Overview of Sinter Plant Process

Introduction

• Purpose: Aimed at understanding the sinter plant in Indonesia.
• Equipment in the video may differ from actual on-site equipment.
• Sintering is the first step in iron making processes.
  • Objective: To create iron ore suitable for use in a blast furnace (above 10 mm).

Sinter Plant Layout

1. Raw Material Handling Facility
   • Stores and discharges materials from the material yard.
2. Sintering Facility
   • Produces the actual sinter ore.
3. Crushing Facility
   • Crushes, screens, and conveys the produced sinter ore.

Dust Collection System

• Exhaust ESP: Collects dust from the sintering process.
• Plant De-dusting ESP: Collects dust from screening and crushing equipment.
• Coke Bag Filter: Collects dust from fuel crushing equipment.
• Additional bag filters may be needed for fuel and material storage bins.

Start of Sinter Process

• Main Material: Iron ore.
• Auxiliary Materials: Serpentine, silica, limestone, blast return fine, sinter return fine.
• Fuel: Anthracite and coke (processed in fuel crushing equipment).
• Material Transfer: Pre-screened materials are transferred to storage bins via belt conveyors.
• Mixing: Raw materials and fuels are mixed in proper ratios in the mixing drum with added moisture.

Granulation and Charging

• Re-rolling Drum: Granulates materials, adds moisture, to improve permeability.
• Surge Hopper: Uses a shuttle conveyor to feed material uniformly.
• Charging Equipment: Consists of gates, drum feeder, and deflector.
  • Controls discharge rate, feeds materials evenly.
  • Adjusts according to operating conditions.

Sintering Process

• Ignition: Surface of mixed material ignited by burner.
• Burning: Coke and anthracite burned from top to bottom by suction pressure.
• Cooling: Quickly cooled by continuously supplied air.
• BTP (Burn Through Point): Indicates completion of sintering process.
  • Rapid increase in exhaust gas temperature signals completion.

Cooling and Screening

• Cooling Process: Cools sinter ore from 800°C to below 120°C.
  • Takes about 1.5 hours using a circular type cooler.
  • Cooling air fan blows fresh air to accelerate cooling.
  • Dust collected by plant de-dusting ESP.
• Screening and Crushing: Screens and crushes ore into proper sizes.
  • Sinter ore of 10-15 mm used for hearth layers.
  • Fine grain sinter ore transferred to storage bin.

Storage and Usage

• Stock Bin: Divides sinter ore into lump and fine grain for blast furnace.
• Sinter Yard: Stores sinter ore for 2-3 days during emergencies.
• Normal Operation: Sinter ore discharged and transferred to stock bin to maintain blast furnace operation.