General Review of the Operation Technique for the Past Decade in Sinter Plant at China Steel

Lee, Gwo-Ching Superintendent of Sinter Plant Ironmaking Department China Steel Corporation 1 Chung Kang Road Hsiao Kang, Kaohsiung 81233 Taiwan, Republic of China Tel: 886-7-8021111 Fax: 886-7-8051295 E-mail: [email protected]

Key Word: Blending technology. Anti-pollution. Waste material recovery. Environmental protection. Production management.

1.INTRODUCTION China Steel Corporation established in 1971 in Taiwan is modern integrated steel works with annual production of 11.2 million tons of crude steel. There are four sinter plants in Ironmaking Department since blow-in of No.4 blast furnace in 1997. Sinter production is approximately 13.2 million tons per year. For the higher productivity of blast furnace, extension of inner volume of #2 blast furnace has been carried during relining at the end of 2005.The extension of pallet width of #2 sinter plant was also decided to increase sinter production. And it had been finished in November 2005. In recent years, low-grade ores became main iron ore sources. A few tests were conducted to further increase the usage of low-grade ores in Sinter Plant. Besides, anthracite was introduced to replace the coke breeze to reduce the operational cost. After revamping control system in 2005, we use PLC system to control the whole plant equipments and replaced power and optical fiber hybrid cable for establishing networks. The graphic monitor system was also built up for upgrading of plant automation. For improving the standard deviation of sinter quality, a development of multi-stage variation mode and recycle process is available. In order to save energy consumption to meet the requirement of blast furnace operation, low slag volume of sinter is required. The effect of reducing SiO2 content is successful. Owing to China Steel Corporation has passed the certification of ISO14001 environment management system in 1998. CSC always keeps better environment quality to cope with the strict challenge from the environmental protection in Taiwan. Sinter plant has the responsibility not only to reduce its own pollutants, but also to recover revert materials in plant. Therefore several sets of waste gas heat recovery and environmental control systems had been installed to improve air quality and enhance energy saving technology. Consequently, a lot of activities have been done and obtained the remarkable improvements in sinter plants.

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2.OPERATION TECHNIQUE 2.1 Production of Sinter Production of sinter at CSC is growing up in the past decade except for the revamping of #3 sinter plant in 1999 and #1/#2 sinter plant in 2005 Fig.1 . After improving operational technique, the productivity for each plant increases from 57679 Ton/Man-Year to 98509 Ton/Man-Year raising more than 70 which is shown in Fig 2 .
14000000
PRODUCTION(tons)

13000000 12000000 11000000 10000000 9000000 8000000

YEAR

Fig 1. Trend of sinter production at China Steel

PRODUCTIVITY (tons/man-year)

110000 100000 90000 80000 70000 60000 50000

YEAR

Fig2. Trend of sinter productivity in the past decade at China Steel 2.2 Raw materials management For finding the way to improve the sintering properties of the blending ore containing high ratio of pisolitic ore, We test the effect of reducing fluxes on the sintering process. As a result of that decreasing the SiO2 content from 4.6% to 4.0%, to raise the basicity from 1.85 to 2.13 and decreasing the MgO content from 1.2% to 0.9% may improve the productivity, TI and coke rate. The high temperature gas resistance decreased with the reduction of SiO2 content. Regarding the softening and melting properties, this can improve the permeability of blast furnace. 2.3 Usages of low grade raw materials The exhaustion of high-grade hematite ores and the rapid development of steel industry in the world had accelerated severe situation of raw material. The production of low-grade ores such as Pisolite, Marra Mamba, and high P Brockman Ores had increased a lot during recent years, and low-grade ores became main iron ore sources. Which generally contained low Fe, high LOI, high water absorbability, or even high P content. These defects were in connection with ore characteristics, and were known as high combined water and high porosity. The effects are lower yield, lower production, lower sinter strength and higher energy consumption in sintering. To overcome

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these problems, the permeability bar has been successfully operated. A few tests were conducted to further increase the usage of low-grade ores in Sinter Plant. We found that the production loss would reach 8.1% when fully replacing hematite ores by Yandi, and would be 2.8% when replacing by Marra Mamba Ore. On the other hand, when blend with slightly lower Yandi but higher Marra Mamba Ore might have the same sinter production and strength. The performance of both sinter production and qualities with blending up to 44% of low-grade ores is acceptable. Another issue for low-grade ores was the high water absorbability caused by porous texture. Burnt Lime addition help to improve bed permeability. Sinter production could be significantly improved by adding 10 kg/TS burnt lime into an ore blend containing low-grade ores. By using of permeability bar, optimizing of iron ores blend, burnt lime addition, increase bed height, and size adjustment of coke breeze, higher than 50% of low-grade ores sintering would be reached without detriment to both production, qualities and coke breeze consumption. Trend of the amount of low-grade ores in the last six years is shown as Fig.3
3048794 2941681 2727714

Tons

2247602

1803692 1595809 1 2000 2 2001 3 4 5 2004 6 2005

Year 2002 2003

Fig.3 Trend of the amount of low-grade ore in the last six years Besides, coke breeze represents 11-13% of the total cost of raw material. Hence, anthracite was introduced to replace the coke breeze to reduce the operational cost. Trend of the amount of anthracite in the last six years is shown as Fig 4.The usage of anthracite of replacing 30-35% coke breeze is successful in CSC NO.4 sinter plant. It is estimated that 0.7% of production cost can be reduced.
115000 105000 95000 85000 75000 65000 55000 45000 35000 25000 15000 2000 2001 2002 2003 2004 2005 Year

Fig.4 Trend of the amount of anthracite in the last six years 2.4 Blending technology CSC has two ore blending plants for four sinter plants. Ore blending control system is originally divided into four subsystems running

Tons

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independently. After control system revamping in 2005, we use PLC system to control the whole plant equipments and replaced power and optical fiber hybrid cable for establishing networks. The graphic monitor system was also built up for upgrading of plant automation. And CCTV system was installed to monitor the actual condition with better functions. After automatic and remote control of stackers and reclaimers were finished, we started to further improve the stabilization of sinter quality by reducing the quality fluctuation of tail ends of blended pile. For this purpose, two modifications in suitable pile stacking and reclaiming process have been done by raw material blending system. One of the countermeasures is to develop multi-stage variation mode shown as Fig 5; the other is to install the recycle process. We found the standard deviation of tail ends were 0.006 higher than middle part in fix mode. After changing to multi-stage variation mode, the standard deviation of both parts was equivalent. By means of stepladder stacking method and the pile recycle operation with the quantity of 600-800T/H each pile, total B2 standard deviation has been improved from 0.042 to 0.035.The sinter chemical stabilization has been remarkably improved shown as Fig 6.

Y
37

x
Y5 X5 Y4 X4 Y3 X3 Y2 X2 Y1

x1
1st layer traverse dis. D+2X1 2nd layer traverse dis.D+2X2 3rd layer traverse dis.D+2X3 4th layer traverse dis.D+2X4 5th layer traverse distance D X1= X2= X3= X4= X5 = 4 5 3 5 2 5 1 5 D X X X X

X1 1 1st layer height Y1 = 5 Y 5

2nd layer height Y2 = 1 Y + 1 Y = 2 Y

2 3 1 3rd layer height Y3 = 5 Y + 5 Y = 5 Y 3 1 Y+ Y= 4 Y 4th layer height Y4 =

5th layer height Y5 = 1 Y + 4 Y = Y

Fig.5 Diagram of Stepladder Stacking Method

0.044

0.042

0.036

0.034

0.040

0.038

Sinter standard deviation

0.0415

03/07 03/09 04/01 04/12

Using tail ends of traditional stacking pile

0.0375

Using tail ends of stepladder stacking pile

0.037

Using middle part of stepladder stacking pile

0.0349

Using recycled stepladder stacking pile

Fig.6 The improved result of standard deviation of B2

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2.5 Sinter quality control The compositions of SiO2, CaO and MgO in sinter are concerned with strength, size distribution, physical and metallurgical properties (RDI, RI). In order to save energy consumption to meet the requirement of blast furnace operation, low slag volume of sinter is required. However, with lower SiO2 in sinter, lower sinter strength and lower sinter production rate occur. The effect of reducing SiO2 content is shown as following Fig 7. To keep the better quality of Sinter properties, some tests of reducing SiO2 were executed. We found when SiO2 content of sinter decreased, burn -through temperature decreased evidently. This showed lower SiO2 operation increased the resistance of permeability in sinter bed. The countermeasures we took to overcome the problem of deterioration were as follows. Permeability bars were installed under roll feeder in sinter machine. The MgO content in sinter was reduced to improve the strength of sinter. The basicity of sinter was increased to improve the permeability. FeO content was increased promptly to avoid 5mm and RDI deterioration.

SiO2 in sinter

Volume of bonding slag

RI

Slag

RDI

Strength

Yield

Permeability of lower part of BF

PC rate

Moderate RDI

Fig 7. The effect of reducing SiO2 content in sinter The level of SiO2 in CSCs sinter was 5.55~5.59% in 1996. After the countermeasures we took, the levels of SiO2 have been reduced from 5.58% to 4.80% (No.1 & No.2SP), and 4.66% (No.3 & No.4SP). The SiO2 content of sinter in China Steel this decade is shown as Table 1. And trend of SiO2 content of sinter in China Steel this decade is shown as Fig 8. Table 1. The SiO2 content of sinter in China Steel this decade Year #1SP #2SP #3SP #4SP 1996 5.55 5.58 5.59 5.55 1997 5.49 5.52 5.48 5.48 1998 5.45 5.48 5.40 5.41 1999 5.35 5.37 5.29 5.28 2000 5.13 5.14 5.04 5.05 2001 5.00 4.98 4.83 4.83 2002 4.95 4.97 4.73 4.73 2003 4.90 4.91 4.71 4.71 2004 4.87 4.88 4.68 4.68 2005 4.80 4.83 4.66 4.66

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5.7 5.5 SiO2(% ) 5.3 5.1 4.9 4.7 4.5

YEA R

Fig.8 Trend chart of SiO2 content of sinter in CSC Owing to the recovery of a large amount of waste material and low-grade ore. Deviation of B2 of sinter is shown as Fig 9. It still needs some effort in future. We think it will be getting better after installing RHF waste material system in the near future.

#1SP

#2SP

#3SP

#4SP

0.045 Devia tion of B2 0.040 0.035 0.030 0.025

20 02

19 96

19 98

20 00

YEA R

Fig.9 Trend chart of B2 of sinter in CSC 2.6 Energy saving Ironmaking process consumes more than 75 of the energy at CSC. Naturally, saving energy is the most important operating policy in Ironmaking Department. Besides, the reduction of CO2 emission is also required to meet the regulation of environmental protection administration. Thus, sinter plants pay more attention to reduce the energy consumption and to upgrade the environmental quality. For having effective energy management in sinter plant, there are some important energy saving stratagem as follows: Improve the efficiency of equipment. Fully recover waste heat of sintering process. Integrate regional energy with local community to create more effect. CSC has preceded the integration of regional energy from 1993 based on the concept of regional energy. WHRS was installed to produce steam since June 2002. Nowadays, the steam of NO.3 & NO.4 WHRS is fully sold to two adjacent factories around CSC about 72 ton/hr. Total quantity of energy sales grows about 30 in the past decade. These two factories may quit the existing poor efficiency boiler to reduce production cost of energy and make more profit. It is found the above measures can also reduce the emission of pollutants and improve the environment quality of Kaohsiung City. The total energy saving is about 48 104 G-cal/year, CO2 emission reduced 13 104T/Year, and sinter plants make profit of 4.8million USD per year.

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3.EQUIPMENT IMPROVEMENT China Steel has four sinter plants since blow-in of No.4 blast furnace in 1997. For the higher productivity of blast furnace, extension of inner volume of #2 blast furnace has been carried during relining at the end of 2005.The extension of pallet width of #2 sinter plant was also decided to increase sinter production. And it had been finished in November 2005. This extension work included extension of cooler width and changing of several facilities of feeding and discharging station, also revamping of waste gas EP, installing a new ignition system and increasing the capacity of screen machine and belt conveyor.

As for the extension of pallet width, total width was increased from 4.0m to 4.5m with 700mm sidewall. As a result of the total sintering area was increased from 400 m2 to 435 m2, which is shown as Fig 10.

450m2 400m2

Modify headpiece

Fig 10. The extension of pallet width of #2 sinter plant. The production has been increased about 12% and increase more than 20 thousands tons of production per year. The quality has improved also, the size distribution of less than 5mm was decreased and the shutter index was increased. The facilities of charging raw mix have relations with charge density in sinter bed. In order to get better permeability and segregation of raw mix loaded on pallet. A slope type permeability bars has been installed under roll feeder in all of four sinter plants since 1996. The bars are made of stainless flat plates. They insert into the sinter bed from the upper portion toward the lower portion of sinter bed. The slope type bars make charge density low. The permeability of sinter bed is improved in a significant level. The suction of sinter bed is improved prominently. The bed height can be promoted. The burn through temperature rises and the exhaust gas temperature also increase and production increase about 6 . For further improving the production, the wire rope type permeability device are just

installed and tested in #1&#2 sinter plant in January 2006.

4.ENVIRONMENT MANAGEMENT Ironmaking process consumes about 75 of energy of the whole steelworks and emits most of pollutants. Sinter plant is regarded as the major emission source. Therefore, It plays a very important role to improve environmental quality in the steel works. Because China Steel Corporation has passed the certification of ISO14001 environment management system in 1998. CSC always keeps better

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environment quality to cope with the strict challenge from the environmental protection in Taiwan. Sinter plant not only has to reduce its own pollutants, but also takes the responsibility of recovering revert materials from the subsequent iron and steel-making process. Therefore several sets of waste gas heat recovery and environmental control systems had been installed in sinter plant to improve air quality and enhance energy saving technology. The investment of above measures will be more than 180 million USD Dollars until 2006. 4.1 Installing De-NOx system For decreasing the NOx emission, three sets of the Selective Catalytic Reduction (SCR) De-NOx facilities were established in the sinter plants since 1997. The concentration of NOx is reduced to 25ppm~55ppm. To improve environment management, some study and test have been done in 2005.And the countermeasures are shown as following: A: Change the original De-NOX to De-DXNs/NOx catalyst to increase the efficiency for DXNs removal. B: Adding of burnt lime to improve the permeability of sintering and reduce dust emission and the formation of DXNs, SOx and NOx. C: To strengthen the efficiency of existing EP. . D: Adopt an EP dust washing system to remove 90% of the salts by-product. E: Introduce the limestone with lower sulfur content to reduce SOx emission. F: Introduce low sulfur and low nitrogen anthracite with about 30% replacement of coke to reduce the NOx and SOx emission . G: To install a high performance soot blower for the SCR system. 4.2 Reducing the dioxins emission According to dioxin regulation of government. The emission Control standard of dioxins will be 2.0ng-TEQ/Nm3 on January 1 2006, and 1.0 ng-TEQ/Nm3 on January 1 2008 respectively for existing sinter plants. Owing to DXNs emission can be found in sintering process. Some study has been taken and make some major conclusions (1) Without the utilization of waste material, the DXNs may be reduced. (2) The presence of a SCR De-NOx system was effect for eliminating DXNs. (3) Adding burnt lime or several kinds of anthracites was approved for SOx reduction. For reducing the dioxins emission, the original SCR system has been modified and changed to dual function of de- NOx and de-dioxin at #3 and #4 sinter plants before June 2005. The third one also has already installed in #1 sinter plant in January 2006. The efficiency for DXNs and NOx removal always keep above 80 . Some remarkable improvements would be seen in the near future. 4.3 Improving efficiency of de-dusting system Sinter plants have already constructed anti-emission cover and enhanced sealing of transfer tower, conveyor and transportation system to prevent dust emission. Besides, multi-pulse systems are installed to improve the efficiency of EP de-dusting system in all of the sinter plants. For solving this perplexed situation, a water spray system in mixing drum stack was adopted to wash out dust emission. The countermeasure could successfully catch the particle content in plume. The facilities contains one cone two spray nozzles and one drain outlet, which were installed near stack end and providing sufficient water to catch dust particle in plume through the cone. Recovering and reusing waste materials to achieve no waste are dumped is one of CSC environmental policies. How to treat the spraying wastewater became a new issue. After evaluating, it was decided to drain the waste spray water to sewer. This suspension solid in wastewater is a useful raw material owing to containing a lot of iron ingredients. From mixing drum stack emission measuring data, it is learned that the spray facility could wash out about 60 to 70 dust particle in plume. And suspension solid concentration in spray facilitys wastewater could be reduced from 1000 to 100ppm by depositing sink. Besides, increasing BOF slurry reuse and recovery

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dust emit from stack plume have saved the raw material cost. 4.4 Waste material recovery Waste material recovery is one of the most important policies. Trend of Waste material recovery is shown as Fig11. The Mini-Pellet system is useful and has been operated since 1998. These pellets are composed of several revert materials in CSC, such as EP dust, BF flue dust, B.O.F dust, B.O.F slurry, BF Low-Zn sludge and bag house dusts. More than 1000 tons of mini-pellets are recovered per day and charged to the raw material system of NO.3 & NO.4 sinter plant in CSC. Influence on the operation is shown as following: (1) The permeability of sinter bed is improved by adding mini pellet and raise production rate about 350tons per day. (2) Owing to the fixed carbon contents in mini pellet, which can save coke breeze consumption in sintering process. The actual coke rate can be reduced about 4 kg /TS. (3) By using mini pellet, sinter mean size drop about 0.5mm, -5mm increased 0.2%, RDI raised from 31.3% to 34.3%. But there is no apparent change shown in sinter strength. (4) The stack opacity increases from 10% to 12%. After installing of multi-pulse energizer, its beneficial for EP efficiency to recover the Mini-Pellet material.

1000000 900000 800000 700000 600000 500000 400000 300000 200000 100000 0 2000 2001 2002 2003 2004 2005 YEAR

Fig.11 Trend of Waste material recovery in sinter of China Steel 5.CONCLUSION Sinter plant of China Steel has developed certain amounts of operation technique for the past decade, including raw materials management, blending technology, usage of low-grade ores and anthracite, sinter quality, anti-pollution, energy saving, waste material recovery, etc. The successful improvements in sinter plants are remarkable. Average SiO2 is reduced from 5.50 to 4.60
3

TONS

NOx is bellow

50 ppm, particulate emission is less than 15 mg/Nm . Dioxins removal of waste gas is more than 80 . Sinter production increases about 30 . After revamping of #1 #2 Sinter Plants at the end of 2005, there are many improvements in the process. We use PLC system to control the whole plant equipments and replaced power and optical fiber hybrid cable for establishing networks. The graphic monitor system was also built up for upgrading of plant automation. And CCTV system was installed to monitor the actual condition with better functions. To further improve the stabilization of sinter quality by reducing the quality fluctuation. One of the countermeasures is to develop RHF, which will be constructed in the near future. We think environmental quality; sinter quality and production will have excellent achievements.

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