SINTERING EQUIPMENT - Uralmash · PDF fileHistory In thirties, after start-up Uralmashplant...
Transcript of SINTERING EQUIPMENT - Uralmash · PDF fileHistory In thirties, after start-up Uralmashplant...
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
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* 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
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Уровень постелиУровень шихты
Уровень колосниковУровень осей роликов тележек
Направление движения тележек
1 2 3 4 5 6 7 8 9 10
1112
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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
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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
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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.
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**
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
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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
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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
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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
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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
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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
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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°
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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
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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.
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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: [email protected] Http://www.uralmash.ru