sintering equipment

SINTERING
EQUIPMENT
The “Uralmashplant” Joint-Stock Company is the leading Russian supplier of plants and
machinery for oil-and- gas production and mining sectors, as well as the iron and steel
industry.
In the middle of 90ths, the “Uralmashplant” was included in OMZ – United Heavy
Machinery (Uralmash – Izhora Group), and since 2007 it constitutes a part of
the Machine-Building Corporation “Uralmash”.
Engineering, marketing and sales of equipment organized on a product basis:
Oil-and-gas Division: complete mobile, cluster, and stationary drilling rigs with capacity
from 160t to 600t, sets of drilling equipment.
Mining Equipment Division: mining shovels and draglines, grinding and crushing
equipment, cement production machinery,
etc.
Metallurgical Equipment Division: sintering
equipment, pelletizing plants, presses, blast
furnace equipment, continuous casters,
equipment for hot and cold rolling shops, rolls
for rolling mills, etc.
NPO VNIIMETMASH focuses on design and
engineering of materials handling equipment:
heavy-duty cranes for iron and steel
companies, materials handling machinery for
nuclear power plants, special- and generalpurpose overhead travelling cranes.
We strive to become a world-class machinebuilding company, which will be able to fully
meet the Customer's needs.
The “Uralmashplant” Joint-Stock Company has
a complete production cycle: engineering,
steel-making, welding, machining and
assembly departments.
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SINTERING
EQUIPMENT
History
In thirties, after start-up Uralmashplant began to manufacture sintering equipment.
Up to 1941, Uralmash supplied its unique products, including sinter machines, to many
industrial enterprises of the USSR, among which there were such giants as Magnitogorsky
and Kuznetsky integrated iron-and-steel works.
To eighties, 78% of sinter in the USSR was produced at the sintering equipment issued by
Uralmashplant.
Since 1950, Uralmashplant has begun to supply sintering equipment abroad, to Rumania,
Bulgaria, Poland, Hungary, China, India, Korea, Egypt, Finland, Iran, Turkey, Nigeria, Cuba.
The scope of supplies for seventy years, namely, 284 complexes with sinter machines
manufactured and put into operation for the domestic and foreign metallurgical
companies, is evidence of great experience acquired by Uralmashplant in creation of
sintering equipment.
For the last ten years, the specialists of Uralmashplant carried out reconstruction and
updating of many sinter plants.
Simultaneously the Uralmash continues to build new machines of any grate area (from 18
to 600 m2) and of capacity to 3.0-4.7 mil tons of sinter per year.
3
Standard sizes of sinter machines
Type of
sinter machine
ÀÊÌ90
ÀÊÌ22.5
90
22.5
Grate area, m2
3
1.5
Cake width, m
0.4
0.6
Maximum cake thickness, m
4.5
0.6
Maximum pallet speed, m/min
125-140
8
* Capacity, t/h
Fecement
Product
pellets clinker
ÀÊÌ- ÀÊÌ- ÀÊÌ36
75
192
36
1.5
0.6
0.6
18.5
cement
clinker
ÀÊÌ200
ÀÊÌ250
75
192
204
3
3
4.4
0.5
0.6
0.3
4.5
4.5
6
90 220-260 200-240
FeFeFesinter sinter
sinter
250
4.4
0.44
6
250
Fesinter
ÀÊÌ312
ÀÊÌ- ÀÊÌ312 360
312
312
360
4
4
4
0.35
0.35
0.35
6
6
8
400-500 125
340
FephosFesinter phorite sinter
* Capacity depends upon quality of the components used for sintering and upon
the local process conditions
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SINTERING
EQUIPMENT
Sinter machine diagram
1
2
4
3
5
6
7
8
9
10
11
12
13
Направление движения тележек
Уровень шихты
Уровень колосников
Уровень осей роликов тележек
14
Уровень постели
15
1.
2.
3.
4.
5.
6.
7.
8.
Unloading sprocket
Windbox
Extension hood
Ignition furnace
Burden damper
Stabilizing device
Burden seal
Feeder drum
9.
10.
11.
12.
13.
14.
15.
5
Burden bin
Bed bin
Bed damper
Pallet feeder bin gate
Pallet
Drive sprocket
Load clamp
The delivery set of sinter machine
incorporates
dum mixers
pelletizers
mixers-pelletizers
shuttle conveyors
sinter crushers
hot and cold sinter screens
sinter coolers of bowl and ring type
small-sized ignition furnaces with direct burden ignition burners located along arch
pallets of steel or spheroidal graphite cast iron
drives of sinter machine, crushers and other mechanisms with planetary spur and
planetary reduction gears of small dimensions, weight and oil bath lubrication
two-level automatic control system with the use of hardware and software of the leading
world-famous electrical companies
The delivery set depends upon the accepted sinter plant diagram
Sinter machine AKM-75
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SINTERING
EQUIPMENT
Sintering equipment
Ignition furnaces
The ignition furnace is economical, heat consumption shall not exceed 40-80 thd kJ/t of
sinter (9500-19000 Cal/t), i. e. one-fifth or one-sixth as large as compartment furnace with
heat consumption of 150-250 thd kJ/t (35000-60000 Cal/t).
Technical data
Nominal heat power, kW
200
3
Nominal natural gas consumption, m /h
22
Nominal gas pressure in front of burner, kPa
125
Nominal excess air factor
1.8
Maximum heat power, kW
250
Minimum heat power, kW
50
Nominal air pressure, kPa
17.5
The burners are located in box square girders equipped with air jet cooling system. Hot air
from the cooling system can be used both for burning and for heating of sinter burden
before ignition or for its additional heating after ignition.
The burners are installed in rows with a space of, approximately, 700 mm. Number of
burners is calculated. Rows of suspended arch refractory elements are located between the
girders.
In the process of repair the ignition furnace can move over the guide rails.
9
Pallets
The pallets of spheroidal graphite cast iron are more efficient in production and have a
longer service life.
cast iron has higher casting characteristics that allow the pallet body to be cast as one
piece instead of two or three parts interconnected by bolts. Such process reduces labor
expenditures in manufacture and weight of the article
the pallets of cast iron are not subject in service to sagging in its middle part, hence they
do not require repair and have longer service life
the mechanical properties of the pallets of cast iron are similar to those of steel ones
1. Pallet body
2. Running roller
3. Load roller
4. Top board
5. Bottom board
6. Plate made of wear-resistant
material
7. Grate bar
Movable longitudinal sealing is built in
the pallet body
The main advantage of such sealing is reduction of harmful leaks.
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SINTERING
EQUIPMENT
Scraper
The scraper is designed to remove spill from under the sinter machine of AKM type.
The double-acting scraper has been designed to be used when spill is loaded in the spill
removal conveyor, by turns, in the head and unloading section of the sinter machine.
Description
Specifications
Scraper speed, m/s
3
Scraper volumetric capacity, m
Maximum scraper capacity, t/h
Rope pull, kN (tf)
Speed of winch drum rotation, min-1
Rope diameter, mm
Electric motor power, kW
Weight of scraper with electrical equipment (maximum), t
ÀÊÌ-75
ÀÊÌ-90/180
0.57
0.2
23*
20 (2)
7
22
22
32
0.48
0.2
5.2
20 (2)
7
22
22
25**
* scraper is unloaded in head and unloading section of the sinter machine
** weight without chute
9
Movable unloading section of the sinter
machine with load hold-down offers
the following advantages
contact-free running of pallets when they transfer from top run to the bottom one, strikes
are excluded, service life of pallets is increased
the pallets are kept pressed to one another in operation, thus harmful air inflow and spill
are reduced
The loads pressing the pallets to each other are suspended from rigid levers. Number of loads
shall be minimum but sufficient to press the pallets to each other.
Release is carried out by means of hydraulically-operated or screw jacks. A version with
application of locks is also acceptable, in this case release is carried out by means of the
sinter machine drive reverse. The sprockets used in the unloading section are similar in their
design to the head section sprockets.
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SINTERING
EQUIPMENT
Drives with planetary reduction gears
The drives of sinter machines, crushers and other mechanisms with planetary reduction
gears have small dimensions and weight.
The planetary reduction gears may be as a separate reduction gear or as change modules
engaged with the central gear fitted, in cantilever, to the drive sprocket shaft. Application of
the modular design decreases, appreciably, dimensions and simplifies maintenance.
Two or four modules are installed depending upon the torque being transmitted, thus
unification of drives is achieved.
Mixer
The drum mixer is designed to mix components of the sinter burden and return it with
water addition.
Mixer is used in the same process line with the sinter machines.
Design features
the drum consists of optimal number of sections with the welded shrouds machined to
suit the flange dimensions for the purpose of increasing smoothness of drum rotation
a special sealing of elevator type excludes burden spill between stationary chute of the
charging device and rotating drum
the charging chute is equipped with a vibrating device to prevent sticking of burden to
the chute walls
pneumatically-and-hydraulically-operated nozzles used in the wetting system allow
industrial water to be used
the lubrication system of the bearing units and working surfaces of gearing and shrouds
is of automatic type
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SINTERING
EQUIPMENT
Pelletizer
A pelletizer of drum type is designed for balling and wetting of sinter burden with the
purpose of making it granular and gas-permeable.
The pelletizer is used in the same process line with the sinter machines.
Design features
the drum consists of the optimal number of sections equipped with shrouds welded
therein and machined in combination with the seating flanges of the sections to increase
smoothness of the drum rotation
a cutter bar, built in the drum, flattens the adhered burden layer and promotes balling of
burden and increasing of drum rotation smoothness
a special sealing of elevator type excludes burden spill between the stationary charging
chute and rotating drum
pneumatically-and-hydraulically-operated nozzles used in the wetting system allow
industrial water to be used
lubrication system of the bearing units and working surfaces of gearing and shrouds is of
automatic type
13
Stock distributors
The stock distributor is designed to transport material to the sinter machine and distribute it
uniformly over the discharge hopper width.
Design features
the reverse drive and conveyor drive are located in the side frame section to simplify its
maintenance
the drive drum is made of gummed rubber
the electric circuit incorporates time delay when the electrical equipment is shifted over to
reverse
by the customer's request, the rack can be continuous, in this case reverse is not available
Specifications
Type of stock distributor
ÐØ 800õ3000
ÐØ 1õ7
ÐØ 1.2õ12.5
ÐØ 1.4õ12.5
ÐØ 1.4õ30.5
120-150
400-460
450
750-1000
750-1000
3
7
12.5
12.5
30.5
Width, m
0.8
1
1.2
1.4
1.4
Speed, m/s
1
1
1.3
1.3
1.45
Stock distributor speed, m/s
0.25
0.2
0.2
0.2
0.2
Track gauge, m
1.38
1.77
1.97
2.16/3
1.85/3
Conveyor drive motor power, kW
4.5
3.7
7.5
7.5
15
Reverse motor power, kW
1.7
2
1.8
1.8
3.5
Stock distributor stroke, m
2.134
2.5
3.5
3.5
3.5
Weight, t (with electrical equipment)
3.33
7.25*
12.23
12.52
40.27
Capacity, t/h (maximum)
Conveyor length, m
Conveyor belt, m
* without electrical equipment
14
SINTERING
EQUIPMENT
One-roll crushers
The crushers are designed for crushing of hot sinter leaving the sinter machine.
Design features
the heatproof sprockets are made of high-alloy steel and hard-faced
grate bars are furnished with change heat-resistant straps made of high-alloy steel and
hard-faced
drive with planetary reduction gear
roll and grade bars can be easily replaced in the process of service
Type of crusher
Specifications
ÄÎÇ 1300õ3200
ÄÎÇ 1300õ4200
Capacity for source material (no less than), t/h
450
1000
Roll sprocket diameter, mm
1300
1300
Working length of roll, mm
3150
4200
Rotational roll speed, rpm
6
6
Inlet sinter temperature, degree °Ñ
850
850
Size of final product, mm
150
150
Power, kW
90
150
Weight, t (without electrical equipment)
90
107
15
Unbalanced-throw screen
The unbalanced-throw screen is used for sorting of hot and cold sinter, fired pellets, ores and
the like.
Design feature
wear-resistant screen plate is made of alloy heatproof steel or chromium steel
a drive is of self-synchronizing type from two independent kinematic electric motors
the electric motor torque is transferred to the vibration driver shafts via a propeller shaft
a lubrication unit with heat exchanger ensures lubrication and cooling of the vibration
driver bearings
the electric circuit of the drive incorporates electrical braking to decrease the screen
oscillation amplitude in stop and, hence, to reduce the foundation loads
the screen is placed on the roll-away trolley to simplify its maintenance
Specification
Capacity (charging), t/h
ÃÈË 22
1000õ2200/1860
50
Type of screen
ÃÑÒ 61
ÃÑÒ 81
2000/5200
3000õ6400
ÃÑÒ 91
3450õ8000
200-300
400-500
700-800
2
Total screen plate area, m
10.48
20.4
28.98
Temperature of material being screened, degree, °C
800
800
800
950
730
735
735
3.2-3.4
5-5.3
5-5.5
5-5.2
Screen oscillation range in transient conditions, mm
40
75
75
75
Power, kW
30
15 (2 pc)
30 (2 pc)
30 (2 pc)
10300
19000
24000
18.5
37
43.5
Number of screen oscillations, qty/min
Screen oscillation range in steady conditions, mm
Weight of rocking parts, kg
Weight (with electrical equipment), t
2.26
16
SINTERING
EQUIPMENT
Sinter coolers of bowl type
The cooler is designed for cooling of sinter of not more than 150 mm in size from the initial
temperature of 900 °C to a temperature of 100 °C.
Design features
bearings of the central support are cooled with ambient air at the expense of cross
ventilation of the space under bell by natural draft
leak-in of ambient air into the draught system is reduced thanks to using a new throat
sealing
split design of the gear ring simplifies its erection and replacement during repairs
louvered grate in the form of aerodynamic wing increases consumption of filtering air
passing through the sinter layer
Designation of cooler
Capacity, t/h
Weight, t (with electrical equipment)
3
Air consumption, m /t
Rotational speed of platform, rpm
Rated cooling time, min
Bin height, m
Type of support
Cooling product
Type of bowl cooler (platform diameter)
Ø8
Ø9
Ø 10
Ø 10,4 Ø 11,8
Ø 12
Ø 13,5
Ø 19
70
62.85
2500
0.6 0.086
33
1.5
70-100
97.36
3000
0.6 –
0.086
45-63
3
110
104.7
2500
0.6 –
0.086
40-63
2.5
110
174.7
1700
0.6 –
0.086
45-47
2.8
110
173.2
1400
0.6 –
0.086
57
3
224
255.4
1450
0.6 –
0.086
35
3.8
228
330.5
1370
0.6 –
0.06
64
4.645
240
647.6
1550
0.244 –
0.081
47
2.6
at column
sinter
Агломерат
17
pellet
sinter
Automatic process control system
of sintering equipment
By the customer's request, the machines and units are equipped with complex automatic
electric drive and process control system. The Automatic process control system allows
optimization of the process to be implemented on the basis of the mathematical models.
The software of the leading electrical companies, including Siemens, ABB, Rockwell
Automation, is used.
Engineering services
collection of initial data and approval of the request for proposal
execution of the technical proposal on the equipment reconstruction
- with inspection of the equipment erection in the existing building of the workshop
- with examination of a possibility of keeping the axes of loading, unloading, elevations
- with rational matching of the existing equipment or part of it with new equipment
installed in reconstruction
designing of working drawings for the equipment being supplied
designing and submission of the foundation plans for equipment and specifications for
electric drive to the customer
submission of the service documentation for equipment, namely
- general view drawings of the machines
- working drawings of quick-wearing parts
- technical description of erection, start and service
- technical machine certificates
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SINTERING
EQUIPMENT
Reconstruction of sinter machines
New technical decisions
Introduction of new technical decisions offered by the designers and scientists of Uralmash
allows the sinter machine capacity to be increased by 12%:
increase of pallet width to 4.5 m, with the dimensions of the previous propel mechanism
being kept
increase of pallet service life thanks to a possibility of turning the body middle part
through 180°
17
Reconstruction of mixing and balling units
Introduction of new technical decisions will increase a degree of mixed burden
homogeneity to 90% and a degree of balling to more than 40%, which allows the sinter
machine capacity to be increased by 4-5%
increase of efficiency of sinter wetting, mixing and balling
automatic control of mixing and balling sections and reliable operation of the required
protection and interlocking
improvement of burden quality and correction of its physical and mechanical properties
Drum mixer is equipped with paddles for more intensive mixing of burden.
The mixer has a frequency drive with smooth start and controlled frequency of revolutions
performed by means of frequency converters.
A new wetting system is used. It is equipped with generators-mixers and direct-flow nozzles
that are not clogged and ensure fog spray of water.
It is offered to equip the mixers with automatic burden humidity sensors, Automatic
humidity control system that incorporates burden composition and humidity analysis
equipment and is integrated with the existing sinter machine control system.
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SINTERING
EQUIPMENT
Sinter quality control system
Functions
on-line prediction of chemical composition of sinter and returns
on-line development of optimal specifications for sinter burden component consumption
to produce sinter of the specified chemical composition
on-line control of iron ore burden homogenizing
on-line control of sintering thermal conditions
Initial
burden
composition
Consumption of coke, concentrates,
limestone, moisture
Sintering process model
Material balance of
sintering process
Heat balance of sintering process
Caking process
indices (specific
capacity of sinter
machine, exhaust
gas composition)
21
Sinter quality indices
(cake yield, good
product yield, sinter
reducibility etc.)
control
Technical
requirements
to sinter:
Fe0, basic capacity
Automated sinter sampling station “Sample tower”
The station is the base of the system of on-line control of ready-made product quality in the
real-time mode and makes it possible to prepare, quickly and in workmanlike manner,
samples; a process of sample preparation incorporates the process of crushing, sorting,
milling and submission for chemical analysis.
For gravity passing of sample via equipment, the latter is located on metal structures of three
levels in height.
The “Probe tower” incorporates three lines operating under parallel-series conditions
a line of sinter grain-size composition estimation
a line of sinter mechanical property estimation
a line of sample preparation for chemical analysis
Sampler
Weight
measuring bin
Crushing in jaw
crusher
Divider
Screening
0-5
0-5
+40
5-40
Weighing in bins
5-40
Divider
Crushing in roll
crusher
+40
Crushing in
jaw crusher
5-40
0-40
Screening
0-10
10-40
Dump
Divider
Divider
Crushing by disk
grinder
Weight measuring bin
Test in drum as per
ÄÑÒÓ 3200-95
Crushing by vibrating
grinder
Screening
Sizing in sieve
analyzer
Sample for Sample for
storage chemical analysis
-0,5
-0,5
To dump
22
+5
0,5-5
Weighing in bins
0,5-5
+5
SINTERING
EQUIPMENT
Service
designer's supervision of the equipment erection, adjustment and putting in service with
bringing the indices of its operation to design ones
technical maintenance, diagnostics in guarantee and post-guarantee periods
supply of spare parts for repair services
participation in updating of the equipment issued earlier
joint activity on the contract basis with the specialized service organizations
Guarantees
Uralmashplant guarantees trouble-free operation of the equipment within one year but not
more than within 18 months since the date of its shipment, provided that the conditions of
transportation, storage, erection, adjustment, tests, putting in service are observed.
The guarantee does not cover the quick-wearing parts.
Reference list for 2000-2009
Supply
year
Customer
Country
Type of equipment
Qty
2012
Magnitogorsk Iron and Steel Works, Magnitogorsk
Russia
Ignition furnace for Sinter machine ÀÊÌ-75
1
2010
Novolipetsky Iron and Steel Works, Lipetsk
Russia
Pallets ÒÑÃ-4
42
2009
Transnational Company “Kazhrom”
Kazakhstan
Sinter machine AKM-60/120
1
2007
Zapadno-Sibirsky iron and steel works
Russia
Pelletizer
1
2007
KGOK Vanadium
Russia
Screen ÃÒÑ-81 3000õ6400
1
2007
Domnaremont (Severstal)
Russia
Screen ÃÑÒ-81
4
2006
Vysokogorsky GOK, Nizhny Tagil
Russia
Screen ÃÑÒ-61
1
2005
Chelyabinsk Iron and Steel Works, Chelyabinsk
Russia
Mixer ÑÁ 3.2õ12.5
1
2005
Evrazruda, Abagurskaya sintering factory
Russia
Sinter machine (reconstruction)
1
2005
Magnitogorsk Iron and Steel Works, Magnitogorsk
Russia
Sinter machine
2
2005
Chelyabinsk Iron and Steel Works, Chelyabinsk
Russia
Pelletizer ÎÁ 3.2õ8
2
2005-2006
Chelyabinsk Iron and Steel Works, Chelyabinsk
Russia
Screen ÃÑÒ-82
6
2005
Novolipetsky iron and steel works, Lipetsk
Russia
Screen ÃÑÒ-81
1
2004
Vysokogorsky GOK, Nizhny Tagil
Russia
Screen ÃÈÑË-52 1750õ5000
1
2004
Vysokogorsky GOK, Nizhny Tagil
Russia
Screen ÃÑÒ-61
1
2003
Magnitogorsk Iron and Steel Works, Magnitogorsk
Russia
Sinter machine
2
2003
Severstal, Cherepovets
Russia
Sinter machine (reconstruction)
1
2003
Severstal, Cherepovets
Russia
Sinter machine (reconstruction)
1
2003
Novolipetsky iron and steel works, Lipetsk
Russia
Screen ÃÑÒ-81
1
2002
Magnitogorsk Iron and Steel Works, Magnitogorsk
Russia
Sinter machine
2
2000
Magnitogorsk Iron and Steel Works, Magnitogorsk
Russia
Sinter machine
1
23
Metallurgical Equipment Division
Pervoy Pyatiletki sqr.,Ekaterinburg, Russia, 620012
Phone: +7 (343) 327-59-35 Fax: +7 (343) 327-59-41
E-mail: [email protected], [email protected], Http://www.uralmash.ru