RMHS Manual 2.1

RMHS & Logistics Department,Technical Reference Manual

FOREWORD

It gives me immense pleasure to present to you the Technical Reference Manual for Tata

Steel Orissa Project’s RMHS & Logistics Department. This manual is the perfect

amalgamation of departmental overview and technical insights for novices and experts alike

and gives a holistic view of the various processes involved.

The various sections in the manual are richly illustrated with relevant drawings, process flow

diagrams, data tables and graphs to enable a deep understanding of the department.

I believe that whether you are a seasoned professional or a person just joining the

department, you will find this immensely helpful in understanding the functions and

objectives of our department.

(C L Karn)

Chief RMHS & Logistics

Tata Steel Ltd, Orissa Project India

PREFACE

With so many independent units in the department, there was a need to collect the

information about the various process units and the theoretical background behind the

processes and major equipment involved in each process, so that a complete one stop

manual could be created which can be referred by any person to get a holistic

understanding of RMHS & Logistics.

The Training Manual is the result of combined efforts of many officers of our department

who painstakingly collected all the information and organised it in an easy to understand

manner.

Special thanks to Mr B C Kedia for his guidance.

(Arindam Das) (Anshul Maheshwari)

Manager, RMHS & Logistics Senior Manager, RMHS & Logistics

Tata Steel Limited, Orissa Project India Tata Steel Limited, Orissa Project India

Tata Steel Limited - Overview

Tata Steel Limited has operations in 26 countries, commercial presence in over 50 countries

and 80,000 employees across five continents. What sets the company apart is not just

extent or magnitude of its operations - it is the excellence of its people, innovative

approach, and overall conduct. Established in 1907 as Asia's first integrated private sector

steel company, Tata Steel Group is among the top-ten global steel companies with an

annual crude steel capacity of nearly 30 million tonnes per annum. It is now the world's

second-most geographically-diversified steel producer. The Group recorded a turnover of

US$ 24.81bn in FY 14.

Over the years Tata Steel has enriched the glorious legacy handed over by its Founder J.N.

Tata, by placing equal emphasis on stakeholder value creation and corporate citizenship.

Underpinning this vision is a performance culture committed to aspiration targets, safety

and social responsibility, continuous improvement, openness and transparency. What binds

together every member of the global Tata Steel family today is a shared corporate culture,

shaped by value-based guiding principles and the lineage of some of the world’s most

pioneering and respected entities - the Tata group itself, British Steel, Koninklijke Hoogovens

and NatSteel.

Tata Steel Limited, Orissa Project India

Conforming to Tata Steel’s vision of Value Creation and Corporate Citizenship and its

commitment to nation building and strengthening its partnership with the State of Odisha,

the Company is setting up a 6 million tonnes per annum capacity integrated steel plant in

Kalinganagar Industrial Complex in Jajpur district of Odisha. Subsequent to the signing of the

MOU, 3470 acres of land was allotted to the Steel Company for setting up the steel plant.

The proposed plant site happens to be a part of six revenue villages - Gobaraghati,

Chandia, Gadapur, Nuagaon, Khurunti and Baragadia - of the Sukinda Tehsil in Jajpur

District. While the plant site at Kalinganagar Industrial Complex is beside the National

Highway 200, the all-weather ports at Paradip and Dhamra are at a distance of about 100 to

110 km by rail route. Similarly, the iron ore mines are located at a distance of about 200 km

from the project site.

Kalinganagar – Project Highlights

MoU for the steel project was signed between the Government of Odisha and Tata Steel

on November 17, 2004.

As per the MoU, Odisha Government agreed to provide 3,471.808 acres of land,

earlier acquired through the Industrial Development Corporation of Orissa.

MoU was also signed with the Nippon Steel Corporation on August 28, 2005 for offering

technical assistance for the project.

As per the terms of the MoU, Government of Odisha would be allocating an iron

ore mine to the Company on completion of 25% of the project work.

The state-of-the-art, Kalinganagar Project is being established in two modules of three

million tonnes each. The plant, which boasts of the Blast Furnace of 4330 cum capacity, will

roll out high-end flat products.

During the first phase, the Blast Furnace will have a capacity of 3.3 Million Tonnes Per

Annum (MTPA) of hot metal and the Coke Plant will have a capacity of 1.65 MTPA (recovery

type oven). While the Sinter plant will have a capacity of 4.91 MTPA, the Steel Melting Shop

(SMS) and the Hot Strip Mill (HSM) will have capacity of 4.1 MTPA and 3.5 MTPA,

respectively.

The project will have a 3X67.5 MW gas-based Captive Power Plant. New technologies like

Granshot Systems & CAS OB will be introduced in the plant for steelmaking. The plant is also

designed for Zero Liquid Discharge, Waste Recycling Plant and Central Effluent Treatment

Plant. High-end flat products will be rolled out from Kalinganagar plant.

Layout of Kalinganagar Project Odisha

RMHS & Logistics Department – Overview

The department aims at an uninterrupted supply of raw materials to its customer

departments like Coke Plant, Sinter Plant, Blast Furnace, Lime Calcining Plant and Steel

Melting Shop as per their demand without any adverse impact on the Environment and

Society.

Inward Traffic:

Iron ore, the basic raw material consisting of size ore and fine ore aggregating to 5.50 Mtpa

will be received from Tata Steel’s captive mines of Joda/Khonbond. The pelletization plant

will be set up at the plant end for conversion of fine ore into pellets.

Besides, the plant will need 3.0 million tonnes of coking coal annually. The requirement of

coal will comprise of indigenous and imported coal. The imported coal will be received

through Dhamra port.

CPP (Captive Power Plant) which will be set up along with the steel plant will require 2.1

Million ton of Thermal which will be mainly imported through Dhamra port. The rest of the

coal will be met from coal-meddlings generated in the Tata Steel’s captive coal mines in

Barkakana area. If any more coal is required then the same will be procured commercially

from domestic mines in Talcher Coalfields, etc.

The lime stone requirement consisting of BF and SMS grades, will be imported through

Dhamra port only.

Outward Traffic:

The plant will finally produce 6.0 MTPA of steel annually after Phase I and Phase II, out of

which Tata Steel proposes to dispatch 4.0million tonnes of steel by rail annually and the

balance will move via road. Of the assessed rail borne traffic, about 1.0 MTPA will be

exported through Dhamra port while 3.0 mtpa will be dispatched to major consuming

centres situated all over India. About 2 million tonnes of granulated slag will move to the

cement plants located in Central India or consumed in Orissa.

The material flow within KPO is majorly handled by the conveyors that connect every department together; starting from the RMHS and Logistics department. However, the inbound and outbound materials solely depend on the means and support provided by the logistics railway network that connects the plant to the outside world via Jakhapura station. Once inside the plant boundary, the inbound wagons unload at the Wagon Tippler Complex (from where the materials are distributed throughout the plant via the rich network of conveyors). The outbound wagons carry the finished product from the dispatch yards. A certain level of intra-plant logistics is present in certain special cases like that in case of Hot Metal Logistics; where hot metal is carried from Blast Furnace to SMS using Torpedoes.

A layout of the entire rail network in KPO is presented below.

Process Flow Circuits in RMHSThe circuits shown above highlight the major material flow within the plant. However, to

understand the circuits in detail it is necessary to segregate them into functional

components and look at them separately. For this reason the entire material flow has been

divided into 7 separate circuits as given below. These circuits together make up the entire

flow of materials to and from various departments within the plant and looking at them

individually lets us know more about the major equipments and process involved.

Circuits:

1. Coke Oven Input Circuits1.1. Coal from Wagon Tippler to Coal Yard1.2. Coal from Coal Yard to Coal Tower1.3. Coke spillage from Coke Oven Battery to Coal Tower via Secondary Crusher House

2. Coke Oven Output Circuits2.1. Coke from Coke Oven to Coke Storage Yard2.2. Coke from CPSH to CSBB

3. Sinter Plant Input Circuits3.1. Ore & Flux from Wagon Tippler to Ore & Flux Yard3.2. Iron Ore Fines from Ore & Flux Yard to PBB3.3. Fuel from Coke Stock Bin to PBB3.4. Base Mix from PBB to Sinter Plant via Base Mix Yard

4. Sinter Plant Output Circuits4.1. Sinter from Sinter Plant to Sinter Stock House4.2. Sinter from Sinter Plant to BF Stock House

5. BF Input Circuits5.1. Ore & Flux from Ore & Flux Yard to BF5.2. PCI coal from WT to Coal Injection Plant5.3. Coke from Coke Storage Yard to BF5.4. Coke from Coke Breeze Shed to BF

6. BF Output Circuits6.1. Slag to corresponding Loading Stations6.2. BF Sludge to CSBB and fines to PBB

7. SMS Input Circuits7.1. Limestone from Ore & Flux Yard to LCP7.2. Lime from LCP to SMS7.3. SMS grade ore from Ore & Flux Yard to SMS

1. Coke Oven Input Circuits

The above circuit shows the movement of coal from the Wagon Tippler to the Coal Tower.

1.1 Coal from Wagon Tippler to Coal Yard

The circuit begins at the Twin Wagon Tippler 1 in the Wagon Tippler complex where the

incoming rakes of coal are unloaded. The coal falls through the hoppers (beneath the twin

tippler) onto the apron feeders below. From there, coal is conveyed via conveyors CC-1, CC-

2, CC-3, CC-4 and CC-5, via Junction Houses JH-1, CJH-1, CJH-2 and CJH-3, until it reaches the

Stacker cum Reclaimers (SRC-1, SRC-2 and SRC-3 in future) in the Coal Yard. There the coal is

first stacked and later reclaimed (by CC-6, 7 and 8) as per demand.

Twin Wagon Tippler 1

Twin Wagon Tippler-1

Introduction:-

There are total four wagon tipplers in KPO out of which first two are twin and the other two

are single tipplers. The wagon tippler which is used in circuit 1 is twin wagon tippler 1 (TWT

1) and this tippler is entirely dedicated for handling coal. The twin tippler machine consists

of three major components – indexer, sidearm charger and wagon tippler. The indexer is

used for pulling the rake while the sidearm charger is used for placing the two wagons

simultaneously at the tippling area over the two hoppers and the wagon tippler is used for

unloading the material into the hoppers. In twin wagon tippler-1, coal falls through hoppers

over two apron feeders and from there it is guided to CC-1 and with the help of further

conveyors it is stacked in coal yard. Two dribble conveyors are placed below two apron

feeders to avoid spillage.

The Wagon Tippler Unit mainly consists of:

Wagon Tippler drives with brakes, lubrication systems and position control.

Side Arm Charger with position control.

Indexer with position control

Hydraulic system for wagon holding on the Wagon dumper, gripper on tippler table &

grippers at inhaul and outhaul

Hydraulic system on the Indexer for luffing arm & de-coupler cylinder

Hydraulic system on the SAC for luffing arm & de-coupler cylinder

Environmental measures (Pre-wetting and water spraying during tippling)

The twin tipplers are capable of handling two wagons at a time unlike single wagon in the

present tipplers. This means that de-coupling for a whole rake consisting of 59 wagons will

require 30 cuts instead of present 59. Handling capacity of twin tipplers is 8 rakes and that of

single tippler is 5 rakes per day respectively. Each tippler is designed to have minimum 25 tips

per hour. This has been arrived on the basis of following calculation.

SL NO ACTIVITY TIPPLER TIME ASSESSMENTSINGLE TWIN

1 No. of tips/wagons per hour 25 25

2No. of wagons handled per

hour25 50

3Time required for tippling a 59

wagon rake.142 minutes 71 minutes

4Placement and release time in

pre tippling line30 min 30 min

5

Grouping, engine attaching,

creation of air pressure and

evacuation from post tippler

line

60 min 60 min

6Total time for unloading of

one rake

232 min = 3 hours 52

min.

say 4 hours

161 min = 2 hours 41 min.

Say 3 hours

7 Cushion time to EOL time limit 1 hour 2 hours

8

Time allowed under EOL

concept by railway for

unloading of one rake with 59

BOXN wagons.

4 hours

9

Number of rakes that can be

handled in 21 hours leaving 3

hours for tippler maintenance.

1260 ÷ 232

= 5.43 or say

5 rakes.

1260 ÷ 161

= 7.826 or say

8 rakes

Operation:

Depending upon the Wagon Type the rake is Pulled or Pushed on to the Wagon Tippler

table.

For placing of Loaded Wagon rake at inhaul position, we have Indexer machine. Placement

by Indexer is achieved with the help of 5 No’s of Electromechanical (VFD Driven) drives.

For placing of Loaded Wagons to be tippled on Tippler Platform, we have Side Arm Charger

machine (SAC) Placement of loaded wagon on platform will be achieved by SAC with the

help of 3 No’s of Electromechanical (VFD Driven) drives.

Wagons shall be gripped at Inhaul Side (WG-1&2) & Outhaul Side (WG-3) during placement

of wagons on rail track.

Wagons will be clamped on table with Horizontal Side Wall clamping (Unloading side) &

Vertical Top clamping (Unloading side & Opposite to Unloading side) on Tippler table.

Programmable Logic Controller (PLC S7-4H) is of Siemens make.

Operation modes:

The wagon tippler system is equipped with control devices which allow the following operating

modes:

Manual mode - Operation initiated from Control Desk by operator in predetermined

operational sequence.

Auto Mode - Operation initiated from Control Desk by operator with all sequential

operation carried out from PLC.

Local Mode - Operation initiated from Local Control Stations by Local operator for

respective equipment.

Technical Detail of Twin Wagon Tippler -1 :

Wagon Tippler is provided with Electro-mechanical drive driven through VVVF Drive with

regenerative braking with active front end for tippling motion. WT serves the purpose of

unloading two wagons placed on the table by SAC into the hopper. Tippling angle of the table

shall be from 0 Degree to 180 Degree. For equal load & speed sharing each motor is supplied

with Tacho generator in close loop operation with VVVF Drive.

All the VVVF motor drive units are run in Master-Master configuration.

Technical Detail of SAC of Twin Wagon Tippler-1:

SAC is provided with Electro-mechanical drive driven through VVVF Drive with

1 Material To Be Unloaded Coal

2 Type Of Wagon To Be Unloaded Boxn, Boy-25, Boxnha, Boxnhs, Boxnlw, Boxnhl, Wagons

Operating At Dfc & Feeder Route.3 Track Gauge & Rail Size 1676 Rail Gauge & Rail Uic 60

4 Wagon Unloading Capacity 2*25 Wagons/Hr (Max.)

5 Rotating Speed Of Tippler Approx 1.5 M/S

6 Design Base As Per RDSO G-33(Rev-A) May 2010

7 Design Load 280 Ton

8 Tippling Angle 180 °

9 Top & Side Clamping Through Hydraulic Cylinder With Power Pack

10 Type Of Tippler Rotary ’ C ’

11 Positioning Device Indexer & Side Arm Charger

12 Installed Power 250 K.W * 2 Nos.

13 Quantity 2 Nos.

14 Total Weight Per Machine Approx 380 Tons.

regenerative braking with active front end for travel motion. SAC serves the purpose of

placing the two loaded wagons on table & pushing empty wagons / rake out of the

table. SAC also serves the purpose of pulling/pushing locomotive. Operating zone of

SAC will be from wheel gripper W2 to wheel gripper W3.

In order to push or pull, the SAC arm is lowered to zero degree position & coupled with the

wagon either at inhaul or outhaul side as required. For equal load & speed sharing each motor

is supplied with Tacho generator in close loop operation with VVVF Drive. All the VVVF motor

drive units are run in Master-Master configuration.

SAC Arm luffing is achieved with the help of Hydraulic system driven by Sq. cage Electric motor.

1 Max. No. Of Wagons To Be Pulled / Pushed2 Loaded Wagons To Be Pulled & 58 Nos. Empty Wagons To Be Pushed

On Straight & Levelled Track

2 Type Of Luffing System Hydraulics Cylinder

3 Rail (Track) Crs 1600mm

4 Operational SpeedForward With Wagons 0.7m/s (Max.)

Return 1.4 m/s (Max.)

5 Type Of Power Supply Energy Drag Chain

6 No. Of Running Wheels – 630 Dia. 4

7 No Of Guide Wheels- 800 Dia. 4

8 Travel Drive Arrangement Rack & Pinion Type

9

Drive Type Electro-Mechanical With VVF Drive

Electric Motor Kw 110

Qty. 3 Nos.

10 Brake Disc Brake On Gear Box Input Shaft Of Each Drive

Technical Detail of Indexer of Twin Wagon Tippler-1:

Indexer is provided with Electro-mechanical drive driven through VVVF Drive with regenerative

braking with active front end for travel motion. Indexer serves the purpose of pulling the

complete rake upto handing over zone of SAC. In order to pull & push the rake/ wagon &

locomotive respectively, Indexer arm is lowered to zero degree position & coupled with wagon

either at inhaul side as required. For equal load & speed sharing each motor is supplied with

Tacho generator in close loop operation with VVVF Drive. All the VVVF motor drive units are

run in Master-Master configuration. Indexer Arm raise/lowering is achieved with help of

Hydraulic system driven by Sq. cage Electric motor.

Technical Detail of Apron Feeder for Twin Wagon Tippler 1:

Apron Feeder system is provided with common Hydraulic Power pack with dedicated Electric

motor & pump system for Feeder-1 & Feeder-2. AF system serves the purpose of receiving

1Max. No Of Wagon To Be

Pulled

60 Loaded Wagons + 2 Locomotives On

Straight And Levelled Track

2 Type Of Luffing System Hydraulics Cylinder

3 Rail (Track) Crs 1600mm

4 Operational SpeedForward With Wagons 0.6 M/S (Max.)

Return 1.2 M/S (Max.)

5 Type Of Power Supply Energy Drag Chain

6No. Of Running Wheels – 630

Dia.4

7 No Of Guide Wheels- 800 Dia. 4

8 Travel Drive Arrangement Rack & Pinion Type

9 Drive Type Electro-Mechanical With VVF Drive

10 Electric Motor Kw 110

11 Quantity 5 Nos.

10 BrakeDisc Brake On Gear Box Input Shaft Of

Each Drive

material dumped by Wagon tippler into the hopper & further feeding to preceding conveyor.

AF hydraulic system is provided with Spider controller for close loop controlling of feeder.

Technical Detail of Dribble Conveyor for TWT 1:

Two dribble conveyors are placed below the two apron feeders of TWT-1 to convey the spilled material of apron feeder towards the CC-1 conveyor.

Wagon Tippler lubrication system:

Centralized Automatic Lubrication Systems is provided at strategic locations of the Wagon

Tippler. Manual lubrication is provided for SAC & Indexer.

Lubrication Systems for Wagon tippler provided are:

a) Motorised Lubrication system for Horizontal & Vertical Holding Devices – 1 No.

Sl No. Equipment Specification1 Width of pan 2130mm2 Length of apron feeder 11000 mm (head shaft to tail shaft CSR)3 Design Capacity 1750 TPH4 Lump size (-) 50 mm5 Chain speed (range) 0 – 13.2 m/min6 Drive Hydraulic drive

Sl No. Equipment Specification

1 Belt width 2000 mm

2 Length (pulley centre) 11900 mm

3 Capacity 100 TPH

4 Pulley dia (drive & non drive) 500mm

5 Belt speed 0.26 M/sec

6 Belt type Fire resistant nylon 400/4

7 Belt cover thickness(top/bottom)

5mm & 3mm

8 Drive Electro mechanical

b) Motorised Lubrication System for Drive Pinions – Inhaul & Outhaul Side – 1 No. each

c) Motorised Lubrication System for Drive pinion bearings, Runner wheels, Guide wheels –

Inhaul & Outhaul Side – 1 No

.

Safety Measures :

Operate the wagon tippler system only on condition that all safety devices, in particular the

limit switches and sequential interlocks are complete and ready for operation.

In case of power failure, WT machine will come to standstill. The clamping System will hold

the wagon in clamped position & all the actions such as tippling of table & SAC/Indexer

travel will be stopped.

Prior to commencing the shift, inspect the wagon tippler system for externally visible

damages and faults.

In the event of malfunctions stop the wagon tippler system immediately and lock it. Have any

defects rectified immediately.

Conveyors:

In circuit 1, conveyor line starts from CC-1 which connects Twin Wagon tippler-1 (TWT-1)

to JH-1. And from JH-1, coal transfers to CC-2 which is underground up to Pent House-2

(PH-2) and there after above ground up to CJH-1. There is a separate circuit for pulverized

coal from CJH-1 to PCI Building which will be explained later. Between JH-1 and PH-2, there

is one Metal Detector (CMD-1) to detect the metallic impurities and one Magnetic

Separator to remove the metallic impurities. CJH-1 connects CC-2 and CC-3, CJH-2 connects

CC-3 and CC-4 and similarly CJH-3 connects CC-4 and CC-5. Between PH-2 and CJH-1, there

is Belt Scale (CBS-1) to weigh the coal and just before CJH-2, there is Coal Sampler (CS-1) to

collect the sample of coal. CC-5 has a tripper conveyor which can move to and fro to supply

material to CC-6, CC-7 or CC-8 as per requirement. CC-6 is used for stacking as well as

reclaiming coal from Stacker Reclaimer-1 (SRC-1), CC-7 and CC-8 does the same for Stacker

Reclaimer-2 and Stacker Reclaimer-3 respectively. In phase I, we have only Stacker

Reclaimer-1&2 and Stacker Reclaimer-3 will be coming in phase II.

Technical description of conveyors

Conveyor Length (meters)

Width (mm)

Capacity (tph)

Belt Speed (m/s)

Motor capacity(KW)

Coupling type

CC-1 150 2000 3500 3.8 300 Scoop

CC-2 474 2000 3500 3.8 740 DFC

CC-3 746 2000 3500 3.8 580 DFC

CC-4 453 2000 3500 3.8 400 DFC

CC-5 (Tripper Conveyor)

CC-5 has a travelling tripper (with two ways discharge chute) which can move to and fro to discharge coking coal in the conveyors CC-6, CC-7 & CC-8 (one at a time) that are associated with Stacker cum Reclaimers - SRC-1, SRC-2 & SRC-3 respectively of Coal Yard. SRC-3 will be coming in Phase II.

Tripper Data Table (CC-5)SL No. Parameters Equipment Description

1 Type Motorised self-propelled2 Conveyor No. CC-53 Location Coal tripper building4 Belt Width 2000 mm5 Belt Speed 3.8 m/s6 Rated/Designed Capacity 3500 TPH / 3850 TPH7 Material Coking coal8 Bulk Density 0.8 T/m39 Max. Lump Size -25 mm

10 Moisture Content 10 % (max)11 Travel Speed 0.25 m/s12 Travel Length 200 m (Approx.)13 Track Rail Size 52 kg/m14 Estimated Weight of Tripper 40 Tonnes (Approx.)15 Power Feeding Arrangement Through cable reeling drum16 Type of CRD Motorised composite CRD unit17 Type of Power Feeding Centre feed18 Supply Voltage 415 V. ±10 %. 50 Hz ± 5 % 3 phase. AC.19 Troughing Angle 45 degree20 Pulley Diameter 800 mm21 Chute Profile Two ways

Technical Data of Tripper Conveyor (CC-5)

Discharge Pulley

SL. No. Description Specification

1 Pulley Dia. * Face Width * BRG. Dia. 800 * 2200 * 240

2 BRG. Dia / Type 240 mm / SPH. Roller

3 Lagging 10 mm THK. Plain Lagging

Hot Lagged With Vulcanised Natural Rubber

Bend Pulley





Drive Wheel & Axle

1 Wheel Tread Dia. 400 mm ( Double Flange)

2 Wheel / Axle Material Forged Steel


Non Drive Wheel & Axle




Travel Drive

1 Electric Motor AC SQ. Cage 2 * 5.5 KW @ 1500 RPM With 60 Start/ Stop

2 Gear Box ( 2 No.’s)Bevel Helical Hollow Shaft With Shrink Disc,

Ratio 130:1, Rating - 12.40 KW

3 H.S Coupling Resilient Type

4 Brake ( 2 No.’s) D.C Electro Magnetic Brake

5 Braking Torque ( Min) 5.35 Kg.m. Each

Yard Machines- SRC-1, 2 & 3

RMHS’ Coal Yard has three Stacker Reclaimers out of which Stacker reclaimer-1 (SRC-1) and

Stacker racliamer-2 (SRC-2) are being commissioned in phase I and Stacker Reclaimer-3

(SRC-3) will be commissioned in phase II. Conveyor associated with SRC-1, SRC-2 and SRC-3

is CC-6, CC-7 and CC-8 respectively. Storage capacity of the entire Coal Yard is 400000 T.

Stacker cum Reclaimer

General Description

The rail mounted stacker cum reclaimer is suitable for building stockpiles on either side of

the track rails and subsequently reclaiming these materials from the piles and feeding them

for onward usage. The machine is designed for working with a unidirectional yard conveyor

with additional provision for direct feeding with the machine by-passed.

The machine is designed and built to incorporate the latest technological progress in the

engineering of large bulk material handling equipment.

Technical Specifications of Stacker Reclaimers (Coal Yard)

Material Handled

Material Handled

Bulk density (t/cu.m) Size (mm) Angle of repose

(degree)Moisture

content (%)

Coal 0.9 to 0.8 +1 to -25 36-38 9-10

Stockpile

Total Nos. 2Pattern ChevronSection Linear triangular and conical

Maximum base width 40 metresMaximum height above ground level 15 metres

Depth below rail level 0.80 metres

Capacity

Capacity (tph) CoalReclaiming 800(rated)/960(design)

Stacking 3500(rated)/3850(design)

Luffing range

Luffing range ( degree ) CoalMax down -8.1

Max up +13.5Parking -4

Operating speeds

Bucket wheel 48 discharges/minBoom conveyor 3.8 m/s

Luffing 4.5 m/minSlewing 7 – 35 m/minTravel 7.5 – 30 m/min

Yard conveyors (CC-6, CC-7 & CC-8)

Conveyors CC-6, CC-7 & CC-8Length 698 meters

Belt width 2000 mmTroughing angle 45 degree

Speed 2 m/sType of Belt Steel cord

Wind loads

Operating 80 km/hrNon-operating 180 km/hr

Track rails

Size 60 kg/mGauge 8.2 m

Other specifications

Boom length 41 metresSlewing range +110 to -110 degree

Total travel of machine 460 metresAmbient temperature 50 degree centigrade

Duty of machine Continuous, 24 hours

Design standard ISO 5049/1 – Mobile continuous bulk handling equipment

Power supply 6.6 kv,450 MVA, 3 Ph (HT), 50 Hz, 415 V, 3 Ph (LT)

Principles of operation

The rail mounted stacker cum reclaimer is suitable for serving two parallel stockpiles, one on

either side of the track rails.

The machine is designed to operate with a yard conveyor with provision for feeding at one

end for stacking and discharging at the other end during reclaiming, i.e. a non-reversible

one.

The following modes of operation are possible:

Stacking mode

Reclaiming mode

Direct feeding mode

50% stacking & 50% direct feeding

Emergency Stop

The mushroom head, press to stop lockable, rotate to release type emergency Stop (E-Stop)

stations are strategically located at different parts of the machine. Pressing this button gets

the topmost priority of operation and stops the machine irrespective of the mode of

operation.

Technical Detail of Critical Parts of Stacker Reclaimer of Coal Yard:

Boom ConveyorDrive name Boom conveyor

Driven by LT cage motor through fluid coupling

Type of control Reversible DOLRating 180 KW,4p(160KW,4p for ore)

Location of L/R sel sw. MCC feeder

Controlling hardware locationOf operation MCCB, contactor and MPR in MCC

Mode and location of operation•Local from LCS/individual feeder at MCC

•Remote(manual/auto) from HMI

Hydraulic Power Pack for Bucket WheelDrive name Hydraulic power pack for bucket wheel

Driven by Hydraulic motor power pack and pump

Type of control DOL(for pump);SPIDER control system for hydraulic

Rating 75 KW 4p(for pump) 132 kw 4p (for ore)

Mode and location of operation

For pump•Local from LCS / individual feeder at MCC

•Remote(manual/auto) from HMI for hydraulic power pack•Local from SPIDER control panel

•Remote from HMI

PLC control interfaces with MCC (for pump) and SPIDER for hydraulic power pack

Hydraulic Power Pack for Bucket Wheel & Stacking SkirtDrive name Hydraulic power pack for bucket wheel & stacking

skirtDriven by Hydraulic motor ,power pack

Type of control DOL (for pump) solenoid valves for flap gate chute, stacking skirt and bucket wheel chute

Rating 3.7kw, DOL for pumpLocation of L/R sel sw. MCC feeder

Controlling hardware locationOf operation MPCB, contactor & EOCR in MCC

Mode and location of operationFor pump

•local from LCS•REMOTE ( manual /auto)from HMI

Hydraulic Power Pack for Boom Luff and cabin CylinderDrive name Hydraulic power pack for boom luff & cabin

levellingDriven by Hydraulic motor ,power pack & hydraulic pump

Type of control DOL (for pump)Rating 30kw,4p

Location of L/R sel sw. MCC feederControlling hardware location

Of operation MCCB,contactor & EOCR in MCC for the pump


•local from LCS/individual feeder at MCC•REMOTE ( manual /auto)from HMI

Long TravelDrive name Long travelDriven by LT AC sq. cage motor ( total 14 motors)

Type of control VVVF drive (single drive for 14 motors) reversible , with bypass facility

Rating 5.5 kw every motors , 4pLocation of L/R sel sw. Drive panel

Controlling hardware locationOf operation MCCB, contactor & master drive in the VVVF drive panel

Mode and location of operation •local from LCS•REMOTE ( manual /auto)from HMI

Hydraulic Power Pack for Slew

Drive name Hydraulic power pack for SlewDriven by Hydraulic motor, power pack & hydraulic pump

Type of control DOL (for pump)Rating 30 KW, 4p (for pump)

Location of L/R Sel sw. MCC feeder

Controlling hardware locationOf operation

MPCB, contactor & EOCR in MCC &control for hydraulics in SPIDER control panel (common with

bucket wheel

Mode and location of operation

For pump•local from LCS/Individual Feeder at MCC

•REMOTE ( manual /auto)from HMI for hydraulic power pack

Power Cable Reeling DrumDrive name Power Cable Reeling Drum

Driven by Slip ring stall torque AC motors

Type of control Torque control by variable resistance method

Rating 5.5 KW

Location of L/R Sel sw. Not applicable

Controlling hardware locationOf operation

MPCB, contactor & variable resistance controls in the MCC panel

Mode and location of operation Not applicable

Rail ClampDrive name Rail Clamps

Driven by Hydraulic pump & its power pack

Type of control DOL (for pump)

Rating 3.7 KW, 4p (for pump)

Location of L/R Sel sw. LCS, MCC feeder


•local from LCS•REMOTE ( manual /auto)from HMI

1.2 Coal from Coal Yard to Coal Tower

Coal from coal yard is reclaimed by the stacker reclaimers - SRC-1,2 & 3 (SRC-3 will come in

phase II) at the reclaiming rate of 800tph to the conveyors- CC-6, 7& 8 respectively. There is

a common conveyor CC-9 which receives coal from CC-6, 7& 8 through junction houses CJH-

4, 5& 6 respectively. Between CJH-6 and CJH-7, there is one Belt Scale (CBS-2) to weight the

coal. Thereafter, CJH-7 connects CC-9 and CC-10 and the coal gets transferred from CC-9 to

CC-10, a tripper conveyor. Coal from CC-10 is discharged to the 10 bins in Coal Blending

Bunker Building (CSBB). Each bin has a storage capacity of 1500 T.

CC-11 carries coal from CSBB to Primary Coal Crusher House. In between CSBB and primary

crusher, there is coal sampler (CS-2) to collect the sample and then Magnetic Separator

(CMS-1) to remove the metallic impurities from the coal. Thereafter, there is Metal Detector

(CMD-1) to detect any metal and stop the flow of the circuit to prevent damage to the

primary crusher. In CC-11 conveyor after CMD-1, there is Belt Scale (CBS-5) to weigh the

coal.

The crushed coal from the primary crusher is discharged to the CC-15, which in turn

discharges the coal into the hopper above secondary coal crusher house. Between the two

houses, there is one Magnetic Separator (CMS-5) to remove the metallic impurities from the

coal. Thereafter, there is Metal Detector (CMD-3) to detect any metal and stop the flow of

the circuit to prevent damage to the secondary crusher. After CMD-3, there is Microwave

Type Moisture Gauge (MMG-1) and Moisture Addition Facility to regulate the moisture

content as per requirement (Generally 5 %). After this, there is Coal Sampler (CS-4) to collect

the sample and Belt Scale (CBS-7) to weigh the coal.

The crushed coal from the secondary crusher is discharged to the CC-19; where a

Microwave Type Moisture Gauge (MMG-4) and Moisture Addition Facility is used to

regulate the moisture content if further required. The coal from CC-19 is then conveyed to

Coal Junction House (CJH-8). CJH-8 connects CC-19 and CC-21, CJH-9 connects CC-21 and CC-

23 and similarly CJH-10 connects CC-23 and CC-24.

CC-24 is a reversible conveyor that can feed both CC-25 (via CJH-11) and CC-26 which will

lead to Coal Tower 1 and Coal Tower 2 respectively.

CC-10 (Tripper Conveyor)

CC-10 has a travelling tripper (with two ways discharge chute) which can move to and fro to discharge coking coal in all the 10 bins (one at a time) of Coal Blending Bunker Building.

Tripper Data Table (CC-10)SL No. Parameters Equipment Description

1 Type Motorised self-propelled2 Conveyor No. CC-103 Location Blending bunker4 Belt Width 1600 mm5 Belt Speed 3 m/s6 Rated/Designed Capacity 1800 TPH / 1980 TPH7 Material Coking coal8 Bulk Density 0.8 T/m39 Max. Lump Size -25 mm

10 Moisture Content 10 % (max)11 Travel Speed 0.25 m/s12 Travel Length 117 m (Approx.)13 Track Rail Size 52 kg/m14 Estimated Weight of Tripper 30 Tonnes (Approx.)15 Power Feeding Arrangement Through cable reeling drum16 Type of CRD Motorised composite CRD unit17 Type of Power Feeding Centre feed18 Supply Voltage 415 V. ±10 %. 50 Hz ± 5 % 3 phase. AC.19 Troughing Angle 45 degree20 Pulley Diameter 800 mm21 Chute Profile Two ways

Technical Data of Tripper Conveyor (CC-10)

Discharge Pulley






Bend Pulley





Drive Wheel & Axle








Travel Drive







Coal blending bunker building (CSBB):

Coal Blending Bunker Building

CSBB is for storage of 15000 T (1500 x 10) coal; received through travelling tripper (CTT-3).

Each blending bunker is provided with one radar type level indicator and transmitter for

getting the level of the bunker in the CHP PLC system. Each bunker has been provided with

two discharge facilities at the bottom, one for the Phase I and other for the Phase II.

Flow diagram of CBB Building

Different types of coal (by composition & source) will be available at the coal blending

bunker bins and the blending is carried out at predetermined rate through weigh feeders.

Number of Coal Blending Bins 10

Capacity of each bin 1500 T

Number of Coal Rod Gate (CRG) 10

Number of Coal Rack & Pinion Gate (CRPG) 10

Number of Coal Way Feeder (CWF) 10

Capacity of output conveyor (CC-11) 400 TPH

Belt Speed of output conveyor (CC-11) 2.8m/s

Size of Input Coal -80 mm

Similarly for the Phase II same discharge and blending facility will be provided.

Primary Coal Crusher House:

There are two surge bins each 140T used to receive the incoming blend coal from the

bunkers before conveying to the crusher (each 400TPH capacity). 2 No’s level indicators are

located on the bins to measure the level of the material heap.

Primary Coal Crusher House (Outside View)

The blended coal from bins will be crushed as per battery requirements (generally -3mm)

through primary & secondary crushers. There is a moisture adjustment system after the

primary crusher. The primary crusher is equipped with surge bunker of capacity of 140T. The

crusher is operating with 900KW HT motors and operating with one standby.

Primary Crusher House (Inner View)

Hammers Inside Primary Coal Crusher

Flow diagram of Primary Coal Crusher House

Number of Surge bins 2


Number of Coal Rod Gate (CRG) 2Number of Coal Rack & pinion gate (CRPG) 2

Number of Retractable Coal Belt Feeder (RTCBF) 2

Capacity of Retractable Coal Belt Feeder (RTCBF) 40 – 400 TPHNumber of Coal Crusher (CCR) 2

Number of hammers per crusher 96

RPM of Rotor 600



Output Coal Size -3mm

Secondary Coal Crusher House:

There are two surge bins each 140T used to receive the incoming blend coal from the

primary crushers before further pulverising at the secondary crushers, (each 400TPH

capacity). 2 Nos level indicators are located on the bins to measure the level of the material

heap.

Secondary Coal Crusher House (Outside View)

There is also a moisture adjustment system after the secondary crusher. There is also an

arrangement to by-pass the Secondary Coal Crusher house if the required crushing is

achieved through Primary Coal Crusher House.

Secondary Coal Crusher House (Inside View)

Hammers Inside Secondary Coal crusher

Flow Diagram of Secondary Coal Crusher House

Number of Coal Blending Bins 3


Number of Coal Rod Gate (CRG) 3

Number of Coal Rack & pinion gate (CRPG) 3

Number of Retractable Coal Belt Feeder (RTCBF) 2

Capacity of Retractable Coal Belt Feeder (RTCBF) 40 – 400 TPH

Number of Coal Way feeder ( for spillage coal ) 1

Number of Coal Crusher (CCR) 2

Number of hammers per crusher 96

RPM of Rotor 600



Output Coal Size -3mm

1.3 Coke spillage from Coke Oven Battery to Coal Tower via

Secondary Crusher House

There is another bunker, having 150 T capacity, used to receive the excess / spillage coal

from the coke oven batteries via junction houses SPJ – 1 and 2. These are then fed back into

the system as input via Coal Towers.

This bunker has a level indicator to measure the level of the material heap.


Conveyor Length (meters) Width (mm) Capacity

(tph)Belt Speed

(m/s)

Motor Capacity

(KW)

Coupling Type

CC-6 705 2000 3500 3.8

CC-7 705 2000 3500 3.8

CC-9 363 1600 1800 3

CC-10 236 1600 1800 3

CC-11 333.85 1000 400 2.8

CC-13 (RS) 16.625 1200 400 1.55

CC-15 247 1000 400 2.8

CC-17 (RS) 20.4 1200 400 1.55

CC-19 209 1000 400 2.8

CC-21 62 1000 400 2.8

CC-23 275 1000 400 2.8

CC-24 (R) 80 1200 400 2.8

CC-25 76 1000 400 2.8

CC-26 76 1000 400 2.8

SPC-1 183.886 1000 600 2.8

SPC-2 70 1000 600 2.8

2. Coke Oven Output Circuits

This circuit begins at the coke warf of the battery from where the coke is conveyed to the

Coke Screening House (CPSH). The coke from CPSH is sent to the coke stock bins, to be sent

to fuel crushing later, and to the coke storage yard to create the buffer stock to be sent to

the blast furnace tripper as per operation requirements.

Coke reaches the Coke Stock Bins by conveyors CK- 11, 12, 15 and 16 via junction houses KJ

– 1 and 1A. It is diverted towards the Coke Storage Yard by the conveyors CK – 18, 28, 29

and 30 via junction houses KJ – 2, 6 and 7, and it is stacked in the yard by the Coke Stacker.

2.1 Coke From Coke Oven to Coke Storage Yard

Coke Screen House

Coke Screen House

Flow Diagram of Coke Screen House

Side View of Coke Screen House

Top View of one of the Screens of Coke Crusher House

Coke from the Coke Oven Battery is brought to the Screen House by the conveyors CK-3 and

4 (future), where it is received by the 400T Coke Surge Bin. The Surge Bin distributes

incoming coke into 5 Vibrating Screens (2 of which are to be commissioned in the future)

each having a capacity of 200TPH.

The screens separate incoming coke into three sizes: -10 (Coke Breeze), 10-34 (Nut Coke)

and +34 (Coke Breeze).

These are then distributed on to three separate conveyors CK – 15, 11 and 18 which carry

screened coke of sizes -10, 10-34 and +34 respectively. Another conveyor CK – 19 will be

commissioned in the future to carry screened coke of size +34.

+34 (BF Coke) screened coke is taken by CK – 18 (and 19 in future) to junction house KJ – 2

from where a reversible conveyor directs it on to CK – 22 for BF Stock House or to CK-28 for

conveying to Single Boom Stacker for ground stock, in case BF Stock House is not ready to

receive the coke.

10-34 (Nut Coke) screened coke is taken by CK-11 to junction house KJ-1A from where it

leads to Coke Stock Bin Building by series of conveyors.

-10 (Coke Breeze) screened coke is taken by CK-15 to junction house KJ-1 from where it

leads to Coke Stock Bin Building by series of conveyors.

Equipment Details of Coke Screen House:

Coke Surge Bin (KSB) 1 No.

Rod Gate (KRG) 5

Rack & Pinion Gate (KRPG) 5

Vibrating Feeder (KVF) 5

Capacity of Vibrating Feeder 20-200 tph

Vibrating Screen (KVS) 5

Capacity of Vibrating Screen 200 tph

Flap Gate (future) (KFG) 5

Coke Storage

CK-18 takes the BF Coke (+34) towards KJ-2 where it falls on CK-20(R), a reversible conveyor

which can take the coke towards the BF Stock House by series of conveyors ( CK-22, CK-24,

CK-24A, CK-26) or towards the Single Boom Stacker for coke storage by series of conveyors

(CK-28, Ck-29, Ck-30) where it is stacked by the Coke Single Boom Stacker (KSBS-1).

Coke Single Boom Stacker

Coke Single Boom Stacker

Coke Single Boom Non Slewable Luffing Stacker will create a stock pile of BF Coke using

Chevron Method. The Stock Yard is located on the west side of the Sinter Plant adjoining NS-

30 Road. The coke will be reclaimed using pay-loaders on to the return conveyor CK-31 and

will subsequently be transferred to the Blast Furnace. The Stacker is of FL Smidth make with

a capacity of 500 TPH and will create a stock pile of approximately 200 layers to a height of

11m and length 260m. Storage capacity of the BF Coke Yard is 19000T.

Technical Specification of Coke Luffing Stacker

General Equipment Specification

Name Non slewable single boom luffing stacker

In/Outdoor Outdoor

Stacking Capacity (tph) 500

Design Capacity (tph) 550

Type of Support Three point corner

Stacking Boom Length (m) 21.38

Stacking Method Chevron method

Max Wind Velocity (operation) 80 km/h

Max Wind Velocity (non-operation) 180 km/h

Boom Luffing MechanismType of Drive Hydraulic operated system

Luffing Speed 2 m/min at boom discharge pulley

Type of Mounting Clevis mounted with spherical bearing

Luffing Range Luff up: +12 degree; Luff Down: -14 degree

No. of Cylinders 1

Make Rexroth

Hydraulic Unit 1 Hydraulic power pack

Motor Power 3.7 kW

Make Rexroth

2.2 Coke from CPSH to CSBB

Coke Breeze (-10mm) after getting screened from CPSH is conveyed by the conveyor CK-15.

KJ-1 connects CK-15 to Ck-16 which takes Coke Breeze to Coke Stock Bin Building. Similarly,

Nut Coke (10-34mm) after getting screened from CPSH is conveyed by the conveyor CK-11.

KJ-1A connects CK-11 and CK-12 which takes Nut Coke to Coke Stock Bin Building.

Coke Stock Bin Building

Coke Stock Bin Building

Flow Diagram of Coke Stock Bin Building

There are 5 surge bins in Coke Stock Bin Building, out of which 2 No.’s are for Nut Coke, 2

No.’s are for Coke Breeze and 1 No. is for Anthracite. Each bin has a storage capacity of 100

T. The coke is then transferred to the common conveyor CK – 41 by various reversible

conveyors, and then CK -41 takes both the coke breeze and the nut coke to the Coke Breeze

Shed, where they are stacked by using a travelling tripper KTT -1. The coke from CK-41 is

conveyed to KTT-1 by series of conveyors (CK-42, CK-46, CK-47, CK-48 & CK-49).

The coke can also be sent towards the Fuel Crushing System through conveyor CF -1 and

other downstream conveyors.

The Nut coke, Coke Breeze and Anthracite from Coke Breeze Shed is reclaimed by Pay-

Loader and unloaded on Hoppers on CK-51 conveyor and then the same is transferred to

Coke Stock Bin Building through series of conveyors (CK-51, 52, 53& 54).

There is also a provision of sending Nut Coke (10-34) from Coke Stock Bin Building to BF-I

Stock House through series of conveyors (CK-41, CK-42 and CK-43) using flap gate located at

KJ-10.

KTT-1 (Tripper Conveyor)

KTT-1 has a travelling tripper (with one way discharge chute) which can move to and fro to discharge material in the Coke Breeze Shed.

Tripper Data Table (KTT-1)

SL No. Parameters Equipment Description

1 Type Motorised self-propelled

2 Conveyor No. KTT-1

3 Location Coke breeze shed

4 Belt Width 800 mm

5 Belt Speed 1.6 m/s

6 Rated/Designed Capacity 100 TPH / 110 TPH

7 Material Coke

8 Bulk Density 0.5 to 0.6 T/m3

9 Max. Lump Size -34 mm

10 Moisture Content 3.5 % (max)

11 Travel Length 350.5 m (Approx.)

12 Estimated Weight of Tripper 25 Tonnes (Approx.)

13 Power Feeding Arrangement Through cable reeling drum

14 Type of CRD Motorised composite CRD unit

15 Type of Power Feeding Centre feed

16 Supply Voltage 415 V. ±10–15 %. 50 Hz ± 6 % 3 phase. AC.

17 Troughing Angle 35 degree

18 Pulley Diameter 950 mm

19 Chute Profile One way

Technical Data of Tripper Conveyor (KTT-1)

Discharge Pulley




3 Lagging Drive/Non Drive 12 mm Ceramic Embedded Rubber Lagging/

10 mm Plain Rubber Lagging

Bend Pulley



3 Lagging Drive/Non Drive 12 mm Ceramic Embedded Rubber Lagging/

10 mm Plain Rubber Lagging

Drive Wheel & Axle





1 Wheel Tread Dia. (Tail) 500 mm ( Double Flange)



Travel Drive

1 Electric Motor AC SQ. Cage 30 KW @ 1475 RPM

2 Gear Box ( 2 No.’s)Helical, Ratio 31.5:1, Rating -40 KW

(Mechanical)

3 H.S CouplingTyre Type (High Speed) & Geared (Low

Speed)



Coke Return Fines from Blast Furnace is also conveyed to the Coke stock Bin Building

through series of conveyors (Ck-56A, 56, 57).

Details of Coke Stock Bin Building:

No. of Stock Bins (KSB) 5

No. of Continuous Level Indicator (KCLI) 5

Capacity of each Stock Bin 100 T

No. of Rod Gate (KRG) 5

No. of Rack & Pinion Gate (KRPG) 5

No. of Vibrating Feeder (KVF) 5

Capacity of Vibrating Feeder 100 tph


Conveyor Length (m) Width (mm) Capacity (tph) Belt Speed (m/s)

Motor Capacity

(KW)

Coupling Type

CK-3 7 1400 400 1.6

CK-11 336.3 1000 200 1.6

CK-12 34 1000 200 1.6

CK-15 339.33 1000 200 1.6

CK-16 32.15 1000 200 1.6

CK-18 313 1400 400 1.6

CK-28 209.35 1400 400 1.6

CK-29 82.1 1400 400 1.6

CK-30 372 1600 400 1.45

CK-41 268.97 800 100 1.6

3. Sinter Plant Input Circuits

The circuit shows how different raw materials are carried to the Proportionate Bin Building.

3.1 Ore & Flux from Wagon Tippler to Ore & Flux Yard

As shown in the circuit, there are total 3 wagon tipplers (1 twin and 2 single) dedicated for

Ore & Flux Circuit - WT-2 is twin and WT-3, 4 are single tipplers. The circuit is designed in

such a way that each of the three tipplers can be used for iron ore, iron ore fines and flux.

CO-1, C0-2 & CO-3 are the associated conveyors for WT-2, WT-3& WT-4 respectively. The

material gets dumped in respective hoppers by wagons and then respective apron feeders

through hoppers. There is also dribble conveyor below each apron feeder to prevent

spillage of material.

WT-1 and WT-2 are both identical twin tipplers and so their technical specifications and

working principle are also similar to each other. WT-1 is already explained in details in coal

circuit. WT-3 and WT-4 are both identical single tipplers.

There is metal detector in each of the three conveyors (CO-1, CO-2, and CO-3) to detect any

metallic material. Thereafter, JH-1 connects CO-1 to CO-9, CO-2 to CO-8 and CO-3 to CO-7.

CO-7, 8& 9 are underground conveyors till Pent House -1 (PH-1) and aboveground after it

and these conveyors ultimately lead to JH-2.

Between PH-1 and JH-2, we have Magnetic Separator House (MSH) to separate the metallic

material and Belt Scale (BS) to weigh the material.

There is also an additional circuit straight for quartz and pyroxenite from Ground Hopper-1

(GH-1) through Pent House (PH-3), CO-10 connects Ground Hopper (GH-1) to JH-2.

JH-2 also connects CO-7 to CO-11, CO-8 to CO-12, CO-9 to CO-13 and CO-10 to CO-14. CO-

11, 12, 13& 14 are all Reversible Shuttle (RS) conveyors which can discharge material in any

of the three conveyors (CO-15, CO-16, and CO-17).

CO-15, 16, 17 each connects with Tripper Gallery which has three tripper conveyors one for

each CO-15, 16, 17. Now each tripper conveyor in tripper gallery can discharge material in

any of the four Stacker-cum-Reclaimers of Ore and Flux yard.

Two Stacker-cum-reclaimers (SR-1 and SR-2) are coming in Phase I while the other two (SR-

3 and SR-4) are coming in Phase II. CO-19 and CO-20 are the associated conveyors for SR-1

and SR-2 respectively which can stack as well as reclaim material as per requirement.

CO-15, CO-16 & 17 (Tripper Conveyors)

CO-15, CO-16 and CO-17 each has a travelling tripper (with single way discharge chute) which can move to and fro to discharge iron ore fines and fluxes in the conveyors CO-19, CO-20, CO-21 & CO-22 (one at a time) that are associated with Stacker cum Reclaimers - SR-1, SR-2, SR-3 & SR-4 respectively of Ore & Flux Yard. SR-3 and SR-4 will be coming in Phase II.

Tripper Data Table (CO-15, CO-16 & CO-17)SL No. Parameters Equipment Description


2 Conveyor No. CO-15, CO-16 and CO-173 Location Tripper gallery

4 Belt Width 1600 mm

5 Belt Speed 2.75 m/s6 Rated/Designed Capacity 3500 TPH / 3850 TPH

7 Material Iron ore fines and fluxes

8 Bulk Density 2.1 T/m39 Max. Lump Size -10 mm

10 Moisture Content 10 % (max)

11 Travel Speed 0.25 m/s12 Travel Length 208 m (Approx.)

13 Track Rail Size 52 kg/m



16 Type of CRD Motorised composite CRD unit17 Type of Power Feeding Centre feed

18 Supply Voltage 415 V. ±10 %. 50 Hz ± 5 % 3 phase. AC.

19 Troughing Angle 45 degree20 Pulley Diameter 800 mm

21 Chute Profile Single way

Technical Data of Tripper Conveyor (CO-15, 16 & 17)

Discharge Pulley






Bend Pulley





Drive Wheel & Axle








Travel Drive







Stacker Reclaimer (Ore Yard)

Stacker cum Reclaimer – Ore Yard

Part Wise Specification of SCR – 1Equipment Name Equipment Parts Unit Description

Bucket Wheel

Type Cell-LessWheel Dia. Mm 6000

No. of Bucket 8

Bucket Capacity Cu m. 0.6 max (max fill factor 0.85-0.9)

DriveType

Hydraulic Motor (132 kW) [Make – Hagglands]

Speed r/min 8.5

Boom Conveyor

Length (pulley crs.) Mm 42400Speed m/sec 2.75

Belt

1600 mm all nylon, heavy duty, 630/4

cover grade FR, Top cover = 6mm, bottom

cover = 3mm

Ore SCR – 1

Process Unit Capacity

Reclaiming T/hr 1800(rated)~2160(designed)

Stacking T/hr 3500(rated)~3850(designed)

Travel (LT) M 459 (max.)

Height of Stockpile M 15 (max.)

Slew Deg. -105 to +105 (max.)

Luffing Deg. -7.71 to +13.5 (max.)

Ore Stacker cum Reclaimer SCR – 1Equipment Name Equipment Parts Unit Description

Boom conveyor

Pulleys

Driving

630 dia, 1800 face, ceramic

lagging & shell thickness = 16

mm

Non-Driving

630 dia, 1800 face, neoprene rubber lagged, lagging & shell thickness = 12

mm

Idlers

Carrying (ø152.4, 3 roll, 45 deg, spacing = 1000 mm, bearing I/D =

35mmReturn (ø152.4, 2 roll, 10 deg, trough spacing = 3000 mm, bearing I/D = 30

mm)Impact (ø190.3, 3 roll, 45 deg, Trough

spacing = 400 mm, bearing I/D = 35 mm, neoprene rubber thk. = 25 mm,

hardness = 65±5(shoreA)

Take Up typeScrew type take

up unit with hydraulic jack

Slew Drive

Speed m/min 7.35 (at BW tip)

Range Degree -105 to +105 (max.)

Motor Hydraulic motor (make – Parker)

Ore Stacker cum Reclaimer SCR - 1

Equipment Name Equipment Parts & Unit Description

Luffing of Boom & other components

Operation Through Hydraulic Cylinder

Range Deg -7.7 to +13.5

Speed m/min 4.5 (at bucket wheel centre)

Cylinder

Cylinder for skirt arrangement at slew centreLuff cylinder

Bucket wheel chute cylinderCabin levelling cylinder

Seal kit for above cylindersHose for above cylinders

Material Specification

Property

Sized

iron ore

Iron ore and fines

Limestone (BF Grade)

Limestone (SMS

grade)Quartzite Pyroxenite Anthracite Dolomite

Lump size (mm)

10-40 -10 10-50 10-80 10-40 10-50 -25 30-80

Bulk Density (T/m3)

2.2+-0.1

2.2+-0.1

1.5+-0.1

1.5+-0.1

1.4+-0.1

1.5+-0.1

0.9+-0.1

1.5+-0.1

Max. Moisture content

(%)

8-10 8-10 4.5 4.5 4.5 4.5 8.9 4.5

Angle of repose (deg)

36-40

36-40 34-37 34-37 20-38 34-37 36-38 34-37

OPERATION MODE OF CONVEYOR CKT.

In direct feeding mode we can also do 50-50% direct feeding & stacking

OPERATING MODES

BASED ON EQUIPMENT POINT

OF VIEW

BASED ON PROCESS POINT OF VIEW

LOCAL MODE REMOTE MODE

AUTO MODE

OPERATION MODE OF STACKER CUM RECLAIMER

Operating Modes

Based on Equipment

Point of view

Based on process point

of view

Auto Reclaiming

Auto DirectfeedingAuto StackingRemote mode

Local mode

SAFETY DEVICES-CONVEYOR

Equipment Equipment Safety Person Safety

Conveyor Belt

Zero Speed Switch Pull Chord

Belt Sway Switch Conveyor Safety Guard

Belt Snap Switch Emergency Stop Switch

Guide Roller Hooters

Scrapper PA SYSTEM

Fire Hydrant

Metal Detector

Magnetic Separator

Chute Block Sensor

Stacker Cum Reclaimer Equipment Safety Person Safety

Boom Conveyor

Zero Speed Switch Pull ChordBelt Sway Switch Conveyor Safety GuardBelt Snap Switch Emergency Stop Switch

Guide Roller HootersScrapper Walk Way With Toe Guard

Fire HydrantBucket Wheel Bucket Wheel Guard

Operator Cabin

Pile Height Sensor Fully Covered With GlassSpeed Sensor Stairs With Hand Rail

Walk Way With Toe GuardWipers

Luff Limit Switch HooterSlew Limit Switch Hooter

Long Travel

Storm Lock HooterLimit Switch

BufferSafety Guard

Drivers Coupling Guard Coupling GuardRail Track Track Cleaner Plate Track Guard

Wind Speed Sensors Hooter HooterDiverter Gate Limit Switch


SAFETY DEVICES-SCR

Conveyor Length (m) Width (mm)

Capacity (tph)

Belt Speed (m/s)

Motor Capacity

(KW)

Coupling Type

CO-1 145.3 1600 3500 2.8

CO-2 109.6 1600 1750 2.8

CO-3 92.2 1600 1750 2.8

CO-7 625 1600 1750 2.8

CO-8 635 1600 1750 2.8

CO-9 639 1600 3500 2.8

CO-15 308 1600 3500 2.8

CO-16 365 1600 3500 2.8

CO-17 308 1600 3500 2.8

CO-19 606.4 1600 3500 2.75

CO-20 606.4 1600 3500 2.75

3.2 Iron ore fines & flux from Ore & Flux Yard to PBBIron ore fines and flux is reclaimed from the yard with the help of two stacker-cum-

reclaimers (SR-1 and SR-2). CO-19 and CO-20 are the associated conveyors for SR-1 and SR-2

respectively. While reclaiming CO-19 connects to CO-23 via JH-9 and CO-20 connects to CO-

24 via JH-8. Again, CO-23 and CO-24 are Reversible Shuttle Conveyors which can discharge

material to any of the four conveyors namely FX-1, OF-1, CO-30 and CO-27 out of which CO-

27 is coming in Phase II.CO-23 and CO-24 are reversible conveyors which can discharge the

required material in the required circuit. FX-1 is associated with the fluxes and OF-1 is

associated with the iron ore fines. JH-10 connects FX-1 to FX-2 and OF-1 to OF-2. Iron ore

fines (-3mm) reach to Proportionate Bin Building (PBB) via JH-15 and OF-3.

Flux is first passed thru Flux Crusher House (via FX-3) where it is crushed by hammer mill

and then sent to Flux Screen House (via FX-5). Flux that is crushed to less than -3mm is sent

to PBB building via JH-16, FX-8 and FX-9 and the flux whose size is still greater than +3mm is

sent back to Flux Crusher House via FX-7 and this cycle is repeated till the required size of

flux is attained.

Flux Crusher House

There are five bins each of capacity 480 T each in Flux Crusher House. FX-4 is the reversible

shuttle conveyor of which feeds material to all the five bins. Below the five bins there are

five Reversible Belt feeders (RBF) one for each bin and below each Reversible Belt Feeder

there is a Flux Crusher of capacity 225 TPH. Material after getting crushed from each crusher

falls on FX-5 and from there it is sent to Flux Screen House.

Flux Crusher House

Total number of Stock Bins for Flux (FXSB) 5

No. of bins for Limestone 3

No. of bins for Pyroxenite 1

No. of bins common to Limestone & Pyroxenite 1

Capacity of Stock Bins 460 t

Flux Rod Gate (FXRG) 5

Flux Rack & Pinion Gate (FXRPG) 5

Retractable Belt Feeder for Flux (FXRBF) 5

Capacity of Retractable Belt Feeders 25-225 tph

No. of Flux Crushers (FXCR) 5

Type of Flux Crushers Hammer Mill - Impactor Type

Capacity of Flux Crushers 225 tph

Flux Screen House

Flux Screen House

Flow Diagram of Flux Screen House

Five Screens at Flux Screen House

Top view of one of the screens at Flux Screen House

Like Flux Crusher house, there are five bins of capacity 200 T each in Flux Screen House. FX-6

is the Reversible Shuttle conveyor which feeds material to all the five bins. Below the five

bins there are five Vibrating-Feeders (VF), one for each bin, and below each Vibrating

Feeder there is a Vibrating Screen (VS) of capacity 225 TPH. Material whose size is less than -

3 mm falls on FX-8 and sent to PBB and material whose size is more than +3 mm falls on FX-

7 and sent to Flux Crusher House for re-crushing.

Total number of Stock Bins for Flux (FXSB) 5

No. of bins for Limestone 3

No. of bins for Pyroxenite 1

No. of bins common to Limestone & Pyroxenite 1

Capacity of Stock Bins 200 t

Flux Rod Gate (FXRG) 5

Flux Rack & Pinion Gate (FXRPG) 5

Vibrating Feeder for Flux (FXVF) 5

Capacity of Vibrating Feeders 25-225 tph

No. of Flux Crushers (FXCR) 5


Conveyor Length (m) Width (mm) Capacity (tph)

Belt Speed (m/s)

Motor Capacity

(KW)

Coupling Type

CO-23 (RS) 9 1600 1800 2

CO-24 (RS) 9 1600 1800 2

FX-1 273.5 1400 1800 2

FX-2 519 1400 1800 2

FX-3 30 1600 1800 2

FX-4 (RS) 23.8 1800 2315 2

FX-5 284 1000 675 2

FX-6 (RS) 19.8 1200 675 2

FX-7 280.9 1000 675 2

FX-8 406.9 1000 675 2

FX-9 24.05 1000 675 2

OF-1 277.5 1400 1800 2

OF-2 577 1400 1800 2

OF-3 35.2 1400 1800 2

RF-1 595.56 1200 800 1.35

3.3 Fuel from Coke Stock Bin to PBB

The fuel from coke stock bin passes through Fuel Screen House and a Fuel Crusher House;

where a rod mill operates to crush fuel down to the required size. Thereafter it is conveyed

to the PBB via a network of conveyors and junction houses.

Fuel Screen House

Fuel Screen House

Flow Diagram of Fuel Screen House

Fuel Screen House receives fuel from the Coke Stock Bin by the conveyor CF – 1, which

dumps the incoming fuel into Fuel Stock Bins. The screen house has 5 stock bins, 3 of which

will be commissioned in the future. Each of these stock bins transfer the fuel on to a

vibrating feeder and then on to a vibrating screener which separates the fuel into two size

grades: -3 and +3 – 34.

The separated fuel grades then exit the screen house via separate conveyors: CF – 3 and CF

– 4 for grades -3 and +3 – 34 respectively.

Fuel Cross Belt Magnetic Separator (FCBMS) 1

Fuel Metal Detector (FMD) 1

Fuel Belt Scale (FBS) 1

No. of Bins in PH I (FSB) 2

Capacity of Bins 100 tph

No. of Load Cells per bin 3

Rod Gate (FRG) 1/ bin

Vibrating Feeder (FVF) 1/ bin

Capacity of Vibrating Feeder 10-100 tph

Vibrating Screen (FVS) 1/ bin

Capacity of Vibrating Screen 100 tph

Fuel Crusher House

Fuel Crusher House

No. of Bins in PH I (FSB) 2

Capacity of Bins 80 tph

No. of Load Cells per bin 3

Rod Gate (FRG) 1/ bin

No. of Retractable Belt Feeder (RTFBF) 1/ bin

Capacity of Belt Feeder 5-50 tph

No. of Rod Mills (FRM) 1/ bin

Capacity of Rod Mill 50 tph

Flow Diagram of Fuel Crusher House

The crusher house receives sized fuel (+3 – 34) from the Fuel Screen House via conveyor CF – 4. The fuel drops into 3 Fuel Stock Bins, from where exiting fuel drops on to Retractable Belt Feeders. The fuel is then fed to corresponding Fuel Rod Mills for crushing (each has a capacity of 50tph).

Crushed fuel is taken up by a common conveyor CF – 6 which takes the material to the fuel junction house: FJ – 5.

Fuel to Proportioning Bin Building

Fuel from the screen house is taken towards the PBB by a conveyor system that consists of CF – 3, 8, 9, 10, 11, 12 and FX – 9. These conveyors pass through junction houses FJ – 6, 1, 2, 3, 4 and JH – 16.

While fuel of size -3 follows this route directly, the fuel of size +3 – 34 first gets crushed, passes through FJ – 5 and is then fed to CF – 3 to be carried to PBB.

In future a conveyor CF – 6B will send a part of crushed fuel from FJ – 5 to the Fuel Screen House for further screening and subsequent crushing as and when required.



Belt Speed (m/s)

Motor Capacity

(KW)

Coupling Type

CF – 1 229.3 800 100 1.6

CF – 2 (R) 8 1000 100 1.6

CF – 3 388.3 800 100 1.6

CF – 4 281.3 800 80 1.6

CF – 5 (RSC) 15 1000 80 1.6

CF – 6 132.5 800 100 1.6

CF – 6A 12.1 800 100 1.6

CF – 8 19.298 800 100 1.6

CF – 9 428.75 800 100 1.6

CF – 10 77.4 800 100 1.6

CF – 11 14.9 800 100 1.6

CF – 12 22.35 800 100 1.6

3.4 Base Mix from Proportionate Bin Building to Sinter

Plant via Base Mix Storage Yard

First of all, the conveyor BMS – 1 carries out the Base Mix. The contents are then either

directly taken to Sinter Plant or to the Base Mix Yard and the corresponding circuits

separate at the junction house BMJ – 1. From there conveyors BMR – 3,4 and 5 go towards

Sinter Plant via junction houses BMJ – 2, 3 and 4.

In the Base Mix Yard, the Twin Boom Stacker is used to stack the Base Mix whereas the

reclamation is done by a Barrell Reclaimer.

Proportioning Bin Building

Proportionate Bin Building

Flow Diagram of Proportionate Bin Building

As the name suggests, this building is responsible for making the base mix, which goes into

the making of sinter, by carefully mixing all the necessary ingredients in calculated

proportions.

The building houses 12 bins to receive incoming materials from various sources – 2 bins for

return fines via RF – 1, 2 bins for coke fines via CF – 12, 1 bin each for Pyroxenite and

Anthracite and 2 bins for Limestone via FX – 9, and 4 bins for iron ore fines. The capacities of

all the bins are as follows:

Bin number and material Capacity in tonnes

PB – 1 & 2 (Return Fines) 675

PB – 3 & 4 (Coke Fines) 390

PB – 5 (Pyroxenite) 515

PB – 6 (Anthracite) 320

PB – 7 & 8 (Limestone) 1040

PB – 9, 10, 11 & 12 (Iron Ore Fines) 1430

No. of Proportioning Bins (PB) 12

No. of Load Cells (PLC) 3/ bin

No. of Rod Gates (PRG) 1/ bin

No. of Weigh Feeders (PWF) 1/ bin

Type of Weigh Feeders Load cell based

Weigh Feeder number Capacity (tph)

1 & 2 25-250

3 & 4 15-150

5 & 6 10-100

7 & 8 25-250

9, 10, 11 & 12 180-1800

Once the proportions have been decided the materials are dropped down from the weigh

feeders, situated just below each bin, on to the common conveyor BMS – 1. This conveyor

carries the material out of PBB and transfers it on to BMS – 2 which connects PBB to the first

junction house of the circuit: BMJ - 1

Base Mix to the Base Mix Yard

At the junction house BMJ – 1, the incoming conveyor BMS – 2 meets the reversible

conveyor BMS – 3 which dumps the material on to either BMR – 3 (towards Sinter Plant) or

BMS – 4 (towards Base Mix Yard).

BMS – 4 is the conveyor on which the Twin Boom Stacker TBS – 1 operates and the same is

used to stack the Base Mix in the yard.

Twin Boom Stacker

Twin Boom Stacker

The purpose of the stacker is to stack the material in the storage yard by 400layers. The

material is being received from the yard conveyor through tripper. The flow rate of the

stacker is 2500 to/h. The stockpile area consists of 2 piles. The first pile is above of conveyor

belt BMR-1 (Pile I). The second one is below the conveyor belt BMR-2 (Pile II). Stacking of

both piles will be done by the Twin Boom Stacker TBS-1.

The Twin Boom stacker consists of:

A Boom conveyor - 1 at pile side -1

A Boom conveyor -2 at pile side - 2

One flap gate with diverting chute

A wire rope luffing winch system for Boom conveyor - 1

A wire rope luffing winch system for Boom conveyor -2

A travel system on fixed side

A travel system on pendulum side

An automatic rail clamp on fixed side

An automatic rail clamp on pendulum side

One automatic grease lubrication systems for long travel wheels

A MV cable reel for 6.6 KV supply with holding brake

A radio communication system for communication to:

Barrel Reclaimer BR-1

Central control station (CCS)

Operation Modes

The mode of operation is to be selected in the operator cabin on the machine itself. The

following operation modes can be selected:

Remote Automatic Mode

In this operation mode the automatic process can to be started and stopped from central

control room (CCR). All machine interlocks are active.

Automatic Mode

In this operation mode the automatic process can be started and stopped on the machine

only. A movement of single drives in operation cabin is not possible. All machine interlocks

are active.

Manual Mode

In this operation mode each motor can be started and stopped separately from the operator

cabin. All machine interlocks are active.

Local control mode

In this operation mode the drives can be moved manually. Additionally certain motors can

be started and stopped separately on the local control panel outside of the operator cabin.

Certain interlocks of sensors or with other drives are disabled in this mode.

Technical Details

Boom Conveyor Belt

No. Of Boom conveyor 2Drive pulley diameter 630 mm

Discharge pulley diameter 500 mm

Length between above pulleys 27.25 mBelt width 1400 mm

Belt speed 2.8 m/s (Motor 1500 rpm)Conveyor capacity 2500 t/h

Number of motors for each boom 1

Boom Luffing Winch

Luffing drive system Steel rope winchLuffing range min -12 degLuffing range max +32 deg

Operating range min (Stacking) -12 degOperating range max (Stacking) + 15 deg

Shunting position +32 degDiameter of drum 648 mmDiameter of rope 24 mm

Length of rope 100 mLuffing force (approx.) 50 kN

Rope speed 7 m/minNumber of motors for each system 1

Travel System

Travelling drive system electro mechanical

Number of motors 6

Motors on fixed side 3

Motors on Pendulum side 3

Max. travel distance (approx.) 291m

Rail length stockyard (approx.) 2 x 352 m

Rail span 6 m

Pile width 38 m

Max. travel speed 35m/min

Gear ratio 80:1 (Motor 1500 rpm)

Wheel diameter 630 mm

Reclaimation

Barrel Reclaimer

The purpose of the Barrel Reclaimer is to scrape material and deliver it to a yard conveyor

(BMR – 1 or 2). The flow rate of the reclaimer can be regulated between 920 and 2750

tonnes/hour.

The stockpile area consists of 2 piles. The first pile is above of conveyor belt BMR – 1. The

other one is below BMR – 2. The reclaiming of both piles will be done by the Barrel

Reclaimer BR – 1. For changing the stockpile, the Barrel Reclaimer can be moved from one

pile to the other by the transfer car.

The Barrel Reclaimer consists of the following:

A hydraulic driven drum.

A separate cooler unit for the hydraulic unit of the drum.

One automatic oil lubrication system for gear and pinion (drum).

A reversible cross conveyor belt.

A harrow luffing winch drive.

A hydraulic rake travel system.

A travel system on the fixed side.

A travel system on the pendulum side.

An automatic rail clamp on the fixed side.

An automatic rail clamp on the pendulum side.

One automatic grease lubrication system for fixed side.

One automatic grease lubrication system for pendulum side.

A MV cable reel for 6.6kV supply with holding brake.

A plug socket for 415V supply on ground level used for power supply at pile change.


Twin boom stacker

Transfer car

Central control station

Operation Modes






Automatic Mode



are active.

Manual Mode



Pile Change Mode/ Transfer Mode

This mode is similar to manual operation mode, so in this mode certain motors can be

started and stopped separately but not on the operation desk but on the local control

panels outside the operator cabin. Certain interlocks of sensors are disabled in this mode.

Some drives are basically disabled in this mode.

Local control mode




Technical Details

Drum Drive

Length of drum 40000 mm

Drum body diameter 4200 mm

Drum cutting diameter 6200 mm

Number of buckets in middle row 6

Max number of buckets 62

Number of permanent buckets 58

Number of buckets for monsoon period 4

Width of one bucket 2111 mm

Max capacity of one bucket 420 liter

Used capacity of one bucket 150 liter

Bucket discharge angle 70 degrees

Drive design Hydraulic

Cross Conveyor Belt

Drive pulley diameter 630 mm

Discharge pulley diameter 630 mm

Length between above pulleys 44m

Belt width 1400 mm

Belt speed 2.2 m/s

Conveyor capacity 2750 tph

Number of motors 1

Harrow Luffing Winch

Luffing drive system Steel rope winch

Luffing range min +36 degrees

Luffing range max +42 degrees

Luffing distance (top end to ground) 15.98 m at 42 degrees

Operating range min +38 degrees

Operating range max +40 degrees

Diameter of drum 295 mm

Diameter of rope 20 mm

Length of rope 67 m

Harrow weight 30 tonnes

Luffing force 75 kN

Number of motors 1

Rake Travel System

Number of raking device 1

Type of raking device travelling harrow

Number of harrows 1

Width of harrow 30400 mm

Travel length of harrow 2 X 1.0 m

Operation travel speed 96 mm/s

Travel System


Number of motors 10


Motors on pendulum side 5

Max travel distance (including transfer car) 343 m

Rail length stockyard 2 X 323 m

Distance rail fixed side to rail pendulum side 40 m

Pile width 38 m

Max travel speed (under no-load) 10000 mm/min

Travel speed (under load) 36.8 – 110.4 – 220.8 mm/min

Gear Ratio 481:01


Base Mix to Sinter Plant

At the junction house BMJ – 1, the incoming Base Mix from PBB and the reclaimed Base Mix

from the Base Mix Yard are transferred onto BMR – 3. This begins the transfer of the Base

Mix to the Sinter Plant by conveyors BMR -4 & 5 via junction houses BMJ – 2, 3 & 4.


Conveyor Length (metres)

Width (mm)

Capacity (tph)

Belt Speed (m/s)

Motor Capacity

(KW)

Coupling Type

BMS – 1 57.4 1400 2500 2.8

BMS – 2 66.4 1400 2500 2.8

BMS – 4 413.5 1400 2500 2.8

BMR – 1 403.4 1400 2500 2.6

BMR – 2 403.4 1400 2500 2.6

BMR – 3 47.4 1400 2500 2.8

BMR – 4 124.4 1400 2500 2.8

BMR – 5 71.6 1400 2500 2.8

4. Sinter Plant Output Circuits

The circuit explains the movement of sinter after it exits the sinter plant. The sinter is either

directly sent towards the BF stock house or is sent towards the sinter stock pile, where the

sinter is first stacked and later reclaimed to be sent towards the BF stock houses via a Sinter

Storage Building.

By The sinter that has been sent towards the stockpile can also be allowed to bypass

stacking and go directly to the Sinter Storage Building. So effectively, there are three ways of

transferring sinter from the Sinter Plant to the BF stock house – Direct, Semi-direct and

Indirect.

From Sinter Plant

Sinter is taken up at the exit of Sinter Plant by conveyor SC – 1. Thereafter the sinter travels

to the junction house SJ – 3 by conveyor SC – 2.

At SJ – 3 the sinter can be sent towards BF or towards the Sinter Stockpile by operating a

flap-gate at the tail end of SC – 2. The junction house also has the incoming conveyor,

carrying reclaimed sinter, from the Sinter Storage Building. That conveyor transfers material

on to the conveyor directed towards BF stock house.

4.1 To Sinter StockpileAt the junction house SJ – 3, once the sinter has been directed towards storage, the sinter is

taken along the conveyors SC – 3, 4 and 5 towards the stockpile via junction houses SJ – 4

and 5.

Conveyor SC – 5 runs over a travelling tripper STT – 1 which is used to trip and stack the

incoming sinter onto the stockpile (capacity 55000 tonnes). The conveyor can also carry the

sinter directly to the junction house SJ – 6 without stacking the sinter. From there the sinter

is taken to the Sinter Storage Bunkers in the Sinter Storage Building by the conveyors SC – 6

and 7 via SJ – 7.

SC-5 (Tripper Conveyor)

SC-5 has a travelling tripper (with three ways discharge chute and a flap gate) which can move to and fro to discharge sinter in the Sinter Stock Yard

Tripper Data Table (SC-5)



2 Conveyor No. SC-5

3 Location Sinter Stock Yard




7 Material Sinter

8 Bulk Density 1.7 T/m3

9 Max. Lump Size +5 mm to -50 mm


11 Travel Speed 0.16 m/s

12 Travel Length 210 m (Approx.)









21 Chute Profile Three ways with flap gate

Technical Data of Tripper Conveyor (SC-5)

Discharge Pulley






Bend Pulley





Drive Wheel & Axle








Travel Drive



Ratio 130:1, Rating – 6.73 KW




Sinter Storage Building

This is primarily a storage building where 16 bunkers, adding up to a capacity of 15750 tonnes, are used to store incoming sinter.

Firstly, the sinter is received from SC – 7 by a reversible conveyor SC – 8. This conveyor is

used to fill the storage bunkers first. Whenever required, the sinter is then taken out of

these bunkers and transferred on to the conveyors SC – 9 and 10 to be carried away from

the storage building. These conveyors also receive sinter from the sinter loading station

when pay-loaders are used to reclaim the stacked sinter from the sinter stockpile.

Finally, the exiting sinter is carried to the junction house SJ – 3 by the conveyors SC – 11 and

12 via junction houses SJ – 5 and 4.

Flow Diagram of Sinter Storage Building

No. of Sinter Storage Bunkers 16

Total Capacity 15750 t

No. of Level Indicators (SBLI) 16

No. of Rod Gates for Sinter (SRG) 2/ bin

No. of Rack & Pinion Gates for Sinter (SRPG) 2/ bin

No. of Vibrating Feeders for Sinter (SVF) 2/ bin

Capacity of Vibrating Feeders 100 tph

4.2 To BF Stock House

As mentioned in the beginning, the sinter from Sinter Plant can be directly sent towards BF

stock house by operating the flap-gate in SJ – 3. Now, we have seen that the sinter directed

towards the Sinter Stockpile or the Sinter Storage Building is also brought to SJ – 3 after

storage and reclaimation.

In SJ – 3, the conveyor SC – 13 collects all the sinter that needs to be sent to the BF stock

house. From there onward the sinter is carried on by the conveyors SC – 14, 15, 16 and 17

(future) to the junction houses SJ – 10 and 11 (future) via SJ – 9, KJ – 3 and 4. The final

junction houses then transfer the sinter to the respective BF stock houses.


Conveyor Length (m)

Width (mm)

Capacity (tph)

Belt Speed (m/s)

Motor Capacity (KW) Coupling Type

SC – 1 69.8 1400 1200 1.5

SC – 2 71.4 1400 1200 1.5

SC – 3 120.17 1400 1200 1.5

SC – 4 134.7 1400 1200 1.5

SC – 5 315.1 1400 1200 1.5

SC – 6 28.8 1400 1200 1.5

SC – 7 173.8 1400 1200 1.5

SC – 9 224 1400 1400 1.5

SC – 10 224 1400 1400 1.5

SC – 11 158.8 1400 1400 1.5

SC – 12 116.3 1400 1400 1.5

SC – 13 312 1400 1400 1.5

SC – 14 23 1400 1400 1.5

SC – 15 317 1400 1400 1.5

SC – 16 62 1400 1400 1.5

5. Blast Furnace Input Circuits

5.1 Ore & Flux from Ore & Flux yard to BFBF grade Ore & Flux is reclaimed from the yard with the help of two stacker-cum-reclaimers

(SR-1 and SR-2). CO-19 and CO-20 are the associated conveyors for SR-1 and SR-2

respectively. While reclaiming CO-19 connects to CO-23 via JH-9 and CO-20 connects to CO-

24 via JH-8. Again, CO-23 and CO-24 are Reversible Shuttle Conveyors which can discharge

material to any of the four conveyors namely FX-1, OF-1, CO-30 and CO-27 out of which CO-

27 is coming in Phase II.C0-23 and CO-24 are reversible conveyors which can discharge the

required material in the required circuit. CO-30 is associated with the BF grade Ore and Flux.

JH-10 connects CO-30 to CO-31, JH-17 connects CO-31 to CO-32, JH-18 connects CO-32 to

CO-33 and JH-19 connects CO-33 to CO-34. CO-34 leads to BF-Stock House.


Conveyor Length (m)

Capacity (tph)

Belt Speed (m/s)

Motor Capacity

Coupling TypeWidth

(mm) (KW)

CO-30 280 1400 1800 2

CO-31 625 1400 1800 2

CO-32 771 1400 1800 2

CO -33 47 1400 1800 2

CO-34 329 1400 550 2

5.2 PCI Coal from WT to PCI Coal Injection Plant

The above circuit shows the movement of Pulverized Coal across the plant; from Wagon

Tippler to BF Coal Injection Plant.

As shown, PCI coal follows a familiar route from the WT complex to junction house CJH – 1.

It is at this junction house that it changes track towards the PCI Coal Shed, where it is first

stacked and later reclaimed, instead of going towards the Coal Yard.

From the covered shed, PCI Coal is reclaimed by using a Portal Scrapper-Reclaimer and is

sent via conveyors to the BF Coal Injection Plant.

Wagon Tippler

PCI coal comes inside the plant boundaries via rakes which are unloaded at the WT complex

by using the Twin Wagon Tippler – 1.

The same has been explained in detail in Circuit 1.

To PCI Coal Shed

From the WT complex, PCI coal is taken up by CC – 1 and is transferred to JH – 1. At JH – 1, it

is routed towards the existing coal circuit and is carried by conveyor CC – 2 to junction

house CJH – 1. At this point, a flap-gate is operated at the tail end of CC – 2 to divert PCI coal

towards the shed (and not towards the Coal Yard).

The diverted PCI coal is then transported to the shed by the conveyors PC - 1 and PC - 2 via

junction house CJH – 14.

PC – 2 has a Travelling Tripper (CTT – 1) which helps dump the material on to the PCI

stockpile (capacity 80000 tonnes).

Reclaimation

The stacked PCI coal is later reclaimed from the stockpile by using a Portal Scrapper-

Recliamer.

PC-2 (Tripper Conveyor)

PC-2 has a travelling tripper (with two ways discharge chute) which can move to and fro to discharge PCI coal in the PCI Cover Storage Shed.

Tripper Data Table (PC-2)



2 Conveyor No. PC-5

3 Location PCI cover storage shed




7 Material PCI

8 Bulk Density 0.8 T/m3

9 Max. Lump Size -10 mm


11 Travel Speed 0.25 m/s

12 Travel Length 248 m (Approx.)









21 Chute Profile Two ways

Technical Data of Tripper Conveyor (PC-2)

Discharge Pulley






Bend Pulley





Drive Wheel & Axle








Travel Drive







Portal Reclaimer

The purpose of the Portal Reclaimer is to scrape material from the store and convey it to a

yard conveyor PC – 4. The flow rate of the reclaimer can be regulated between 40 and 440

TPH. The reclaimer PR – 1 is used to reclaim coal. The material is conveyed by the yard

conveyor belt PC – 3 outside of the stockpile area. The stockpile area consists of 2 piles with

almost the same length.

The portal reclaimer consists of:

A (main) scraper chain (hydraulic driven)

A separate cooler unit for the hydraulic unit of the scraper chain.

One automatic oil lubrication system for the main scraper chain.

A (auxiliary) scraper chain (electro-mechanical driven)

One automatic oil lubrication system for the auxiliary scraper chain.

A lifting unit for the main boom.

A lifting unit for the auxiliary boom.

A travel system on the fixed side.

A travel system on the pendulum side.

A manual rail clamp on the fixed side.

A manual rail clamp on the pendulum side.

One automatic grease lubrication system for fixed side.

One automatic grease lubrication system for pendulum side.

A MV cable reel for 6.6kV supply.


Tripper car.

Central control station.

Operation Modes






Automatic Mode



are active.

Manual Mode



Local control mode




Technical Details

Main Scraper Chain

Length of main chain 30 m

Blade dimension 1600 X 350 mm

Pitch of blades 1000 mm

Number of blades 63

Chain pitch 250 mm

Type of chain special roller chain

Speed of chain 0.63 m/s

No. of guide rollers per blade 5 pcs

Drive design Hydraulic

Chain capacity (rated) 40-440 tph

Auxiliary Scraper Chain

Length of main chain 14.3 m

Blade dimension 1000 X 280 mm

Pitch of blades 630 mm

Number of blades 50

Chain pitch 315 mm

Type of chain special roller chain

Speed of chain 0.55 m/s

No. of guide rollers per blade 5 pcs

Drive design electro-mechanical

Chain capacity (rated) 150-165 tph

Number of motors 1

Lifting Unit For Main Boom

Drive system Steel rope controlled by electro-mechanical winch

Lifting range -10 to +40 degrees

Lifting distance 17.7 m

Operating range -10 to +40 degrees

Dia of drum 398 mm

Dia of rope 18 mm

Lifting force 50 kN

Rope speed 3 to 30 m/min

Lifting speed 0.8 to 8.7 m/min

Speed factor between rope and boom top 3.45

No. of rope layers 4

No. of motors 1

Lifting Unit For Auxiliary Boom

Drive system Steel rope controlled by electro-mechanical winch

Lifting range 0 to +39 degrees

Lifting distance 10.6 m

Operating range 0 to +39 degrees

Dia of drum 300 mm

Dia of rope 14 mm

Lifting force 30 kN

Rope speed 3 to 30 m/min

Lifting speed 0.75 to 7.5 m/min

Speed factor between rope and boom top 4

No. of rope layers 3

No. of motors 1

Travel System


Number of motors 5


Motors on pendulum side 2

Max travel distance (including transfer car) 293 m

Rail length fixed side 311 m

Rail length pendulum side 304 m

Distance rail fixed side to rail pendulum side 48 m

Pile width 44.7 m

Max travel speed (under no-load) 10 m/min

Travel speed (under load) 0.15 – 1.5 m/min

Gear ratio 300:01


To BF Coal Injection Plant

Upon reclaimation, the PCI coal is transferred on to the conveyor PC – 3. From there, it is

taken to the coal injection plant by a simple network of conveyors consisting of PC – 4 and 5

via junction houses CJH – 15, 16 and 17.


Conveyor Length (m) Width (mm) Capacity

(tph)Belt Speed

(m/s)

Motor Capacity

(KW)

Coupling Type

PC – 1 221 2000 3500 3.8

PC – 2 353 2000 3500 3.8

PC – 3 519 1000 500 2.75

PC – 4 891 1000 500 2.8

PC – 5 176 1000 500 2.8

5.3 Coke from Coke Storage Yard to BF

Screened coke of size 34+ is taken from the coke storage yard by pay-loaders and is

transferred on to the conveyor CK – 31. The coke is then taken to junction house KJ – 2;

where it meets screened coke of the same size to be transferred directly to BF stock house.

The entire stock of coke is then conveyed along CK – 22, 23, 24, 24A, 25, 25A, 26 and 27 via

junction houses KJ – 3, 4 and 5 to Blast Furnace Stock Houses 1 and 2.

Coke Breeze (-10) and Nut Coke (10-34) are taken by pay-loaders from the storage yard and

are transferred on to the conveyor CK – 51, and passing through CK – 52, 53 and 54 these

are fed back in to Coke Stock Bin Building as input. At the exit side of CSBB, they are put on

to the conveyor CK – 41, but the material is then diverted towards BF (instead of storage

yard) at junction houses KJ – 9 and 10. CK – 45 and 43 take the coke from KJ – 9 and 10

respectively and transfer the same to Blast Furnace Stock Houses 1 and 2.


Conveyor Length (m)

Width (mm) Capacity

(tph)Belt Speed

(m/s)Motor

Capacity (KW) Coupling Type

CK – 22 7 1400 400 1.6

CK – 23 336.3 1000 200 1.6

CK – 24 34 1000 200 1.6

CK – 24A 339.33 1000 200 1.6

CK-26 53 1400 400 1.6

CK – 28 209 1400 400 1.6

CK – 29 82 1400 400 1.6

CK – 30 372 1600 400 1.45

CK – 31 406 1000 150 1.6

CK – 32 169 1000 150 1.6

CK – 35 (r) 19 1200 200 1.6

CK – 36 (r) 19 1200 200 1.6

CK – 37 (r) 25.5 1000 100 1.6

CK – 38 (r) 25.5 1000 100 1.6

Ck – 39 (r) 25.5 1000 100 1.6

CK – 40 (r) 25.5 1000 100 1.6

CK-41 269 800 100 1.6

CK-42 58 800 100 1.6

CK – 43 87 800 100 1.6

CK – 46 263.5 800 100 1.6

5.4 Coke from Coke Breeze Yard to BF

Coke is reclaimed from the Coke Breeze Yard by pay-loaders and is transferred to the BF

Stock House via conveyors CK – 51, 52, 53, 54 and 43 via junction houses KJ – 13, 12, 11 and

10


Conveyor Length (m) Width (mm) Capacity

(tph)

Belt Speed (m/s)

Motor capacity (KW)

Coupling Type

CK-51 334 800 100 1.6

CK-52 137 800 100 1.6

CK-53 187 800 100 1.6

CK-54 573 800 100 1.6

6. Blast Furnace Output Circuits

This circuit shows the movement of BF slag and other outputs across the plant.

6.1 Slag to Corresponding Loading Stations

The primary movement of the slag happens from the Dewatering Bin Building to the Wagon

Loading Station. However, there are intermediate loading points where the slag can be

directly loaded on to the trucks to be carried away.

Also, the slag can be stored in Slag Stockpiles form where it can be reclaimed and fed back

into the conveyor system by reclaim feeders to be carried towards the Wagon Loading

Station again.

Dewatering Bin Building to SJH – 3

BF slag is first taken up by the conveyor SLC – 1 at the exit of Dewatering Bin Building. It is

then carried on towards SJH – 3 by the conveyors SLC – 1A, 2 and 3 via junction houses SJH –

1A, 1 and 2.

Truck loading

Inside SJH – 1 a flap-gate can be operated at the tail end of SLC – 1A to divert the incoming

slag towards Truck Loading Bin. From there the slag can be directly loaded onto trucks to be

carried away.

SJH – 3

The junction house SJH – 3 houses 2 incoming conveyors: SLC – 3 (from Dewatering Bin

Building) and SRC – 3 (from slag stockpile). It also has 2 exiting conveyors: SLC – 4 (towards

slag stockpile) and SRC – 4 (towards Wagon Loading Station).

Incoming slag from SLC – 3 can be directly transferred on to SRC – 4 to be taken away for

loading in to wagons, or it can be diverted on to SLC – 4 by a flap-gate.

Incoming slag from the slag stockpile is carried in by SRC – 3 and is transferred on to SRC – 4

to be taken away for loading in to wagons, or a flap-gate is operated to divert the material

towards a second Truck Loading site.

Slag Stockpile

SLC – 4 and 5 carry the slag towards the stockpile via SJH – 4 and 5. From SJH – 5, the

conveyor SLC – 6 with a travelling tripper is used to create the stockpile (capacity 20000

tonnes). In the future another conveyor, SLC – 8, will be used to create a second stockpile of

the same capacity.

Later, slag is reclaimed from the stockpile and is fed into the conveyor system by reclaim

feeders. The reclaimed slag is taken to the junction house SJH – 3 by the conveyors SRC – 2

and 3 via junction houses SJH – 6 and 4.

Wagon Loading Station

The slag destined to be loaded into wagons exit SJH – 3 by SRC – 4, and reach the Wagon

Loading Station by conveyor SRC – 5 via junction house SJH – 7.

Inside the station, a reversible conveyor deposits the incoming slag into 6 slag bins of

capacity 730 tonnes each.

On the other side of the slag bins are corresponding weigh feeders which finally load the

slag into positioned wagons to be taken away.


Conveyor Length (m) Width (mm) Capacity (tph) Belt Speed (m/s)


SLC-1A 120 1000 750 2.65

SLC-1 305 1000 750 2.65

SLC-2 34 1000 750 2.65

SLC-3 625.5 1000 750 2.65

6.2 BF Sludge to CSBB and fines to PBBBlast Furnace sludge, an outcome of wet scrubbing and thickening of crude gas, is collected

through press filter and is sent to CSBB by conveyors CK – 56A, 56 and 57 via junction

houses KJ – 4 an d 18. The fines generated from the same is sent to PBB by the conveyor RF

- 1


Conveyor Length (m)

Width (mm)

Capacity (tph)

Belt Speed (m/s)


CK – 56A 25 1000 200 1.6

CK – 56 320 1000 200 1.6

CK – 57 72 1000 200 1.6

7. SMS Input Circuits

7.1 Limestone from Ore & Flux Yard to Lime Calcining Plant

Limestone is reclaimed from the yard with the help of two stacker-cum-reclaimers (SR-1 and

SR-2). CO-19 and CO-20 are the associated conveyors for SR-1 and SR-2 respectively. While

reclaiming CO-19 connects to CO-23 via JH-9 and CO-20 connects to CO-24 via JH-8. Again,

CO-23 and CO-24 are Reversible Shuttle Conveyors which can discharge material to any of

the four conveyors namely FX-1, OF-1, CO-30 and CO-27 out of which CO-27 is coming in

Phase II.CO-23 and CO-24 are reversible conveyors which can discharge the required

material in the required circuit. FX-1 is associated with the fluxes including limestone. JH-10

connects FX-1 to FX-2 and JH-14 connects FX-2 to LSC-1. LSC-1 leads to Primary Screening

Station.

Primary Screening Station

Flow Diagram of Primary Screening Station

Limestone from LSC-1 falls on Level Indicator for SMS Limestone (LSLI) of 100 T capacity,

which acts as a buffer for smooth and continuous flow of limestone, to Vibrating Screens

(LSVS-1 and LSVS-2) of 700 TPH capacities each via Vibrating Feeder (LSVF-1).

Screening of limestone is done in three ranges of sizes:

i) + 80

ii) +40 -80

iii) -40

Limestone whose size is greater than 80 mm is collected by pay loader and sent back to ore yard.

Limestone whose size is between 40-80 mm is sent to Limestone Storage cum Secondary Screen House via LSC-3.

Limestone whose size is less than 40 mm is either sent to Flux Crusher House (via LSC-5 and LSC-6) where it is crushed and sent to Proportionate Bin Building (PBB) just like other fluxes or collected by pay loader and sent back to ore yard.

Number of Surge Hopper 1

Capacity of Surge Hopper 100 T

Number of Vibrating Screen for SMS Limestone (LSVS) 2

Capacity of each Vibrating Screen 700 TPH

Number of VIBR-Feeder for SMS Limestone (LSVF) 1

Capacity of VIBR-Feeder 700 TPH

Number of output bins 2

Capacity of output bins 50 T and 150 T

Number of Rod Gate for SMS Limestone (LSRG) 3

Number of Selector Gate for SMS Limestone (LSSG) 2

Number of Bulk Loading Sprout for Limestone (LSBLS) 2

Number of Level Indicator for SMS Limestone (LSLI) 3

Limestone Storage cum Secondary Screen House

Limestone Storage cum Secondary Screen House

Flow Diagram

Limestone whose size is between 40-80 mm is sent to Limestone Storage cum Secondary

Screen House via LSC-3. Limestone from LSC-3 falls on LSC-4, a Reversible Shuttle conveyor,

which can feed limestone to any of the 7 bins of 600 T capacities each. These bins act as

storage of limestone and five of the seven bins are coming in Phase I and the remaining two

are coming in Phase II. Lime stone from bins falls on four Reversible Shuttle conveyors (LSC-

7, LSC-8, LSC-9& LSC-10) via Vibrating Feeders.

Number of Limestone Day Bins 5

Capacity of each Limestone Day Bin 600 T

Number of Vibrating Screen for SMS Limestone (LSVS) 2


Number of VIBR-Feeder for SMS Limestone (LSVF) 7

Capacity of VIBR-Feeder 175 TPH

Number of Reject bin 1

Capacity of Reject bin 100 T

Number of Rod Gate for SMS Limestone (LSRG) 6

Number of Rack & Pinion Gate for Limestone (LS RPG) 6

Number of Flap Gate for Limestone 6

Number of Selector Gate for SMS Limestone (LSSG) 1

Number of Bulk Loading Sprout for Limestone (LSBLS) 1


LSC-7, 8,9,10 feed limestone to Vibrating Screens (LSVS-3, LSVS-4, LSVS-5 and LSVS-6) of 350

TPH capacities each, LSVS-5 and LSVS-6 are coming in Phase II.

After screening, limestone whose size is greater than 40 mm is sent to KILN-1, KILN-2 and

KILN-3 via Skip, KILN-3 is coming in Phase II.

Limestone whose size is less than 40 mm is sent back to Ore Yard via pay loader.


Conveyor Length (m)

Capacity (tph)

Belt Speed (m/s)

Motor Capacity

(KW)

Coupling Type

Width (mm)

LSC-1 25 1000 700 2

LSC-3 233.5 1200 700 1.5

LSC-5 45 800 140 1.65

LSC-6 58.5 800 140 1.5

7.2 Lime from LCP to SMS

Lime from KILN-1 and KILN-2 is carried further by LC-1 and LC-2. LJH-1 connects LC-1 to both

LC-3 and LC-4 by a Flap Gate (LFG-1) arrangement; similarly LC-2 is also connected to both

LC-3 and LC-4 by a Flap Gate (LFG-2) arrangement. LC-3 and LC-4 both lead to Refuse Bin

Building where a sample of lime is collected by Lime Sampler (LSMP-1) and inspected.

Half calcined lime is rejected by Flap Gates (LFG-3 at LC-3 and LFG-4 at LC-4) and falls on LC-

7, from where it is sent to Reject Bin of 100 T capacity and collected by pay loader and

dumped.

Full calcined lime is sent to Lime Storage Building via LC-5 & LC-6.

Lime Calcining Plant

Lime Storage Building

Lime Storage Building

Flow Diagram of Lime Storage Building

Lime from LC-5 falls on LC-8 which is a Reversible Shuttle Conveyor and from LC-6 falls on

LC-9 which is also a Reversible Shuttle Conveyor. Thereafter, lime from LC-8 and LC-9 falls on

Lime Storage Bunkers. There are 14 Lime Storage Bunkers of 150 T capacities each out of

which 10 are coming in Phase I and 4 are coming in Phase II.

Lime from Lime Storage Building is sent to Lime Primary Screen House via LC-10.

Number of Lime Storage Bin 10Capacity of each bin 150 T

Number of Lime Rod Gate (LRG) 10Number of Lime Rack Pinion Gate (LRPG) 10Number of Lime Vibrating Feeder (LVF) 10

Number of Limestone Level Indicator (LSLI) 10Number of Lime Bin Vibrator 10

Capacity of output conveyor (LC-10) 300 TPHBelt Speed of output conveyor (LC-10) 1.2m/s

Lime Primary Screen House

Flow Diagram of Lime Primary Screen House

Lime from LC-10 falls on Lime Bin Vibrator of 75 T capacity which acts as a buffer. Lime from

bin falls on Vibrating Screens (LVS-1 and LVS-2) via vibrating feeder (LVF-15) for smooth and

continuous flow.

Screening of lime is done in two stages:

i) +10 -80

ii) -10

Lime which is between 10 and 80 mm is carried by LC-16 towards JH-20 and from where it

either falls on LC-18 or Lime Bunker Boot (100 T capacity) by a Flap Gate arrangement. Lime

from LC-18 is sent to SMS building and lime from bunker is collected by pay loader and sent

to secondary metallurgy of SMS plant.

Lime which is less than 10 mm is sent to Lime Fines Reject Bin Building via LC-17 where it is

collected by pay loader or sent to Grinding Plant.

Number of Surge Hopper 1

Capacity of Surge Hopper 75 T

Number of Lime Vibrating Screen 2


Number of Lime Vibrating Feeder 1

Capacity of Lime Vibrating feeder 300 TPH

Number of Lime Rod Gate 1

Number of Lime Rack & Pinion Gate 1


Number of output conveyors 2 (LBS-4 & LBS-5)

Capacity of each output conveyor 250 TPH



Belt Speed (m/s)

Motor Capacity

(KW)

Coupling Type

LC-1 85 1200 300 0.85

LC-2 85 1200 300 0.85

LC-3 187 1200 300 0.85

LC-4 LC-4 187 1200 300 0.85

LC-5 86.5 1200 300 0.85

LC-6 86.5 1200 300 0.85

LC-7 11.5 1200 300 0.85

LC-8 (rs) 41 1400 300 0.85

LC-9 (rs) 41 1400 300 0.85

LC-10 562 1000 300 1.2

LC-16 86 650 200 1.2

LC-17 42.5 650 100 1.2

LC-18 387 1000 550 1.2

7.3 SMS grade Ore from Ore & Flux Yard to SMSSMS grade ore is sent directly through tripper gallery by CO-16 which transfers

material to CO-18 at JH-4. CO-18 transfers the material towards JH-5 and from

there it is carried to SMS.



Belt Speed (m/s)

Motor Capacity

(KW)

Coupling Type

CO-16 365 1600 3500 2.8

CO-18 86 1200 1750 2.8

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RMHS Manual 2.1

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