SINTERINGEQUIPMENT

The “Uralmashplant” JSC, is a key equipment supplier for basic industry sectors: mining, metallurgical, and oil-and-gas industries.

In 2013 the “Uralmashplant” marked its 80s anniversary.

The main shareholder of the “Uralmashplant” is the “Gazprombank” JSC, one of the three largest Russian banks.

Today, the “Uralmashplant” JSC is a company providing the state-of-the-art engineering, welding, metal-working, mechanical assembly, and tool production works.

walking and track-type draglines, track-type open-mine excavators,

cone and jaw crushers for all crushing stages, ball and rod grinding mills, semiautogenous

and autogenous grinding mills, concrete-production equipment.

sintering equipment,indurating equipment,

blast furnace equipment, continuous casting machines, rolling equipment, press-forging equipment, rolling mill rolls

complete movable, stationary, and cluster drilling rigs with loading capacity from 160 to 600 tons, drilling equipment packages.

heavy cranes for metallurgical works, handling equipment for nuclear plants, general purpose special and bridge cranes.

hydraulic turbine units, transfer and homogenizing equipment units.

A company development strategy is aimed at creating a world-class machine-building company able to fully fulfill customers' needs for modern equipment.

Main product assortment includes:

Mining equipment

Metallurgical equipment

Oil-and-gas drilling equipment

Handling equipment

Power equipment and nonstandard equipment

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HistoryIn thirties, after start-up Uralmashplant began to manufacture sintering equipment.

Up to 1941, Uralmash supplied its unique products, including sinter machines, to many

industrial enterprises of the USSR, among which there were such giants as Magnitogorsky

and Kuznetsky integrated iron-and-steel works.

To eighties, 78% of sinter in the USSR was produced at the sintering equipment issued by

Uralmashplant.

Since 1950, Uralmashplant has begun to supply sintering equipment abroad, to Rumania,

Bulgaria, Poland, Hungary, China, India, Korea, Egypt, Finland, Iran, Turkey, Nigeria, Cuba.

The scope of supplies for seventy years, namely, 284 complexes with sinter machines

manufactured and put into operation for the domestic and foreign metallurgical

companies, is evidence of great experience acquired by Uralmashplant in creation of

sintering equipment.

For the last ten years, the specialists of Uralmashplant carried out reconstruction and

updating of many sinter plants.

Simultaneously the Uralmash continues to build new machines of any grate area (from 18 2to 600 m ) and of capacity to 3.0-4.7 mil tons of sinter per year.

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SINTERINGEQUIPMENT

Standard sizes of sinter machines

4

* Capacity depends upon quality of the components used for sintering and upon the local process conditions

Type of sinter machine

2Grate area, mCake width, mMaximum cake thickness, mMaximum pallet speed, m/min

Capacity, t/hProduct*

3124

0.356

125phos-

phorite

АКМ-312

22.51.50.60.68

cementclinker

АКМ-22.5

1923

0.64.5

220-260Fe-

sinter

АКМ-192

753

0.54.590Fe-

sinter

АКМ-75

2504.4

0.446

250Fe-

sinter

АКМ-250

361.50.60.6

18.5cementclinker

АКМ-36

3124

0.356

400-500Fe-

sinter

АКМ-312

903

0.44.5

125-140Fe-

pellets

АКМ-90

3604

0.358

340Fe-

sinter

АКМ-360

2044.40.36

200-240Fe-

sinter

АКМ-200

Sinter machine diagram

1.

2.

3.

4.

5.

6.

7.

8.

Unloading sprocket

Windbox

Extension hood

Ignition furnace

Burden damper

Stabilizing device

Burden seal

Feeder drum

9. Burden bin

10. Bed bin

11. Bed damper

12. Pallet feeder bin gate

13. Pallet

14. Drive sprocket

15. Load clamp

5

Уровень постелиУровень шихты

Уровень колосниковУровень осей роликов тележек

Направление движения тележек

1 2 3 4 5 6 7 8 9 10

1112

13

14

15

SINTERINGEQUIPMENT

The delivery set of sinter machineincorporates

Sinter machine AKM-75

dum mixers

pelletizers

mixers-pelletizers

shuttle conveyors

sinter crushers

hot and cold sinter screens

sinter coolers of bowl and ring type

small-sized ignition furnaces with direct burden ignition burners located along arch

pallets of steel or spheroidal graphite cast iron

drives of sinter machine, crushers and other mechanisms with planetary spur and

planetary reduction gears of small dimensions, weight and oil bath lubrication

two-level automatic control system with the use of hardware and software of the leading

world-famous electrical companies

The delivery set depends upon the accepted sinter plant diagram

6

Sintering equipmentIgnition furnaces

The ignition furnace is economical, heat consumption shall not exceed 40-80 thd kJ/t of

sinter (9500-19000 Cal/t), i. e. one-fifth or one-sixth as large as compartment furnace with

heat consumption of 150-250 thd kJ/t (35000-60000 Cal/t).

The burners are located in box square girders equipped with air jet cooling system. Hot air

from the cooling system can be used both for burning and for heating of sinter burden

before ignition or for its additional heating after ignition.

The burners are installed in rows with a space of, approximately, 700 mm. Number of

burners is calculated. Rows of suspended arch refractory elements are located between the

girders.

In the process of repair the ignition furnace can move over the guide rails.

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SINTERINGEQUIPMENT

Technical data

Nominal heat power, kW3Nominal natural gas consumption, m /h

Nominal gas pressure in front of burner, kPa

Nominal excess air factor

Maximum heat power, kW

Minimum heat power, kW

Nominal air pressure, kPa

200

22

125

1.8

250

50

17.5

Pallets

Movable longitudinal sealing is built inthe pallet body

The main advantage of such sealing is reduction of harmful leaks.

The pallets of spheroidal graphite cast iron are more efficient in production and have a

longer service life.

cast iron has higher casting characteristics that allow the pallet body to be cast as one

piece instead of two or three parts interconnected by bolts. Such process reduces labor

expenditures in manufacture and weight of the article

the pallets of cast iron are not subject in service to sagging in its middle part, hence they

do not require repair and have longer service life

the mechanical properties of the pallets of cast iron are similar to those of steel ones

1. Pallet body

2. Running roller

3. Load roller

4. Top board

5. Bottom board

6. Plate made of wear-resistant

material

7. Grate bar

8

9

ScraperThe scraper is designed to remove spill from under the sinter machine of AKM type.

The double-acting scraper has been designed to be used when spill is loaded in the spill

removal conveyor, by turns, in the head and unloading section of the sinter machine.

*

**

scraper is unloaded in head and unloading section of the sinter machine

weight without chute

SINTERINGEQUIPMENT

DescriptionSpecifications

АКМ-75

0.570.2

2320 (2)

7222232

*

АКМ-90/180

0.480.25.2

20 (2)7

2222

25**

Scraper speed, m/s3Scraper volumetric capacity, m

Maximum scraper capacity, t/hRope pull, kN (tf)

-1Speed of winch drum rotation, minRope diameter, mmElectric motor power, kWWeight of scraper with electrical equipment (maximum), t

contact-free running of pallets when they transfer from top run to the bottom one, strikes are excluded, service life of pallets is increased

the pallets are kept pressed to one another in operation, thus harmful air inflow and spill are reduced

The loads pressing the pallets to each other are suspended from rigid levers. Number of loads shall be minimum but sufficient to press the pallets to each other.

Release is carried out by means of hydraulically-operated or screw jacks. A version with application of locks is also acceptable, in this case release is carried out by means of the sinter machine drive reverse. The sprockets used in the unloading section are similar in their design to the head section sprockets.

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Movable unloading section of the sinter machine with load hold-down offers the following advantages

Drives with planetary reduction gearsThe drives of sinter machines, crushers and other mechanisms with planetary reduction

gears have small dimensions and weight.

The planetary reduction gears may be as a separate reduction gear or as change modules

engaged with the central gear fitted, in cantilever, to the drive sprocket shaft. Application of

the modular design decreases, appreciably, dimensions and simplifies maintenance.

Two or four modules are installed depending upon the torque being transmitted, thus

unification of drives is achieved.

SINTERINGEQUIPMENT

The drum mixer is designed to mix components of the sinter burden and return it with

water addition.

Mixer is used in the same process line with the sinter machines.

the drum consists of optimal number of sections with the welded shrouds machined to

suit the flange dimensions for the purpose of increasing smoothness of drum rotation

a special sealing of elevator type excludes burden spill between stationary chute of the

charging device and rotating drum

the charging chute is equipped with a vibrating device to prevent sticking of burden to

the chute walls

pneumatically-and-hydraulically-operated nozzles used in the wetting system allow

industrial water to be used

the lubrication system of the bearing units and working surfaces of gearing and shrouds

is of automatic type

Design features

12

Mixer

PelletizerA pelletizer of drum type is designed for balling and wetting of sinter burden with the

purpose of making it granular and gas-permeable.

The pelletizer is used in the same process line with the sinter machines.

the drum consists of the optimal number of sections equipped with shrouds welded

therein and machined in combination with the seating flanges of the sections to increase

smoothness of the drum rotation

a cutter bar, built in the drum, flattens the adhered burden layer and promotes balling of

burden and increasing of drum rotation smoothness

a special sealing of elevator type excludes burden spill between the stationary charging

chute and rotating drum

pneumatically-and-hydraulically-operated nozzles used in the wetting system allow

industrial water to be used

lubrication system of the bearing units and working surfaces of gearing and shrouds is of

automatic type

Design features

13

SINTERINGEQUIPMENT

The stock distributor is designed to transport material to the sinter machine and distribute it

uniformly over the discharge hopper width.

the reverse drive and conveyor drive are located in the side frame section to simplify its

maintenance

the drive drum is made of gummed rubber

the electric circuit incorporates time delay when the electrical equipment is shifted over to

reverse

by the customer's request, the rack can be continuous, in this case reverse is not available

Design features

* without electrical equipment

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Stock distributors

Type of stock distributor

РШ 800х3000 РШ 1х7 РШ 1.2х12.5 РШ 1.4х12.5 РШ 1.4х30.5Specifications

Capacity, t/h (maximum)

Conveyor length, m

Conveyor belt, m

Width, m

Speed, m/s

Stock distributor speed, m/s

Track gauge, m

Conveyor drive motor power, kW

Reverse motor power, kW

Stock distributor stroke, m

Weight, t (with electrical equipment)

120-150

3

0.8

1

0.25

1.38

4.5

1.7

2.134

3.33

400-460

7

1

1

0.2

1.77

3.7

2

2.5

7.25*

450

12.5

1.2

1.3

0.2

1.97

7.5

1.8

3.5

12.23

750-1000

12.5

1.4

1.3

0.2

2.16/3

7.5

1.8

3.5

12.52

750-1000

30.5

1.4

1.45

0.2

1.85/3

15

3.5

3.5

40.27

One-roll crushersThe crushers are designed for crushing of hot sinter leaving the sinter machine.

Design features

the heatproof sprockets are made of high-alloy steel and hard-faced

grate bars are furnished with change heat-resistant straps made of high-alloy steel and

hard-faced

drive with planetary reduction gear

roll and grade bars can be easily replaced in the process of service

15

SINTERINGEQUIPMENT

Type of crusherSpecifications

ДОЗ 1300х3200

450

1300

3150

6

850

150

90

90

ДОЗ 1300х4200

1000

1300

4200

6

850

150

150

107

Capacity for source material (no less than), t/h

Roll sprocket diameter, mm

Working length of roll, mm

Rotational roll speed, rpm

Inlet sinter temperature, degree °С

Size of final product, mm

Power, kW

Weight, t (without electrical equipment)

The unbalanced-throw screen is used for sorting of hot and cold sinter, fired pellets, ores and the like.

Design feature

wear-resistant screen plate is made of alloy heatproof steel or chromium steel

a drive is of self-synchronizing type from two independent kinematic electric motors

the electric motor torque is transferred to the vibration driver shafts via a propeller shaft

a lubrication unit with heat exchanger ensures lubrication and cooling of the vibration driver bearings

the electric circuit of the drive incorporates electrical braking to decrease the screen oscillation amplitude in stop and, hence, to reduce the foundation loads

the screen is placed on the roll-away trolley to simplify its maintenance

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Unbalanced-throw screen

Specification

Capacity (charging), t/h 2Total screen plate area, m

Temperature of material being screened, degree, °C

Number of screen oscillations, qty/min

Screen oscillation range in steady conditions, mm

Screen oscillation range in transient conditions, mm

Power, kW

Weight of rocking parts, kg

Weight (with electrical equipment), t

50

950

3.2-3.4

40

30

2.26

200-300

10.48

800

730

5-5.3

75

15 (2 pc)

10300

18.5

400-500

20.4

800

735

5-5.5

75

30 (2 pc)

19000

37

700-800

28.98

800

735

5-5.2

75

30 (2 pc)

24000

43.5

Type of screenГИЛ 22

1000х2200/1860ГСТ 61

2000/5200ГСТ 81

3000х6400ГСТ 91

3450х8000

Sinter coolers of bowl typeThe cooler is designed for cooling of sinter of not more than 150 mm in size from the initial temperature of 900 °C to a temperature of 100 °C.

bearings of the central support are cooled with ambient air at the expense of cross ventilation of the space under bell by natural draft

leak-in of ambient air into the draught system is reduced thanks to using a new throat sealing

split design of the gear ring simplifies its erection and replacement during repairs

louvered grate in the form of aerodynamic wing increases consumption of filtering air passing through the sinter layer

Design features

17

Агломерат

SINTERINGEQUIPMENT

Designation of cooler

Capacity, t/hWeight, t (with electrical equipment)

3Air consumption, m /tRotational speed of platform, rpm

Rated cooling time, minBin height, mType of supportCooling product

Type of bowl cooler (platform diameter)

Ø 19Ø 13,5Ø 12Ø 11,8Ø 10,4Ø 10Ø 9Ø 8

7062.8525000.6 -

0.086331.5

70-10097.3630000.6 – 0.08645-63

3

110104.725000.6 – 0.08640-63

2.5

110174.717000.6 – 0.08645-47

2.8

110173.214000.6 – 0.086

573

224255.414500.6 – 0.086

353.8

228330.513700.6 – 0.0664

4.645

240647.61550

0.244 – 0.081

472.6

sinter pellet sinterat column

By the customer's request, the machines and units are equipped with complex automatic electric drive and process control system. The Automatic process control system allows optimization of the process to be implemented on the basis of the mathematical models.

The software of the leading electrical companies, including Siemens, ABB, Rockwell Automation, is used.

ollection of initial data and approval of the request for proposal

execution of the technical proposal on the equipment reconstruction

with inspection of the equipment erection in the existing building of the workshop

with examination of a possibility of keeping the axes of loading, unloading, elevations

with rational matching of the existing equipment or part of it with new equipment installed in reconstruction

designing of working drawings for the equipment being supplied

designing and submission of the foundation plans for equipment and specifications for electric drive to the customer

submission of the service documentation for equipment, namely

general view drawings of the machines

working drawings of quick-wearing parts

technical description of erection, start and service

technical machine certificates

Engineering services

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Automatic process control system of sintering equipment

Reconstruction of sinter machinesNew technical decisions

Introduction of new technical decisions offered by the designers and scientists of Uralmash

allows the sinter machine capacity to be increased by 12%:

increase of pallet width to 4.5 m, with the dimensions of the previous propel mechanism

being kept

increase of pallet service life thanks to a possibility of turning the body middle part

through 180°

17

SINTERINGEQUIPMENT

Introduction of new technical decisions will increase a degree of mixed burden

homogeneity to 90% and a degree of balling to more than 40%, which allows the sinter

machine capacity to be increased by 4-5%

increase of efficiency of sinter wetting, mixing and balling

automatic control of mixing and balling sections and reliable operation of the required

protection and interlocking

improvement of burden quality and correction of its physical and mechanical properties

Drum mixer is equipped with paddles for more intensive mixing of burden.

The mixer has a frequency drive with smooth start and controlled frequency of revolutions

performed by means of frequency converters.

A new wetting system is used. It is equipped with generators-mixers and direct-flow nozzles

that are not clogged and ensure fog spray of water.

It is offered to equip the mixers with automatic burden humidity sensors, Automatic

humidity control system that incorporates burden composition and humidity analysis

equipment and is integrated with the existing sinter machine control system.

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Reconstruction of mixing and balling units

Sinter quality control systemFunctions

on-line prediction of chemical composition of sinter and returns

on-line development of optimal specifications for sinter burden component consumption

to produce sinter of the specified chemical composition

on-line control of iron ore burden homogenizing

on-line control of sintering thermal conditions

21

SINTERINGEQUIPMENT

Technical requirements

to sinter: Fe0, basic capacity

Initial burden

composition

Consumption of coke, concentrates, limestone, moisture

Sintering process model Heat balance of sintering process

Material balance of sintering process

Caking processindices (specific

capacity of sinter machine, exhaust gas composition)

Sinter quality indices (cake yield, good

product yield, sinter reducibility etc.)

cont

rol

The station is the base of the system of on-line control of ready-made product quality in the

real-time mode and makes it possible to prepare, quickly and in workmanlike manner,

samples; a process of sample preparation incorporates the process of crushing, sorting,

milling and submission for chemical analysis.

For gravity passing of sample via equipment, the latter is located on metal structures of three

levels in height.

a line of sinter grain-size composition estimation

a line of sinter mechanical property estimation

a line of sample preparation for chemical analysis

The “Probe tower” incorporates three lines operating under parallel-series conditions

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Automated sinter sampling station “Sample tower”

Sample forstorage

Sample forchemical analysis

Crushing in jawcrusher

Divider

Crushing in rollcrusher

Divider

Crushing by diskgrinder

Sizing in sieve analyzer

Crushing by vibrating grinder

Sampler

Weightmeasuring bin

Divider

Dump

To dump

Weighing in bins

Screening

0-5 5-40 +40Weighing in bins

0-5 5-40 +40Crushing injaw crusher

0-405-40Screening

0-10 10-40

Divider

Weight measuring bin

Test in drum as perДСТУ 3200-95

Screening

-0,5 0,5-5 +5

-0,5 0,5-5 +5

Service

Guarantees

Reference list for 2000-2015

designer's supervision of the equipment erection, adjustment and putting in service with bringing the indices of its operation to design ones

technical maintenance, diagnostics in guarantee and post-guarantee periods

supply of spare parts for repair services

participation in updating of the equipment issued earlier

joint activity on the contract basis with the specialized service organizations

Uralmashplant guarantees trouble-free operation of the equipment within one year but not more than within 18 months since the date of its shipment, provided that the conditions of transportation, storage, erection, adjustment, tests, putting in service are observed.

The guarantee does not cover the quick-wearing parts.

23

SINTERINGEQUIPMENT

2015-2016

201220112010200920072007200720062006200620062005200520052005

2005-200620052004200420032003200320032002

2001-20022000

Supplyyear

Sinter machine-1 (revamping & upgradation) and phase-1 of sinter machine-2 (revamping & upgradation)

Ignition furnace for Sinter machine АКМ-75

Pallets ТСГ-4Sinter machine AKM-60/120

Pelletizer Screen ГТС-81 3000х6400

Screen ГСТ-81Screen ГСТ-61

Screen ГИСЛ-52Screen ГСТ-71

Mixer СБ-3.2×8Mixer СБ 3.2х12.5

Sinter machine (reconstruction)Sinter machine

Pelletizer ОБ 3.2х8Screen ГСТ-82Screen ГСТ-81

Screen ГИСЛ-52 1750х5000Screen ГСТ-61Sinter machine

Sinter machine (reconstruction)Sinter machine (reconstruction)

Screen ГСТ-81Sinter machineScreen ГСТ-61Sinter machine

Screen ГСТ-62

Type of equipment

Visakhapatnam Steel Plant

Magnitogorsk Iron and Steel Works, MagnitogorskNovolipetsky Iron and Steel Works, LipetskNovolipetsky Iron and Steel Works, Lipetsk

Transnational Company “Kazhrom”Zapadno-Sibirsky iron and steel works

KGOK VanadiumDomnaremont (Severstal)

Vysokogorsky GOK, Nizhny TagilEVRAZ NTMK, Nizhny Tagil

Chelyabinsk Iron and Steel Works, ChelyabinskEvrazruda, Abagurskaya sintering factory

Magnitogorsk Iron and Steel Works, MagnitogorskChelyabinsk Iron and Steel Works, ChelyabinskChelyabinsk Iron and Steel Works, Chelyabinsk

Novolipetsky iron and steel works, LipetskVysokogorsky GOK, Nizhny TagilVysokogorsky GOK, Nizhny Tagil

Magnitogorsk Iron and Steel Works, MagnitogorskSeverstal, CherepovetsSeverstal, Cherepovets

Novolipetsky iron and steel works, LipetskMagnitogorsk Iron and Steel Works, Magnitogorsk

Vysokogorsky GOK, Nizhny TagilMagnitogorsk Iron and Steel Works, Magnitogorsk

EVRAZ NTMK, Nizhny TagilChelyabinsk Iron and Steel Works, Chelyabinsk

Customer

India

RussiaRussia

KazakhstanRussiaRussiaRussiaRussia

RussiaRussiaRussiaRussiaRussiaRussiaRussiaRussiaRussiaRussiaRussiaRussiaRussia

Russia

Russia

RussiaRussiaRussia

Russia

Country Qty

1

11642111415

171112461112111221

Pervoy Pyatiletki sqr.,Ekaterinburg, Russia, 620012Phone: +7 (343) 336-61-01 Fax: +7 (343) 336-60-40

E-mail: mail@uralmash.ru Http://www.uralmash.ru