sintering equipment
Transkript
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. 2 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 4 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 6 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. 8 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. 10 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 12 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 18 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. 20 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