge crane from

raw material storehouse to the bin; 10 # ~#11 storage bin set with - 4

reversible tape machine for the fuel into two bins; 12 # lime bin storage bin

receiving the quick lime through the pneumatic conveying pipe. To stabilize

the mixing tank level, each material bin is equipped with material level meter,

which is continuous on-line measurement. In order to prevent the material

flow blockage, storage bin has vibrator or air cannons under them.

Table 2.1-7:1 * 36m2 sintering batching bin volume calculation

Ore groove

No. Materials Qty

Each

Volume

(m3)

Total effective

volume

(m3)

Bulk

weight

(t/m3)

Total

storage

(t)

Material

consumption

(t/h)

Storage time

(h)

1 Fuel 1 55 55 0.6 33 9 3.6

2～6 Iron refined ore 5 51 255 2.20 561 43.33 12.9

7 Returning ore 1 51 51 1.80 91.8 5.22 17.6

8～9 fuel 2 63 126 0.6 75.6 3.4 22.2

10 Lime stone 1 63 63 1.6 100.8 2.98 33

11 Dolomite 1 63 63 1.6 100.8 3.18 31.6

12 Quick lime 1 54 54 0.6 32.4 2.14 15.1

Fuel under the feeding intermediate bin is fed through the "feed trough

+TZG-50-130F vibrating feeder", and unloaded on the burning -1 belt

conveyor to the warehouse ±0.00m platform, and transported to the crushing

chamber for crushing .




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Iron containing material batching adopts "PZ17 disk feeder +B650

electronic belt weigher (fixed speed, uniform)" , flux and fuel batching by

B650 electronic belt weigher (drag from speed), lime by "GY type impeller

feeder + electronic spiral scale + digester" .

The batching chamber consists of two platforms: +10.00m platform for

batching bin platform with the main layout of burning -4 reversible belt

conveyers; all the batching devices and burning -1 tape end frame are

arranged in positions on the ground under the 0.00m. Lime bin top is set with

a +12.00m operating platform and dust collector, digestive equipment and

digestive device are arranged under the bin.

The room is set with 2T electric hoist and 2T manual monorail car each

one as a lifting and maintenance tools.

2.1.6. First mixture chamber

First mixture chamber is 8m * 13.2m, ±0.00m with a 2200 x 7000

cylinder mixing machine on the ground buildings, the installation angle is 1.5

degrees, the cylinder center line and the feeding tape machine are coaxial

arrangement in order to ensure smooth material flow and the funnel not easy

to be blocked.

The chamber is provided with two platforms: the tape feeding machine

is arranged on the +5.00m platform, the drum mixing machine and its driving

device, mixer discharging belt is located in the 0.00m on the ground. At the

top of the plant at the same time, set up two sets of 5T electric hoist for

equipment repair.

2.1.6.5 Second mixture chamber

Second mixture chamber is 8m * 13.2m, ±0.00m with a 2200 x 7000

cylinder mixing machine on the ground buildings, the installation angle is 1.5

degrees, the cylinder center line and the feeding tape machine are coaxial

arrangement in order to ensure smooth material flow and the funnel not easy

to be blocked.




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The chamber is provided with two platforms: the tape feeding machine

is arranged on the +5.00m platform, the drum mixing machine and its driving

device, mixer discharging belt is located in the 0.00m on the ground. At the

top of the plant at the same time, set up two sets of 5T electric hoist for

equipment repair.

2.1.6.6 Sintering main workshop

The main sintering building is a multi-storey building with length 53.25m,

width 12M, consists of six layers: The sixth layers of the +20.80m platform is

set with mixing-4 adhesive tape machine, mixing bunker under the platform;

the fifth layer +13.90m platform as the main sintering platform layout, with

main operating room and dry oil station; the fourth layer +10.60m platform

with single roll crusher; the third +9.80m platform with sintering machine and

single roller operating room; the second layer +6.10m platform with

SZR1545 hot vibrate screen; the first layer + 0.00m with air blower, water

seal and corresponding water seal zipper machine groove, and PZ17 hot

returning ore disk feeder.

The head of sintering machine is equipped with 3350 x 4500 precipitator

and 70m2 four electrostatic precipitator each one, all the dust discharging

pipeline and sintering flue ash falling pipe is directly inserted into the water

tank water seal zipper to improve the environment and avoid air leakage.

The main equipment of sintering room is set with one 5T electric single

girder crane and a 1t electric hoist (maintenance of mixed -4 tape machine).

2.1.6.7 Belt cooling chamber

The sintering discharging machine is arranged with 42m2 blast belt

cooling machine at its end, Belt cooling chamber is divided into four layers:

the fourth layers +8.207m platform with the belt cooling machine

transmission device; the third layer +5.577m platform with cooler head and

equipment overhaul hoisting hole; the second layer +1.80m platform with

cooling belt discharging and equipment overhaul hoisting hole; the first

0.00m plane is open layer. Take the rest with coolers strip layout. Belt




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cooling machine is set with three sets of G4-73-11D blowers.

The cooling belt machine maintenance equipment is 5T electric single

girder crane.

2.1.6.8 Main drawing fan chamber

The main exhauster chamber is 12m * 24m, equipped with a SJ3600

main fan with inlet electric valve and outlet silencer.

The workshop is divided into two platforms: 0.00m planar is fan base

and lubricating station, and have maintenance space on both sides; +1.75m

platform for equipment operation and maintenance platform, with wind

damper actuators placed; at the same time, a small platform 8.200m placed

with high tank. Building insulation measures and design considered.

The room is equipped with a 10t single beam bridge crane hook for

equipment repair.

2.1.7.4 Sintering machine

Table 2.1-10 main technical parameters of 36m2 sintering machine

1 Effective sintering area 36m2

2 Effective sintering length 24m

3 Tail wheel center distance 33.8m

4 Tail wheel diameter 2775.5mm

5 Tail wheel speed 0.131～0.394 r/min

6 Effective size of the trolley 1000×1500×620mm

7 Trolley speed 1.142～3.435 m/min

8 Maximum thickness of material layer 600mm

9 Output 40×104t/A

10 Main drive motor Type No. Y132M-6




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Power 5.5 kW

Rotating speed 960～320 r/min

Specifications f800×1540

Motor type Y112M-6 11 Roller feeder Power 4kW

Specifications f128×1590

Motor type Y90S-4 12 Seven roller feeder Power 1.1 kW

2.1.7.5 Single roll crusher

Single roll crusher specifications should be compatible with the sintering

machine, sintering trolley mainly depends on the discharge width, the design

adopts F1100×1620mm single roll crusher with the following advantages:

uniform broken particle size; main wear parts (gear roller crown, the ① ②

grate plate) is convenient to replace, shorten the repair time, ensure the

operation safety, improve working conditions; main shaft adopts water ③

cooling, roll drive end is provided with a safety device, improves the service

life.

Single roll crusher performance is as follows:

Maximum feed size: 1500 x 1000 x 250mm;

Discharge size: = 100mm;

Speed gear roller: 4.9r/min;

Processing capacity: 60 to 100t/h

2.1.7.6 Hot vibrate screen

Thermal mineral vibrating screen with 1.5m * 4.5m, the performance is

as follows:




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Screen angle: 5 °;

Screen size: 7 x 33mm;

Particle size: less than 100 mm;

Max capacity: 150 t/h

2.1.7.7 Belt cooling machine

Table 2.1-11 42m2 main belt cooling machine technical parameter stable

1 Effective cooling area 42 m2

2 Trolley speed 0.3～0.6m/min

3 Material thickness 1m

4 Process capacity 96t/h

5 Material bulk density 1.6t/m2

6 Feed temperature 700～800℃

7 Discharge temperature ＜120℃

8 Cooling time 45～90min

9 Cooling machine angle 12°

10 Trolley width 1500mm

11 Trolley effective length 700mm

12 Trolley sideboard height 1060mm

13 Trolley quantity 112pcs

Type No. Z2-72

Power 13kW

Rotating speed 1000 r/min 14 Main drive motor

Working term Continuous




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Type No. CS165

Speed ratio 2953.28

Center distance 1650mm 15 Reducer

Maximum

torque 100 kN·m

Type No. G4 - 73 No 11D

Wind pressure 3411 Pa

Wind volume 69427m3/h 16 Cooling fan

Quantity 3 台

Type No. Y280M-4

Power 90 kW 17 Fan motor

Rotating speed 1450 r/min

2.1.7.8 Main drawing fan

The design adopts SJ3600-1.033/0.893 centrifugal sintering fan as the

following parameters:

Table2.1-12: SJ3600 centrifugal sintering fan parameters

1 Inlet flow: 3600 m3/min (working condition)

2 Inlet pressure: 87.57 kPa

3 Inlet temperature: 150 ℃

4 Outlet pressure: 101.33 kPa

5 Static pressure: 13.76 kPa

6 Spindle speed: 1485 r/min

7 Fan rotation direction Counterclockwise




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(from the motor side view)

Power: 1250 kW 8 Auxiliary motor

Voltage rating: 6 kV

2.1.7.9 Electrostatic precipitator

One set of 70m2 horizontal four electric field of electrostatic removal device.

2.1.8 Preheat stove

Ignition and preserve furnace main performance specifications

Table 2.1-11 Preheating and ignition furnace technical performance

No. Items Parameters Unit Remarks

1 Ignition furnace structure Ignition and preserve

furnace

2 Fuel Blast furnace gas

3349.4 kJ /Nm3

3 Furnace gas duct junction

pressure 6000～8000 Pa

4 Air temperature of

preheated ignition furnace 400～450 ℃

5 Preheating and ignition

furnace pressure -10～0 Pa

6 Ignition temperature 1100±50 ℃

7 Ignition time 1 min

8 Holding time 1～1.5 min

9 Heat preservation

temperature 600～800 ℃

10 Sintering ore blast furnace 210 MJ/t




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No. Items Parameters Unit Remarks

gas consumption

11 Ignition furnace gas

consumption 3200 m3/h

12 Ignition furnace air


13 Preheating furnace gas


14 Preheating furnace air


2.2 Iron making process

2.2.1 Overview

The current advanced technology using iron works, in accordance with

the design, high yield, low consumption principles of longevity. Annual

production of 200,000 tons of iron can give full play to the procedure and

process of production.

Blast furnace material structure adopts 100% sintered ore with

comprehensive consideration of the India local conditions and the production

cost, the production operation and management convenience, cost and

other factors, design principle of burden structure is low cost and ease of

procurement,.

The application of distributed control system. The hot blast furnace,

blast furnace, slot in the main control room.

The equipment can carry out remote operation on the computer, also

can be operated manually in the equipment side.

2.2.2 Workshop composition and process flow




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2.2.2.1 Workshops

The iron making blast furnace includes 2X80m3, high silo and feeding

system, gross furnace gas system, hot blast stove system, casting system,

cast iron machine system, slag treatment system, pulverized coal injection

system, dust removal system.

Sinter ore transportation, coke, lump ore transported to the

comprehensive transfer station, single row material bin, two belt conveyors

separately for each bin discharging hopper, because of comprehensive

transfer station’s three connection hopper, the high bin on the belt conveyor

can be switched to each other, when a fault occurs, the other a belt conveyor

can replace its function in a short time, leave enough time to repair.

In order to improve the furnace hopper is high, work environment, a

furnace dust removal system, dust removal system on material, two sets of

operating room together are compact arranged with investment saving,

convenient operation and management.

When the next process is on maintenance of iron or failure, in order to

buffer, iron machine shall digest molten iron in the blast furnace. Cast iron

machine is set with tank repair room, which can make full use of the hoist

capacity with lower investment.

Coal gas dust removal by the gravity dust and nitrogen blowback bag

filter

2.2.3 Raw material and fuel condition

Raw material is sintering ore, lump ore. Fuel is coke, coal.

2.2.3.1 Sintering

Table 2.2-1 Sinter ore composition table

Chemical TFe P S FeO CaO SiO2 MgO Al2O3 CaO/SiO2

Content% 63.8 0.05 0.025 5.5 8.47 4.97 1.71 1.82 1.7

Size: 5 ~ 70mm




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Annual requirement: 350,000 tons

Transportation mode of: the transport belt conveyer

2.2.3.3 Coke

Table 2.2-3 Coke quality

Moisture Ash Volatile S Fixed

carbon M40 M10 CRI CSR

4.52 12.14 1.20 0.62 82.13 89.10 5.60 33% 59%

Size: 5 ~ 50mm

Annual requirement: 117,600 tons

Mode of transportation: belt conveyor to transport from the yard of high

material bin

2.2.4 products and by-products

The main products is hot casting metal, the byproduct is water, gas, gas

ash

2.2.4.1 Molten iron

Table 2.2-6 Molten iron composition table

Chemical C Si Mn P S

% 4.0～4.5% 0.4～0.5% =0.10% 0.03～0.06%

Molten iron temperature: 1430 ℃

Annual output: 200,000 tons, cast iron machine block.

2.2.4.2 Water slag

Table 2.2-7 Water slag composition table

SiO2 CaO Al2O3 MgO FeO S MnO CaO/SiO2

32.51 37.74 15.15 8.81 0.32 1.05 1.16




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Annual output: 100,000 tons

Mode of transportation: slag before furnace is by water flushing filter, filter

bottom pool is by motor grab ransport.

2.2.4.3 Furnace gas

Table 2.2-8 Furnace gas composition table

CO2 CO N2 H2 CH4 O2

19.314 22.714 56.243 0.729 0.686 0.314

Gas temperature: ~ 120 ℃

Gas pressure: 6 kpa

Annual output: 2.12 x 108 Nm3 (the amount of gas pipeline network,

dosage of hot blast stove excluded,)

The mode of transportation: the gas pipeline

2.2.4.4 Gas ash

Blast furnace gross gas dust removal is in gravity precipitator,

Annual output: 13,000 tons

The mode of transportation: dump truck transport to the truck, delivered

to sintering.

2.2.5 Power consumption parameters

Table 2.2-9 Power consumption table

Tons of iron consumption Annual consumption Items

Unit Consumption Unit Consumption

Electricity kwh 920000 kwh 2300

Compressed air Nm3 172000 Nm3 430

Nitrogen Nm3 200000 Nm3 500




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Tons of iron consumption Annual consumption Items

Unit Consumption Unit Consumption

Water m3 28000 m3 70

2.2.6 Main production operation indicators

Table 2.2-10 Production operation index table

No Index items Unit Value

I Blast furnace

1 Blast furnace nominal volume m3 2X80

2 Utilization co-efficiency tHM/m3·d 3.0

3 Coke ratio Kg/t·Fe 700

4 Annual working days days 350

II Annual output

1 Molten iron output 104t/a 20

2 Water slag 104t/a 10

3 Blast furnace gas 108Nm3/a 2.21 (Hot blast stove

consumption excluded)

4 Powder coke 104t/a (Return to the sintering

workshop)

5 Screened sintered ore 104t/a (Return to the sintering

workshop)

Ⅲ Raw material and fuel consumption (Annual)

1 Sintered ore 104t/a 35.8

2 Coke 104t/a 11.79




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2.2.7 Iron making process facilities

2.2.7.1 High position material hopper and top charging system

Blast furnace sinter ore, ore, mixed ore, coke shall be transported to high

position material hopper by belt conveyor, there are gates under the hopper,

the materials shall go through the feeder vibration screening into their

respective weighing hopper by the belt conveyor weighing hopper and then

into the left and right 1.5m3 intermediate weighing hopper, hopper bottom

gate shall open according to the program and unload the material into 1.3 m3

skip, skip shall unload the material into the furnace according to the

requirements of the program, then open and close the small bell, big bell in

turn according to the requirements of furnace iron making process under the

control of the program, the material shall be spread in the blast furnace throat

according to the requirements of the cloth. Go round and begin again,

complete the loading process for the blast furnace.

Sintering ore, lump ore, mixed ore, coke are added to the h igh position

material hopper, screened before the weighing hopper. Coke (5~20mm) can

be added when the mixed ore in the normal production, manganese or fluorite

should be added when abnormal production for cleaning the furnace.

Each blast furnace has two coke bins, the effective volume of coke bin is

180m3; 3 sintering ore bins with total effective volume of 270m3; one flux bin,

the effective volume of each compartment 90m3.

Blast furnace system with double bell top, Vu=6m3, the flexible spreading

furnace top pressure 0.06Mpa, mature and reliable, high work rate.

2.2.7.2 Blast furnace system

The design of blast furnace life is 5 years.

Based on the 2X80m3 blast furnace design and practice experience

combined with the raw material and fuel condition, in order to improve the

permeability of blast furnace, the lower part of blast furnace volume is

increased properly, the dead iron layer thickness heightened, the stack height




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reduced, stocky in design.

Outside furnace cooling form.

Furnace throat steel brick bar structure.

Comprehensive air cooling furnace bottom

One layer half graphite baked carbon brick bottom, two porous baked

carbon brick layers.

The tuyere is equipped with 8 sets of high alumina brick.

Iron mouth adopts with 1 sets of high aluminum brick.

Slag hole adopts with 1 sets of high alumina brick.

The lower part of the body adopts high aluminum brick by brick, the

upper shaft.

The furnace body structure for the frame structure adopts with 1 taphole

and 1 slag outlet.

The main product is molten iron, single blast furnace daily output is 240t

ladle molten iron, the byproducts is gas and water slag, single blast furnace

water slag is 165t, single blast furnace daily gas output is 5.9 x 104Nm.

Table 2.2-11 Parameters of Blast Furnace Inside

Items Sign Unit Parameters

Nominal volume Vu m3 80

Hearth diameter D mm 2100

Waist diameter D mm 3800

Throat diameter d1 mm 3400

Effective height Hu mm 12690

Dead iron layer h0 mm 308

Hearth height h1 mm 2100




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Items Sign Unit Parameters

Waist height h3 mm 1000

Throat height h5 mm 1300

Bosh Angle a 81°35’

Furnace body angle ß 83°55’

Number of iron tapping Piece 1

Slag outlet number Piece 1

Tuyere number Piece 8

Ratio of height to diameter Hu/D 3.34

2.2.7.3 Hot blast stove system

The life of hot blast stove design is 5 years without a major overhaul.

Three sets of top combustion hot blast stoves are responsible for

providing hot air, wind temperature 1100 , two℃ for burning and one for

sending working system. The chimney height is 45m. Single hot blast stove is

110 tons.

2.2.7.4 Raw gas system

The top of the furnace descending pipe diameter is 900mm. The gravity

dust collector is for coarse dust, cylinder diameter 4000. In order to reduce a

second time pollution when the ash is discharging , ash storage silo adopts

artificial gravity humidification dust cleaning.

2.2.7.5 The tapping system

Both in the tapping hole are respectively arranged on a hydraulic mud

gun and a pneumatic tapping machine.

Tap hole and slag outlet are arranged with industrial camera, BF main

control room can monitor.




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Tapping field is designed with a 5T crane, LK=13.5m. Rail surface

elevation 9.2m.

Tapping field periodically the blast furnace molten iron and slag tapping,

12~15 times a day, two blast furnaces shares a 35 meter double chain wheel

cast iron machine, furnace water slag is in the form of water rushing slag with

bottom filter method.

Tapping field is equipped with dust removal, which is for dust produced

skimmer, iron slag ditch with the negative pressure ventilation.

Dust collected by the dust catcher shall be wetted and transported by car

to sintering workshop or sinter material.

The blast furnace water supply and drainage is divided into four systems:

1. The furnace outside cooling wall, the wind cold slag in sets of two

sets of hydraulic station for the medium pressure, furnace cooling water.

2. Three sets of tuyere, top water spray is pressure cooling water.

3. Platform furnace cleaning spray water and later stage of furnace shell

low pressure cooling water.

4. Furnace flushing slag water is turbid circulating water.

2.2.7.6 Cast iron machine

During the rotary furnace maintenance, the excess iron shall be sent into

iron cast machine, cast iron machine capacity is 80t/d, can digest the daily

output of the blast furnace.

2.2.7.7 Slag treatment system

Blast furnace slag after water quenching, the water mixture shall go

through the slag flushing channel into the bottom of filtering pool, filtering pool

is set with two sedimentation pools , one for use and one for preparation, slag

and water can be separated and water slag shall be transported by car

bucket.

3.2 Process control and automation instrumentation




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3.2.1 Sintering workshop

3.2.1.1 Raw materials storage chamber and batching room

(1) 8# ~ 11# bin is by material dragging scale belt control, belt width

650mm, weighing range from 0 to 5t/h.

(2) 2# ~ 7# batching belt scale weight control, belt width 650mm,

weighing range from 0 to 60t/h.

(3) 12# lime spiral quantitative feeding weigher control, weighing range:

0 ~ 3 t/h.

(4) 14 bin (1intermediate fuel bin, 4fuel and flux bins, 6 iron content

material bins, 1 lime bin, 1main sintering workshop bin, 1sintered ore bin)

with material level meter, continuous online measurement, and high and low

level alarm.

All the test parameters shall be input in the microcomputer control

system.

3.2.1.2 Finished sintered ore metering

Finished sintered ore is position detection, detection position is set on

finished-1 tape machine, display in the main control room with display, record,

the cumulative. Weighing range is 0 ~ 35 meters double chain wheel cast iron

machine.

3.2.1.3 Main building part

All the test parameters shall be input into PLC, the control system shares

PLC with professional electric control system. The computer is located in the

main building control room.

(1) When the gas mains pressure and low pressure alarms, it shall be

quickly cut off.

(2) Ignition furnace temperature automatic adjustment

(3) Ratio regulation of the ignition furnace gas flow and hot blast stove




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(4) Ignition furnace gas flow display

(5) Ignition furnace gas pressure display

(6) Hot blast stove inner temperature display

(7) Hot blast furnace gas flow and air flow ratio control

(8) Hot blast furnace gas flow display

(9) Hot blast furnace gas pressure display

(10) Hot blast stove air flow

(11) Hot blast stove air pressure display

(12) Blast stove pipe pressure display

(13) Hot blast stove pipe temperature display and over temperature

alarm interlock with open hot air relief valve

(14)Hot blast furnace gas flow display

(15) No. 1, No. 2 , No. 8, No. 11 and No. 12 sintering bellows

temperature display

(16) No. 1, No. 2, No. 8, No. 11 and No. 12 sintering bellows pressure

display

(17) Sintering flue gas temperature display, record

(18) Sintering flue gas pressure display, record

(19) First mixture, second mixture moisture detection.

3.2.1.4 Ventilation fan room

In order to facilitate the control of the main plant control system, the

entrance room temperature, pressure, flow detection signal of the main fan

ventilation system shall be input in the microcomputer control system of the

main building. All the parameters of main drawing fan room will enter the

ventilation room control displayed by the type III instrument panel.

(1) Main exhaust blower entrance temperature display, record




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(2)Main exhaust blower entrance pressure display, record

(3) Main exhaust blower entrance flow display, record

(4) Main exhaust blower entrance door operation

(5) Cooling water pressure display and alarm

(6)Oil pressure display and alarm

(7) Fan bearing temperature alarm

3.2.1.5 Machine tail dust removal part

Dust removal part of the automatic control is type III instrument panel

display.

(1) Dust removal entrance flow display

(2) Dust removal entrance pressure display

(3) Dust removal entrance temperature display

(4)Dust removal outlet flow display

(5) Dust removal outlet pressure display

(6) Dust removal temperature of collector display

(7) Blower manual valve operation

3.2.1.6 Water pump part

The pump automatic control is type III instrument panel display

(1) The clean water cycle pool, clean circulating heat water sink pool

level remote display, with high and low water level alarm device

(2) The clean water cycle pool, supply pipe flow, pressure, temperature

detection

(3) The clean water cycle pool to the tower’s flow, pressure,

temperature measurement

3.2.2 Iron making workshop




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3.2.2.1 Overview

Automation instrument consists of two parts: field instrumentation and

control system, adoption of PLC as the control system and use the instrument,

electrical integration plan.

3.2.2.2 Design scope

(1)Blast furnace main body

(2) Under groove and feeding system

(3) Gas dedusting

(4)Hot blast stove

(5) Blower station

(6) Circulating water pump station

(7) Water cinder flushing system

(8) Ore groove cleaning system

3.2.2.3 Measurement and control

1) Blast furnace main body

(1) Furnace top pressure measurement, control

(2) Top tank pressure measurement, the lower limit of interlock

(3) Top tank pressure control

(4) Sealing box pressure measurement

(5) Pressure control of gas tight box

(6) Nitrogen tank pressure, low alarm limit

(7)Nitrogen pipe flow measurement

(8) Furnace top (riser) temperature measurement, high limit alarm

(9) Furnace top tank temperature measurement, high limit alarm




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(10) Airtight box temperature measurement, high limit alarm

(11)Cooling wall temperature measurement, high limit alarm

(12)Furnace ling temperature measurement, high limit alarm

(13) Furnace bottom temperature measurement, high limit alarm

(14) Furnace foundation temperature measurement, high limit alarm

(15) Hot blast temperature measurement, control

(16) Air pressure measurement

(17) Furnace body cooling pipe temperature, pressure and flow

measurement, pressure low limit alarm

(18) Tuyere outlet cooling water temperature, pressure and flow

measurement, pressure low alarm limit

(19) Furnace top of the cooling water temperature, pressure and

flow measurement, pressure low alarm limit

(20) Returning water temperature measurement, high limit alarm

(21) Gravity dust removal measurement, high / low limit alarm

2) Under groove tank and feeding system

(22) Sinter weighing hopper weighing

(23) Intermediate ore hopper weighing

(24) Coke hopper weighing

(25) Hydraulic station hydraulic measuring and alarm

3) Gas dedusting

(1)Main entrance of raw gas temperature measurement

(2) Gas Entrance / exit duct pressure measurement

(3) Single box inlet / outlet gas pressure measurement




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(4) Net gas duct temperature, pressure measurement

(5)Net gas pressure measurement of pressure regulating valve

(6) Nitrogen header pressure measurement

(7) Nitrogen gas valve reduced pressure measuring

(8) Cooling water pipe pressure measurement

(9) Ash hopper material level measurement

4) Hot air furnace

(10) Cooling water inlet temperature, pressure, pipe flow

measurement, pressure low alarm

(11) Cold air inlet duct temperature, pressure, flow measurement,

pressure low alarm and interlock

(12) Flue gas heat exchanger before / after temperature and pressure

measurement

(13)Flue, flue gas temperature measurement, high limit alarm

(14) Air preheated before / after the flue gas temperature, pressure

measurement

(15) Hot - blast stove temperature measurement, control and high

limit alarm

(16)Hot blast stove combustion control

(17) Hot air furnace top pressure measurement

(18)Cold wind valve front / rear differential pressure measurement

(19)Flue valve front / rear differential pressure measurement

(20) Blast furnace gas duct pressure measurement and control, high /

low limit alarm

5) Blower station (mechanical and electrical integration)




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(1) Air supply system

(21) Filter differential pressure measurement, high limit alarm

(22) Fan inlet pressure, temperature measurement

(23) Fan pressure, temperature, flow rate measurement

(2) Oil system

(24) Oil temperature, pressure, pressure low alarm limit

(25) Oil filter before / after measuring differential pressure, high alarm

limit

(26) Oil level, oil temperature measurement, low oil level alarm

(3) Cooling water system

(27)Cooling water inlet pressure, low alarm limit

(28) Cooling water pressure, temperature measurement, temperature

high alarm

(4) Blower fan

(29) air blower bearing temperature measurement, high alarm limit

(30) Blower shaft displacement measurement, high limit alarm,

interlocks

(31) Stator temperature, high alarm limit measurement

(32) Fan anti surge control

6) Center circulation water pump station

(33)Blast furnace clean circulation water temperature, pressure, flow

detection

(34)Blast furnace clean circulation water column temperature,

pressure detection

(35) Tuyere small sleeve net ring water to water temperature,




Page 40

pressure, flow detection

(36) Filter clean circulation water tower duct pressure detection

(37) the net ring water tank, clean circulating water heat sink, security

water tower water level detection

7) Water rushing slag system

(38) Blast furnace pipes turbid circulating water slag temperature,

pressure and flow rate of water mains detection

(39)Blast furnace slag pump room wate r level detection

8) Ore groove dust removal system

(40) Ore trough dust collector pressure measurement

(41) Ore trough collector pressure measurement

3.2.2.4 Controlling room

1) Blast furnace tapping side is located in the central control room.

2) Blower station PLC cabinet, blower station circulating pump station

instrument cabinets are placed in their own operating room.

3.2.2.5 Power supply

Instrument power supply adopts 380/220V three-phase four wire AC

power supply, the total capacity is about 20kVA, PLC system and some

instruments are equipped with uninterruptible power supply (UPS), 15

minutes after the blackout, the sustainable power will be supplied (UPS and

electrical combination).

3.6.1 Sintering

3.6.1.1 Blast furnace gas

The project is proposed of 1 * 36m2 sintering workshop, sintering

machine heating is from blast furnace gas. Parameters are as followed:

Gas pressure = 6kPa;




Page 41

Gas calorific value 3140 to 3350Kcal/Nm3;

Consumption: ~ 5000 Nm3/h;

Dust content of gas ＜10mg/m3.

According to the above parameters, sintering gas pipe is determined

with a diameter of 426 mm x 6, into the plant before the gas pipeline are

respectively arranged with gas special manual butterfly valve and the valve

with manhole platform, gas pipeline end is arranged with purging device

3.6.1.2 Nitrogen

Gas pipeline purging medium is nitrogen, consumption volume is

110m3/h, pressure is 0.3 ~ 0.5MPa, diameter f 57 * 3.5 is chosen.

3.6.2.3. Gas pipeline:

The nitrogen needs for the production is 22Nm3/min, pressure 0.7Mpa,

the gas has blowing (intermittent), the kiln top cylinder (intermittent), bag filter

reverse blowing (intermittent), active lime pneumatic conveying (continuous),

instrumentation, valve purge (intermittent).

3.6.3 Iron making

2 x 80m3 blast furnaces, the gas facilities are mainly dry bag dust

removal facilities of gas;

3.6.3.1 Dry bag dust removal facilities

2 x 80m3 blast furnace, the dry cloth bag dust removing technology of

blast furnace gas purification

⑴ Design conditions

Blast furnace volume: 80m3;

Pig iron production for steelmaking: 20 * 104t;

Gas generating quantity: 5.22 * 104m3/h, 6.55 * 104m3/h;

Furnace gas top pressure: 30 ~ 100KPa;




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Furnace top gas temperature: 120 ~ 280 degrees;

Waste gas dust content: 10g/m3;

The net gas duct pressure: 6KPa.

(2) Blast furnace gas dry bag dust removal process

A. Gas system

Gravity dust collector (iron making process) ? bag filter dust removal?

clean gas duct ? muffler, ? gate valve ? butterfly cut off valve ? gas pipe

net.

B. Pulse bag dedust removal system

Application of nitrogen pulse dust cleaning, nitrogen pressure 0.4 ~

0.5MPa, consumption (intermittent use) ~ 5m3/min, 6 ~ 9 times / day.

C. Bag filter ash discharging system

This design uses a centralized ash discharging mode: dust collecting

bucket? upper pneumatic valve, ? middle lower ash bucket? lower

pneumatic ball valve? feeder? ash conveyer? bucket elevator? large dust

bin? dust humidifier ? ash automobile sinotrans.

D. Bag leak detection system

This design has the bag breakage detection, the clean gas duct is

provided with 1 set of automatic gas line leak detector; each box of the dust

removal outlet are respectively arranged with gas automatic online detector

and manual sampling detection point.

(3) Blast furnace gas dry bag dust removal temperature and control

valve

(a) When the normal operation of blast furnace

When the normal operation of blast furnace, gas temperature entering

the bag type dust collector is 100 =T=280 , the gas flow through the bag ℃ ℃

filter and purified (purified gas dust content to ensure that the value is less




Page 43

than or equal to 10mg/m3), and then enters into the clean gas duct through

the gate valve and shut-off valve, extra gas shall be diffused naturally.

(b) When the non normal operation of blast furnace

When the blast furnace is in the non normal operation, gas temperature

will be in 250 =T=450℃ ℃ or T＜120 . ℃ When normal working temperature of

raw gas into the bag filter is too high or too low, that will affect the bag, if the

gas temperature is too high, it will damage the bag; if the gas temperature is

too low, it will make the dust condensed and attached to the bag, causing dust

removal and cleaning difficulties.

When the waste gas is too high (300℃～450 ), the blast furnace ℃

gravity dust removal device shall start water cooling measures, so that the

gas temperature is =250 into the bag filter bag dust collector℃ to ensure

normal work; when the gas temperature is too low =120 ), gas diffusion ℃

process at the top gravity dust collector will start to prevent low temperature

gas into the bag filter bag and damage and condensation.

In order to prevent the gas in the bag type dust collector in dews, when

the temperature is too low, the gas into the dry dust removal system will be

cut off, considering gas releasing technology ,The design of the gas pipeline,

bag dust removal facilities will be thermal insulation;

(c)Bag filter outlet and inlet pipe are provided with pneumatic butterfly

valve and hydraulic valve to cut off the gas for bag dust removal on

maintenance.

(4) Main equipment selection

A. Bag dust removal materials: new FMS (FMS) filter.

B. Bag box number and size

Box number: 5, single row layout;

Box size: F2800mm x 17700mm;

Bag size: F130mmX 6000mm;




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Each box bag number: 130 pieces;

Total bags: 850 pieces;

Each box filter area: 327.4m2;

Dust collector filter total area; 1637m2

During normal operation of bag filter load: 27.29 ~ 31.2m3/m2.h.

C. Pulse dust cleaning devices

Pulse valve total number: 50;

Each box number: 10 pulse valve;

Pulse jet blowing nitrogen pressure 0.4 ~ 0.5MPa.

D Other devices

Buried scraper conveying machine 1 set;

Bucket type lifting machine 1 set;

Dust humidifying machine 1 set;

20m3 large dust bin 1;

E. Pressure regulating valve group (with a silencer) 1;

(5)Main technical and economic indexes

Gas processing capacity: 6.15×104～5.22×104 m3/h；

Clean gas dust content: =10mg /m3;

Clean calorific value: 3344KJ/m3;

Ash content recovery: ~ 0.7t/h (dry basis);

Power consumption

Water: 3t/h, intermittent use;

Power: 50Kwh/h; intermittent use




Page 45

Nitrogen: 5m3/min (pulse cleaning), continuous use, 6 ~ 9 times / day;

3.7 Thermal power facilities

3.7.1 Iron making

3.7.1.1 Overview

The 2X80m3 level of blast furnace, the thermal power facilities includes

blast furnace blower room, blast pipe, air compressor and compressed air

pipe.

3.7.1.2 Blower room

The newly built b last furnace blower room arrangement is three models

of C-430-2.4 centrifugal blower, the working system is dual-use

one-preparation, and the fan outlet air volume is 430m 3/min, the blower

outlet pressure of 0.14Mpa to the blast furnace. (Equipment order shall

prevail the above model, parameters of the equipment.)

3.7.1.3 Heat pipe

Blast furnace workshop heat pipe includes:

(1) The blast wind inletting pipe;

The blast wind inletting pipe starts from blower room to the end of iron

making technology platform. According to the professional requirements of

iron making process, pipe flow volume is designed by 430Nm3/min, pipe

specifications are D530 x 6, the material is Q235-B, the design pressure is

0.45Mpa. Erection method adopts independent support overhead laying, the

upper part of the support structure is steel structure.



Email: [email protected] Cell phone: 0086 132 9904 2234

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Proposal of 200KT PIG IRON PROJECT

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