Internship Report File of Steelmills

PAKISTAN STEEL
INTERNSHIP REPPORT PREPARED BY[ MANESH KUMAR & FAROOQ AHMED SHAIQ] Page 1

PAKISTAN STEEL


The following information related to the internees who
have completed the task.

Farooq ahmed shaiq
Farooqahmed@iiee.edu.pk
Contact:+92300-9558276

Manesh Kumar
maneshkumar@iiee.edu.pk
Contact:+92300-2737236
TECHNOLOGY:
Electronics (Automation & control)
DURATION OF INTERNSHIP:
30
th
of June to 25
th
of July
SUBMITTED TO:
Mr.Yousuf Ayoub
PAKISTAN STEEL


ACKNOWLEDGEMENT

We are highly grateful to Allah, the Almighty, who in his infinite
capacity gave us the strength and latitude to work on this report and made
us succeed in doing so.
It has been an unforgettable experience to spend 4 weeks in Pakistans
lergest steel company Pakistan Steel Mills. By then I want to thank to Mr.Moin Aftab Shaikh
Chairman of Pakistan Steel Mills for providing us such a useful opportunity to strengthen our
skills.
We also take this opportunity to be greatly thankful to Mr. Qaiser Saleem , PEO (HRD) and Mr.
Naresh Kumar Incharge (HRD) for their consideration and supervision.
We are also thankful to Mr.Yousuf Ayoub, D.Manager (IPT) HRD and Mr. Alam Khan for their
cooperation, precious advice, encouragement and help throughout the internship, which
turned this 4 week internship into one of the pleasant experience.

PAKISTAN STEEL


CHAPTER 1

COLD ROLLING MILLS (CRM}

1-1 Executive Summary 06
1-2 Cold Rolling Mills (CRM) 08
1-2.1 Pakistan Steel Hot And Cold Rolled Steel Plant, Pakistan 08
1-2.2 Plant Construction 08
1-3 Cold Rolling Mills Detailed Description 10

CHAPTER 2

STEEL MAKING DEPARTMENT 11
2-1 Steel Making Process In Pakistan Steel 12
2-2 Hot Metal Mixer 14
2-3 LD converter 15
PAKISTAN STEEL


2-4 Charging Materials 16
2-5 Operation Of LD Converter 17
2-6 Primary Steel Making 19
2-6.1 Basic Oxygen Steel Making 19
2-7 Secondary Steel Making 20
2-8 HIsarna Steel Making 21

CHAPTER 3

ELECTRONICS DEVELOPMENT CELL 22

3-1 Electronics Services 21

CHAPTER 4

SINTERING PLANT 24

4-1 Sinter Plant 24
4-2 Production Unit 26
4-3 Charge Preparation 26
4-4 Secondary Mixing 27
4-5 Secondary Section 27
4-6 Sinter Handling 28
PAKISTAN STEEL


Chapter 1

1-1 Executive Summary

Pakistan Steel is strategically located 40km south east of Karachi in close vicinity to portMu ha mma d Bi n
Qa s i m. Pa k i s t a n St e e l i s a c os t a l s i t e , whi c h l i e s on t h e
Na t i o n a l Highway and is linked to the railway network. Spread over an area of 18,600 acres
(29square miles) with 10,390 acres for the main plant, 8070 acres for the township and 200acres for the water
reservoir Pakistan Steel is Pakistan' s largest industrial complex, comprising component
units numbering more than 20.We specialize in the production of flat steel products including, billets, slabs,
hot rolled coils, cold rolled coils, galvanizedsheets/coils/formed sections and corrugated sheets.
We are vital to the supply of highqualit y and cost effective steel products to the
domestic market. Pakistan Steel' sconstant efforts in continuous improvement and quality
management have resulted inaccreditation in ISO 9001, 14001, 17025, SA 8000 and OHSAS
18001. Pakistan steeljust deal with their dealership after verification, which are
consumers and traders. Consumers consume these products in their own use and traders use these products
toresale. Billets, Hot rolled, Cold rolled, Galvanized, Formed section, Pig iron ,
Coke , Oxygen and nitrogen, Refractory bricks, Coal slag(by product), Boarder
slag(byproduct), Granulated slag(by product).
on Ton of Steel Expandable upto 3.0 Million Ton per annum.
Main Products: Coke, Pig Iron, Billets, Cold Rolled Sheets, Hot Rolled Sheets,
Galvanized Sheets

Fig 1-1
PAKISTAN STEEL


Organization Name Pakistan Steel Mills Corporation (PVT) LTD.
Foundation Stone Laid on 30th December, 1973
Foundation Stone Laid By Zulfiqar Ali Bhutto (Shaheed) Prime minister of Pakistan.
Location : 40 km East of Karachi
Production Capacity: 1.1 Million Ton of Steel Expandable upto 3.0 Million Ton per annum.
Main Product
Coke, Pig Iron, Billets, Cold Rolled Sheets, Hot Rolled Sheets,
Galvanized Sheets.

Coke Oven & By Product Plant Coke 02 Batteries each contains 49 ovens
Sintering Plant Sinter 02 sinter Machines
Iron Making Department Pig Iron 02 Blast Furnaces
Steel Making Plant
Cast Bloom, Cast Billet,
Cast Slab
02 L.D.Converters,
01 Bloom Caster
01 Billet Caster
02 Slab Casters
Billet Mill Billets 800 mm Reversible Stand
Hot Strip Mill H.R.Coils / Plates
02 Reheating Furnaces 1700 mm
Universal Stand
Cold Rolling Mill
C.R. Coils / Sheets,Galvanized,Coils / sheets, H.R.
Sheets
Four high reversible machines 01 bell
type Annealing furnace
Refractories Fireclay Bricks, Tar Bonded Dolomite Bricks
Lime rotary kilm,
hydrolic press
power press
Thermal Power Plant & Turbo
Blower Station
Electricity 110 MW 3 Generators of 55 mw each
Oxygen Plant Oxygen 15,200 Nm3/hr Nitrogen 9,000 Nm3 /hr
02 air compressor
42,500 nm3/hr each
PAKISTAN STEEL


1-2 COLD ROLLING MILLS (CRM):

1-2.1 PAKISTAN STEEL HOT AND COLD ROLLED STEEL
PLANT, PAKISTAN
Located some 40 kilometers to the east of Karachi, Pakistan Steel and its related
facilities are spread over an area of 18,600 acres, or about 29 square miles. The
construction of the complex involved the use of 1.29 cubic meters of concrete, 330,000
tonnes of machinery, steel structure and electrical equipment, and the employment of
over 40,000 workers at the peak of construction.
In January 1971, the Governments of Pakistan and the USSR signed an agreement, the
latter undertaking to provide technological and financial assistance for the construction
of a coastal based integrated steel complex. The total capital cost of the project is
estimated at about Rs. 24.7 billion.

1-2.2 PLANT CONSTRUCTION
The construction work on the main plant was started in 1976. Among the main
complexes and units of the project, the first coke oven battery was commissioned in
April 1981, the first blast furnace in August 1981, the billet mill in October 1982, and the
two converters, one bloom caster and two slab casters of the steel making plant
between December 1982 and November 1983. The hot strip mill was commissioned in
December 1983, the second blast furnace in August 1984, the cold rolling mill in
December 1984, the second coke oven battery in May 1985 and the expansion project
billet caster in November 1989.

PAKISTAN STEEL


1-3 COLD ROLLING MILL(CRM)
The cold rolling mill is a cold reversible mill with 200,000 tonnes capacity, from which
10,000 tonnes are turned into cold formed sections. The cold rolling mill operates on hot
rolled sheets and coils produced at the hot strip mill. Cold rolled sheets are used for the
production of enameled wares, bicycles, steel fabrication, steel containers, drums,
barrels, jerry-cans, vehicle and bus bodies, steel furniture, machinery parts, products
and appliances, oil and gas appliances etc. Cold rolled sheets are also used for the
production of galvanized sheets, and black plates and tinplates.

Fig 1-3
Galvanized sheets are used for containers, trunks, boxes, packets, steel shuttering,
desert coolers, construction and roofing, ducting equipment, appliances, paneling,
utensils, air-conditioners, water heaters and fresh water tanks.
Cold and hot-formed sections are used for steel fabrications, furniture, vehicle and bus
bodies, building construction, miscellaneous machinery and equipment/parts, steel
doors and windows.
PAKISTAN STEEL


Fig 1-3 (a)

Fig 1-3 (b)

PAKISTAN STEEL


Chapter 2

STEEL MAKING DEPARTMENT (SMD)

Steelmaking is the process for producing steel from iron and ferrous scrap. In steelmaking,
impurities such as nitrogen, silicon, phosphorus, and excess carbon are removed from the raw
iron, and alloying elements such as manganese, nickel, chromium and vanadium are added to
produce different grades of steel. Limiting dissolved gases such as nitrogen and oxygen, and
entrained impurities (termed "inclusions") in the steel is also important to ensure the quality of
the products cast from the liquid steel.
[1]
There are two major processes for making steel,
namely basic oxygen steelmaking which has liquid pig-iron from the blast furnace and scrap
steel as the main feed materials, and electric arc furnace (EAF) steelmaking which uses scrap
steel or direct reduced iron (DRI) as the main feed materials. Oxygen steelmaking is fuelled
predominantly by the exothermic nature of the reactions inside the vessel where as in EAF
steelmaking, electrical energy is used to melt the solid scrap and/or DRI materials. In recent
times, EAF steelmaking technology has evolved closer to oxygen steelmaking as more chemical
energy is introduced into the process.

PAKISTAN STEEL


Fig 2-1
Steel making department
Steel making department is one of the most important departments of Pakistan steel mill. In these
department can produce 1.1 million tons steel in form of cast slab, bloom and cast billet.
Basic operation of steel making department is to convert hot metal into liquid steel by oxygen
blowing and continuous casting of liquid steel in the form of slab, bloom and billets.
2-1 STEEL MAKING PROCESS IN PAKISTAN STEEL:-
The charging material is charged into the vessel by tilting the vessel. After charging, vessel is
located it position. Lancing is started. The oxygen blowing is continued for 18 minutes. The
blowing has three phases; each phase consists of 6 minutes. In the first phase of six minutes pig
iron deoxidizes and removes the silicon impurity.

PAKISTAN STEEL


In the second phase of six minute other impurities are oxidizes such as sulphur, phosphorous,
manganese etc. In the last phase of blowing the temperature is maintained according to the
requirement. After completion of this conversion process from pig iron to steel, the vessel is
tilted and molten steel is tilted into the steel ladle. In ladle some alloying elements are added
according to demand and mixed by the nitrogen purging.
This purged molten metal is ready to send directly to the mold for casting. A sketch of LD
process is given below.

fig 2-1 (b)
The molten steel is pored into the mold in order to produce slab, billets and bloom. Some
technical parameters so these casting machines are given a under.
Low %C 0.35 0.65
Medium % 0.65 0.75
High %C 0.75 1.25

PAKISTAN STEEL


No. of machines ONE TWO ONE
Type of machine Radial Radial/ curvilinear Radial
No. of strands Four Two Six
Profile size 260 260 W= 1000 1550
Metallurgical length 22meter 24meter 15.8meter
Casting speed 0.7 M/min 0.7 M/min 1.5 M/min
Steel Ladle 130 ton
dolomite lining Life AVG
30 Heats
Tundish capacity 15 ton 5 ton 12 ton

2-2 HOT METAL MIXER:-
Molten pig iron coming from the iron making department is received by hot metal mixer.
The mixer has a capacity of 1300 tons with inner volume approximately 285 m.
The temperature of hot metal is near about 1320 C with the chemical composition as
Carbon not less than 4%
S : 0.04% max
Si : 0.4 0.8%
P : 0.2% max
Mn : 0.5 1.0%
Safety lining of mixer vessel is of fireclay and working lining is made of magnesite. The lining
life of mixer vessel is about 0.8 million ton hot metal cycling.
PAKISTAN STEEL


2-3 LD CONVERTER:
LD converter is used to convert the pig iron into steel. There are two LD converts in steel
making department. Each has metal charging capacity about 130 tons. The converter has height
to diameter ration approximately 1:37. The tap to tap time is 55 minutes.

Fig 2-3
The LD converter is top oxygen blown converter. Oxygen is delivered by the oxygen lance.
Oxygen reacts with unwanted materials and oxides form the top of the vessel. The oxygen flow
rate is 300 45 M/min. the safety lining of LD vessel is chrome magnesite whereas tar bonded
dolomite is used as a working lining refractory. Production rate of each converter is about
27heats per day. In these figure below showing oxygen lacing
When iron is produced from the ore in a blast furnace, it is rich in carbon and also contains many
impurities. It then has to be converted into steel which has controlled quantities of carbon and
much reduced concentrations of impurities.
PAKISTAN STEEL


Fig 2-3 (b)
Bessemer realized that forcing air through molten steel would oxidize impurities in the pig iron
and raise the metal temperature without the need for additional fuel, i.e., `The manufacture of
malleable iron and steel without fuel'.
His invention nearly failed in that some of the iron ores used by those who applied the idea found
the iron to contain larger quantities of sulphur and phosphorus, leading to very poor properties.
However, this was solved by adding ferromanganese to the melt.
The nitrogen concentration of steel produced using the Bessemer process tended to be greater
than desirable because of the use of air (which is mostly nitrogen).

Fig 2-3
PAKISTAN STEEL


This problem was solved in the Linz-Donawitz process (Lenz and Donowitz are both parts of
Austria). In this, high-pressure oxygen is blown at the molten pig iron using a water-cooled
lance. A slag of lime and dolomite is used. The process is fast because of the use of
commercially pure oxygen, and generates large quantities of heat which can be exploited to add
scrap steel to the melt. The basic nature of the flux helps remove phosphorus so there is a greater
tolerance to the raw materials used in the process.
2-4 CHARGING MATERIALS:-
LD converter has capacity of charge 130tons. Detail of input material description given as under.

Hot metal Basic raw material
Steel scrap Coolant
Iron ore Coolant
Oxygen gas for blowing
Lime Fluxing material
Calcium fluoride Slag forming material
Aluminum Deoxidizer
Fe Alloys alloying of steel
Charging of LD vessel
2-5 OPERATION OF LD PROCESS:-
1. Molten iron from a blast furnace is poured into a large refractory-lined container called a
ladle;
2. The metal in the ladle is sent directly for basic oxygen steelmaking or to a pretreatment
stage. Pretreatment of the blast furnace metal is used to reduce the refining load of sulfur,
silicon, and phosphorus. In desulfurising pre treatment, a lance is lowered into the molten
PAKISTAN STEEL


iron in the ladle and several hundred kilograms of powdered magnesium are added.
Sulfur impurities are reduced to magnesium sulfide in a violent exothermic reaction. The
sulfide is then raked off. Similar pretreatment is possible for desiliconisation and
dephosphorisation using mill scale (iron oxide) and lime as reagents. The decision to
pretreat depends on the quality of the blast furnace metal and the required final quality of
the BOS steel.
3. Filling the furnace with the ingredients is called charging. The BOS process is
autogenously: the required thermal energy is produced during the process. Maintaining
the proper charge balance, the ratio of hot metal to scrap, is therefore very important.
The BOS vessel is one-fifth filled with steel scrap. Molten iron from the ladle is added as
required by the charge balance. A typical chemistry of hot metal charged into the BOS
vessel is: 4% C, 0.2-0.8% Si, 0.08%-0.18% P, and 0.01-0.04% S.
4. The vessel is then set upright and a water-cooled lance is lowered down into it. The lance
blows 99% pure oxygen onto the steel and iron, igniting the carbon dissolved in the steel
and burning it to form carbon monoxide and carbon dioxide, causing the temperature to
rise to about 1700C. This melts the scrap, lowers the carbon content of the molten iron
and helps remove unwanted chemical elements. It is this use of oxygen instead of air that
improves upon the Bessemer process, for the nitrogen (and other gases) in air do not react
with the charge as oxygen does. High purity oxygen is blown into the furnace or BOS
vessel through a vertically oriented water-cooled lance with velocities faster than Mach 1.
5. Fluxes (burnt lime or dolomite) are fed into the vessel to form slag which absorbs
impurities of the steelmaking process. During blowing the metal in the vessel forms an
emulsion with the slag, facilitating the refining process. Near the end of the blowing
cycle, which takes about 20 minutes, the temperature is measured and samples are taken.
The samples are tested and a computer analysis of the steel given within six minutes. A
typical chemistry of the blown metal is 0.3-0.6% C, 0.05-0.1% Mn, 0.01-0.03% Si, 0.01-
0.03% S and P.
6. The BOS vessel is tilted again and the steel is poured into a giant ladle. This process is
called tapping the steel. The steel is further refined in the ladle furnace, by adding
alloying materials to give the steel special properties required by the customer.
Sometimes argon or nitrogen gas is bubbled into the ladle to make sure the alloys mix
correctly. The steel now contains 0.1-1% carbon. The more carbon in the steel, the harder
it is, but it is also more brittle and less flexible.
7. After the steel is removed from the BOS vessel, the slag, filled with impurities, is poured
off and cooled.

PAKISTAN STEEL


2-6 PRIMARY STEELMAKING
2-6.1 Basic oxygen steelmaking
Basic oxygen steelmaking is a method of primary steelmaking in which carbon-rich molten pig
iron is made into steel. Blowing oxygen through molten pig iron lowers the carbon content of the
alloy and changes it into steel. The process is known as basic due to the chemical nature of the
refractoriescalcium oxide and magnesium oxidethat line the vessel to withstand the high
temperature and corrosive nature of the molten metal and slag in the vessel. The slag chemistry
of the process is also controlled to ensure that impurities such as silicon and phosphorus are
removed from the metal.

Fig 2-5

The process was developed in 1948 by Robert Durrer and commercialized in 195253 by
Austrian VOEST and AMG. The LD converter, named after the Austrian towns of Linz and
Donawitz (a district of Leoben) is a refined version of the Bessemer converter where blowing of
air is replaced with blowing oxygen. It reduced capital cost of the plants, time of smelting, and
increased labor productivity. Between 1920 and 2000, labor requirements in the industry
decreased by a factor of 1,000, from more than 3 worker-hours per tonne to just 0.003. The vast
majority of steel manufactured in the world is produced using the basic oxygen furnace; in 2011,
it accounted for 70% of global steel output. Modern furnaces will take a charge of iron of up to
PAKISTAN STEEL


350 tons and convert it into steel in less than 40 minutes, compared to 1012 hours in an open
hearth furnace
Electric arc furnace steelmaking is the manufacture of steel from scrap or direct reduced iron
melted by electric arcs. In an electric arc furnace, a batch of steel ("heat") may be started by
loading scrap or direct reduced iron into the furnace, sometimes with a "hot heel" (molten steel
from a previous heat). Gas burners may be used to assist with the melt down of the scrap pile in
the furnace. As in basic oxygen steelmaking, fluxes are also added to protect the lining of the
vessel and help improve the removal of impurities. Electric arc furnace steelmaking typically
uses furnaces of capacity around 100 tonnes that produce steel every 40 to 50 minutes for further
processing.
By-product gases from the steel making process can be used to generate electricity through the
use of reciprocating gas engines.

2-7 SECONDARY STEELMAKING:
Secondary steelmaking is most commonly performed in ladles and often referred to as ladle
(metallurgy). Some of the operations performed in ladles include de-oxidation (or "killing"),
vacuum degassing, alloy addition, inclusion removal, inclusion chemistry modification, de-
sulphurisation and homogenisation. It is now common to perform ladle metallurgical operations
in gas stirred ladles with electric arc heating in the lid of the furnace. Tight control of ladle
metallurgy is associated with producing high grades of steel in which the tolerances in chemistry
and consistency are narrow.

Fig 2-6
PAKISTAN STEEL


2-8 HISARNA STEEL MAKING:
The HIsarna steelmaking process is a process for primary steelmaking in which iron ore is
processed almost directly into steel. The process is based around a new type of blast furnace
called a Cyclone Converter Furnace, which makes it possible to skip the process of
manufacturing pig iron pellets that is necessary for the basic oxygen steelmaking process.
Without the necessity for this preparatory step the HIsarna process is more energy-efficient and
has a lower carbon footprint than traditional steelmaking processes.

Fig 2-7

PAKISTAN STEEL


Chapter 3

ELECTRONIC DEVELOPMENT CELL( EDC)
3-1 Electronics Services
Electronic Development Cell of Pakistan Steel is engaged in designing and development of
indigenous electronic instruments/systems by employing modern micro-controller based digital
electronics for the replacement of outdated/obsolete
equipment and for enhancement of existing
instrumentation and automation of various production
units.
Electronics design engineers in EDC have ability of
programming in low level (Assembly language) and high
level programming languages and designing hardware
based on micro-controllers and digital electronics which
are the basis of all new instrumentation and automation such as PLCs, DCS, and Hybrid
Controllers.
In last two decades EDC has designed and installed more than 200 instruments at various
complexes of Pakistan Steel. These instruments are working round the clock for the
measurements of industrial parameters which includes :
1. Temperature Instruments (Indicators &
Controllers for various furnaces)
2. Flow Indicators (For the measurement of Gas,
Liquid and Steam)
3. Batch/Hopper Weighing (For the preparation of
blend of different materials, Measuring capacity
depends on silos or weighing hoppers)
4. Conveyor Belt Weighing Scales (Online weighing of raw materials transported through
conveyor belts. Maximum weighing capacity is 1000 tones/hours.)
PAKISTAN STEEL


5. Weighing platform Scales (These are portable weighing platforms easily moved or installed
any where. These are used for weighing of finished product upto 15 tones)
6. Process Control Instruments (Like length/speed/width measuring, sheet centering, sheet
detection, coil diameter measuring, level measurements, jumbo process data display, panel
meters etc.)
7. Jumbo Clock (14X4.5 Feet) for Main Gate Entrance Our strong area of specialty is to meet
customer requirements of plant In the field of instrumentation & automation. We can design &
develop electronic instruments to meet specific requirements of process for Which
instruments are not readily available in markets. Further, we have also developed expertise in
the below mentioned areas :
EDC can design and develop functionally
equivalent, electronic cards for the replacement of
irreparable electronic cards of various process
machines to keep machines and process in operation.
EDC can design and develop electronic cards
required for interfacing latest sensors/transducers with
legacy systems and interfacing of old sensors to latest
instruments.
Designing of artwork for single and double sided PCBs (Printer Circuits Boards).
We may extend our skills and expertise for the preparation/vetting of technical
specifications of electronic instruments/equipments required for the procurement from local or
foreign agencies.
EDC is fully capable of implementing new technologies emerging in the field of
automation and instrumentation. We can provide consultancy for selecting and configuring a
wide array of available instruments according to process requirements.
After obtaining ample experience of designing and development of electronic equipment, we are
now in position to extend our expertise and service through this letter to develop bidirectional
relationship for resolving problems and helping you in the field of instrumentation and
electronics technology. We will very much appreciate your interest and enquiries in the specific
areas of your interest.
PAKISTAN STEEL


Chapter 4
SINTERING PLANT
Sintering Department is one of the most important departments of Pakistan Steel Mill it is
designed for the production of sinter, with facilities for supply to the blast furnace for production
of pig iron.
The annual demand of sinter is estimated as 56, 000, 0 tons per annum.

4-1 SINTER PLANT:-
The function of the Sinter Plant is to supply the blast furnaces with sinter, a combination of
blended ores, fluxes and coke which is partially cooked or sintered. In this form, the materials
combine efficiently in the blast furnace and allow for more consistent and controllable iron
manufacture. Figure 1 shows a simplified diagram of a sinter plant.
Materials enter the sinter plant from storage bins. They are mixed in the correct proportions
using weigh hoppers, one per storage bin, except for the return fines for which an impact meter is
used instead. Weighing is continuous, as is the whole sintering process. The weighed materials
pass along a conveyor to the mixing drum where water is added either manually or as a
calculated percentage of the weight of material entering the drum.

Fig 4-1
PAKISTAN STEEL


The moisture content of the coke is measured in the strand roll feed hopper and used to trim the
secondary water flow rate. The mix permeability is also measured and used to modify the
amount of water required.
The mix material is fed onto the strand from the hopper by a roll feeder. The bed depth is set and
kept constant by adjusting the cut-off plate which is fitted with probes to sense the depth of
material and automatically vary the roll feeder speed. The quantity of material in the feed hopper
itself is held constant by automatic adjustment of the feed rates from the individual raw material
bins.

Figure 4-1 (b) Simplified diagram of a sinter plant of Pakistan steel

PAKISTAN STEEL


4-2 PRODUCTION UNIT:-
Sintering plant is mainly composed of following production unit.
Charge preparation
Primary mixing
Secondary mixing
Sintering section

4-3 CHARGE PREPARATION:-
The various substances are first mixed like calcium carbonate, manganese ore, dolomite, raw
silica sand and if desired granulated.
These raw materials in obtained from 12 bunkers which are sided in 2 rows. Each bunker contain
different materials for charge preparation The required size for flux and dolomite is about 0-
50mm which is screened form used for charge preparation. The required size for fuel grinding is
about 0-25mm for sintering of charge preparation. The iron ore required for charge preparation is
about 0-6mm size and these same conditions is also for manganese ore for charge preparation.
Iron ores are agglomerated on the conveyor belts consist of a large number of wagons. These
wagons that have been linked up as an endless conveyor belt which can be as big as 4 m in width
and 100 m in length. The fine ore to be sintered is moistened and fed on to the circulating grid
together with coke slack and additions such as limestone, quick lime, olivine or dolomite.

PAKISTAN STEEL


Primary Mixing:-
The amount of primary water added is about 4-5% proportional to the weight of raw mix
entering the mixing drum.
Fig 4-2
4-4 SECONDARY MIXING:-
The secondary water addition is about 2-3% setpoint is frequently taken as a proportion of the
raw mix belt weighed PV. For greater accuracy, the moisture meter reading is used to trim
the material/water ratio. This corrects the water flow rate according to the measured moisture
content of the raw mix.
Cascade control is not always used but since the water flow loop responds faster than the
moisture loop it does produce better results. Then it is passes through the shuttle conveyors into
the hopper. Then after the hopper it drops into the balling drum for frequent mixing is allowed
for 1-2 hours.
4-5 SINTERING SECTION:-
The materials from the baling drum are passed through in to sintering section. Burners above a
heat-resistant grate belt heat the material to the required temperature (1100-1200 C). In the
PAKISTAN STEEL


sintering machine 92 pellet car are used. In Pakistan steel 2 sintering machine are available but
nowadays only one sintering machine is working

Fig 4-4 (a)
fig 4-4 (b)
This causes the fuel in the mixture to be ignited. The carbon burns with the aid of the air sucked
through the grid into the mixture by means of 8 blower fans at the bottom of sintering machine.
Resulting in the flame front being moved through the sintering bed. The sintering processes are
PAKISTAN STEEL


completed once the flame front has passed through the entire mixed layer and all fuel has been
burnt.
Chlorine compounds can enter into the sinter installation by means of the additive cokes
The raw mix is ignited by the ignition hood, which is fuelled by a mixture of coke oven gas, blast
furnace gas and sometimes natural gas. The calorific value of the mixture and the set hood
temperature are controlled. A separate control system is provided to maintain a fixed hood
pressure by adjusting the wind box dampers immediately under the ignition hood.

Fig 4-4
The sinter strand is a moving conveyor of hot sinter, which continues to cook after leaving the
hood, where air is pulled from the sinter by a strand draught fan.
An important part of the sintering process is burn-through. This is where the sinter layer has
completely burned through its section and is detected by temperature probes under the sinter bed.
Burn through should be achieved but must not occur too soon after the ignition hood. The
draught on the strand is maintained at a preset value by controlling the main fan louvers from
pressure measurements in the wind main. This governs the point at which burn through occurs.

4-6 SINTER HANDLING:-
After the end of the strand, the sinter passes through a spiked roll crusher and the hot screens to
the rotating circular cooler. A number of fans are usually used for cooling, and the speed of the
cooler is determined by:
PAKISTAN STEEL


Strand speed
Bed depth
The fines removed by the hot screens of -8mm size are conveyed to the return fines bin. After
cooling, the sinter is passed into the discharge bunker. At this stage, the level is controlled by
varying the outlet feed rate (usually vibros).
The sinter then passes to the cold screening area, where it is passed through crushers and screens
to produce particles in a specific size range. Sinter below the required size passes over a belt
weigher and returns with the hot fines to the return fines bin.
The difference between the weight of the cold fines, and the weight of the total fines produced,
gives a measure of the hot fines. The following factors can affect the rate at which fines are
produced:
Mix control
Particle size
Chemistry
Weight
Moisture content
Bed depth
Ignition hood temperature and pressure
Warm screens
Two important properties of sinter are basicity, which is controlled by the amount of limestone,
and strength, which is controlled by coke content.
The sinter is passes through conveyor belt which is then screened up to +20mm size which is
used suitable for use in the blast furnace. Conveyors transport the material to the blast furnace
stock house, where it is added to other materials to form the blast furnace burden. The sinter
which is screened up to -20mm size is return to the sinter plant.

Internship Report File of Steelmills

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