REPORT

IRON ORE PELLETIZING CONTROL SYSTEM

ON THE MATERIAL INDUSTRY

Writer :
Anang Maruf 2214 030 005

DEPARTMENT OF ELECTRICAL AUTOMATION

FACULTY OF VOCATIONAL TECHNOLOGY
INSTITUT TEKNOLOGI SEPULUH NOPEMBER
SURABAYA
2017
 CHAPTER I
INTRODUCTION

As the development of science and technology has accelerated the efficiency of human
work so as to facilitate human work. Thus, the consequences of human resource development
in the industry must continue to be improved to fit with the rapid technological developments.
Technological advances are characterized by problem solving in industry using automation
methods. Control and regulation can reduces risk and eliminate adverse impacts on the
environment. Instrumentation, control, and automation are vital areas of the control process.
Control methodology requires a thorough understanding in order to produce safe operations
and not damage the environment.
The current control or control system is beginning to shift in automation control
systems that require the use of computers, so the human intervention in control is very small.
When compared to manual processing, systems controlled by computer equipment will
provide benefits in terms of efficiency, security, and accuracy. The ability of computers, both
hardware and software can be utilized for various control applications, such as temperature
control. The control system has a very important role in the development of science and
technology.

Figure 1. Pelletizing Control System

Pelletizing is a process of agglomeration or clotting concentrates of ores or minerals

that are smooth, generally less than 74 iron particles shaped like marbles or small ball with the
size from 8 up to 25 mm. Main goals of pelletizing stage is formed of particles with a specific
size for easy moved the venue and have properties that can meet the needs of the nature of the
experiment.
Fine particles tend to be more difficult to be handled, both moving from one place to
another, from one process to the next process. In addition, fine particles tend to effect badly
against the stages of the operation or process, machine and the environment. Fine particles
tend to fly/lifted/are inhaled during the process. This can interfere with equipment and litter
the environment. It also can cause wasted ore/minerals, so it can lose earnings.
In principle the pelletizing process consists of two main phases, namely the process of
agglomeration or the manufacture of pellets and induration stages or warming hardening.
Agglomeration stage is the process of the formation of small-sized balls between 8 25 mm
of powder concentrate/ore/minerals. This agglomeration result pellets known as green pellets.
While induration is the process of heating the product against the results of the agglomeration
or green pellets in temperatures of about 1,200 degrees Celsius. Induration done in the kitchen
heater is called with indurator. Product of the induration phase is referred to as burnt pellets or
pellet fuel.
The main purpose of the stages is to get a pellet induration that have properties such as
the experiment of mechanical properties or strength and the nature of the reduction. The
strength required to withstand the mechanical load of pellets during a next process. While the
nature of the reduction needed to ease the onset of this process of reduction during the
manufacture of sponge. At this stage of the reaction between the oxygen contained in the air
with a compound that is found in Green pellets. Moisture content and compounds that burn
easily escape. With this excess oxygen mineral iron magnetite (Fe3O4) reconstruction can be
transformed into hematite (Fe2O3). After this induration stage will be produced pellets that
have properties experiment is needed.

Figure 2. Pelletizing Schematic System

Schematic stage of the process of making pellets can be seen in the figure 2. The
process starts with the manufacturing operations of green pellets. This operation is equipped
with mixer, water tank and disc pelletizer. Concentrates and binders with a certain ratio routed
into the mixer in order to be mixed homogeneously. Generally the binder that is added to the
amount of bentonite is 2 percent of the mix.
Then the mixture is homogeneous among concentrates and binder was fed into the disc
pelletizer with additional water. Water is added about 5 percent. The mechanism of Disc
pelletizer in producing green pellets smaller than 30 mm.

TK4 Series Air Control Valve Temperature

Thermocouple

Figure 3. Closed Loop Control System

This closed loop system based on the block diagram above where the controller is a
temperature control TK4S, a tool used to read temperatures, control the temperature so that it
corresponds to the expected specifications. The main purpose of control is maintaining the
stability of the temperature on the variable control on expenditure so that the combustion gas
temperature has been set to run constantly. the controller compares the set point signal (input)
and present value/output signal with the sensor used is a thermocouple sensor.
 CHAPTER II
PROBLEM STATEMENT

Pelletizing process will produce iron ore from the chemical compounds that are mixed
together in one tank. For mixing the compounds, it takes the heater to reacting concentrated
into pellets of iron. The heater is used in the form of heated air that its fuel derived from the
gasifier. The fuel is channeled through pipes connected with the furnace. The air is heated up
to temperature of 1100 c. Main results in the form of liquid iron and slag in the form of by-
products. Any mixing of the compound there is a certain temperature settings are done
gradually. Therefore it needs a system of control that can adjust the temperature of the air
heater gradually from 120 C to 1100 C so that the obtained results are good iron ore
pellets.
 CHAPTER III
RESULT AND DISCUSSION

3.1 Temperature Controller TK4

Controllers are widely used in industrial control systems to adjust or maintain desired
outputs of specific processes within a desired range. Autonics provides a diverse range of
highly accurate and reliable controllers for ideal system control.

Figure 3. TK4 Series

Temperature Controllers, used in wide variety of industries, is the starting and

important tools for the controlling of the temperature to get desired results in various
industries. Autonics' Analog/Digital(PID) temperature controllers, offer quick setup and
provide precise temperature management and control for a variety of applications while
offering the better price, design and easy operation. They will be the definite choice for your
successful control in any temperature applications.
Standard type PID temperature controllers TK Series realizes more powerful
controlling with super high-speed sampling cycle of 50ms and 0.3% display-accuracy. It
supports heating/cooling simultaneous control, automatic/manual control, SSR output/current
output selectable function, SSRP output function and communication function. In addition, it
covers diverse input sensor support, multi SV setting, high resolution display part and
compact size.

Air Control
Valve
Oil

Figure 4. Wiring Diagram System

 Figure 4 is the wiring in the control TK4S temperature associated with some of the
other components. On TK4S the pin associated with the SCM-USB8I that serves as a liaison
between TK4S to the computer so that the data from the sensors can be sent to the computer.
TK4S got supply 220 VAC 50 Hz using the plug through the pins 5 and 6 on TK4S. While,
the actuators used a temperature control valve which is connected to pins 3 and 4. The
thermocouple is connected on pin 11 and 12. So, the temperature data can be acquisited from
TK4.
2.3 DAQ Master Software

Figure 5. DAQ Master Software

In the use of DAQ master software above we must make the first configuration
between the hardware with the software used. Then connect and scanning the DAQ master
toolbar. To be able to assign values and set values Parameters can be changed directly through
the equipment or through software. Changes via the equipment is done by going to the
Parameter menu (Press Mode button 3 seconds, then change the desired parameters). Changes
through the software can be done by changing the items in the Property sub-window.
2.4 ON/OFF Mode Measurement
This graph below, shows the temperature signal using ON/OFF mode.
 Figure 6. ON/OFF Graphic Data
In the above system there is ON-OFF Control where to use the system by
Press Mode for 3 seconds on TK4S, Select PAr 3, press Mode, select Unit change to
C, Press Mode, choose o-ft to set Heating mode / Cooling switch to Heating mode.
Select PAr 3, press Mode, go to C-nd to change the setting type, select ON / OFF,
Press Mode, then PAr 2, select HHYS (Heating Hysteresis) with a value of 2. Graph
In Figure 6 shows a response resembling a response graph of order 1, but on the
graph when it reaches a predetermined set point of 32 C the lamp (the time-
controlled medium) will die, and when the temperature has dropped to 31 C The
lamp will still die until the new temperature 30C back light will light up. This
happens because the value of hysteresis that has been given, after the temperature
reaches 30 C it will be warmed up again until the controller to detect the temperature
of 32 C and the light will die again. In ON / OFF controller will continue to do so
can be said in this system produce a control that is fixed (discrete). On the system ON
/ OFF also only has two commands that lights on and lights off only.

2.5 PID Mode Measurement

Auto tuning measures the control subject's thermal characteristics and thermal
response rate, and then determines the necessary PID time constant. (When control
type [C-MD] is set as PID, it is displayed.) If error [OPEN] occurs during auto
tuning, it stops this operation automatically.To stop auto tuning, change the set as
OFF. (It maintains P, I, D values of before auto tuning.

Auto-tuning start/stop setting :

Auto-tuning automatically stores PID time constants upon termination. These PID
time constants can then be modified by the user to suit their usage environment.
When auto-tuning is in progress, the AT indicator located on the front of the
controller flashes in 1 sec. intervals. When auto-tuning finishes, the AT indicator
automatically goes off and the auto-tuning parameter will return to OFF.
When auto-tuning is in progress and digital input key [DI-K] is STOP (switching
RUN/STOP) or AT(auto-tuning RUN/STOP) is set, and digital input terminal
function [DI-1, DI-2] is STOP (switching RUN/STOP) or MAN(AUTO/MANUAL
control selection), auto- tuning will be automatically ended, if concerned DI is
inputted or a sensor disconnection error occurs. (Restored the PID used prior to the
auto-tuning session)

In this experiment, we use auto-tunning to get the value of PID controller. And here is
the value :

Heating_Proporsional Band 3 C
Heating_Integral Time 40
Heating Derivation Time 5
 Table 1. PID value data

This graph below, shows the temperature signal before using auto-tuning PID.

Figure 7. PID Graphic Data

This graph below, shows the temperature signal before after active the auto-tuning PID.
 Figure 8. Auto Tunning PID Graphic Data

After activating the auto tuning PID, the PID of data obtained as follows.

Heating_Proporsional Band 1 C
Heating_Integral Time 23
Heating Derivation Time 5

Table 2. Auto Tunning PID value data

In the controller using PID it can compare between controlled variables with set point
values and give control action to correct set point deviation to zero. This controller has three
components each of which has its own role, the first P (Proportional) to accelerate the start
from the initial temperature to 35 C, then I (integral) keep the temperature when it reaches 35
C so that no increase or decrease occurs, and which The last D (derivative) function keeps
the temperature of 35 C during the process. With this controller then the required
temperature will remain constant, although no changes will not be too large from the desired
temperature. So for the use of this controller is suitable in the industry because it can provide
stability at the desired temperature.
 CHAPTER V
CONCLUSION

The control system (control system) has a very important role in the development of
science and technology. One of the tools of the auto industry is the Temperature Controller.
Autonics Temperature Controller is a tool that can control the temperature to control the
cooler / heater in accordance with the rules as desired. Autonics Temperature Controller can
process changes in ambient temperature can be measured and detected. One type of Autonics
temperature controller is TK4 series. It helps us to control the temperature automatically and
easily. Standard type PID temperature controllers TK Series realizes more powerful
controlling with super high-speed sampling cycle.
Auto tuning measures the control subject's thermal characteristics and thermal
response rate, and then determines the necessary PID time constant . Auto-tuning
automatically stores PID time constants upon termination. These PID time constants can then
be modified by the user to suit their usage environment. PID control is useful to minimize
overshoot. PID control will maintain the output temperature to keep it in accordance with a
predetermined limit value.
Depending on the ON / OFF controller that has only 2 conditions off and on, so the graph that
comes with this controller will continue to rise and fall with the temperature difference
according to the given hysteresis value. Using a PID controller, output temperature obtained
will reach steady state more rapidly and would be in a stable condition.
 REFERENCES

User Manual TK Series High Accuracy Standart Temperature Controller

Datasheet TK Series Autonics Sensors & Controller
www.autonics.com
https://ardra.biz/sain-teknologi/mineral/pengolahan-mineral/proses-pembuatan-
pelet-bijih-besi-pelletizing/
http://kimiadasar.com/proses-pembuatan-besi/