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    Prem Kumar
    This document summarizes the key components and processes involved in a pellet production plant, including: 1) A horizontal mixer that mixes raw materials at 200 tons per hour and feeds balling discs. 2) Four balling discs that form green balls through a rolling and water spraying process at 55 tons per hour each. 3) Screening and sorting of green balls by size on conveyors, with oversized and undersized balls recycled to balling. 4) A rotary kiln that indurates the green balls at 1250-1350 degrees Celsius and outputs pellets to the annular cooler. 5) An annular cooler that cools the indurated

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    This document summarizes the key components and processes involved in a pellet production plant, including: 1) A horizontal mixer that mixes raw materials at 200 tons per hour and feeds balling discs. 2) Four balling discs that form green balls through a rolling and water spraying process at 55 tons per hour each. 3) Screening and sorting of green balls by size on conveyors, with oversized and undersized balls recycled to balling. 4) A rotary kiln that indurates the green balls at 1250-1350 degrees Celsius and outputs pellets to the annular cooler. 5) An annular cooler that cools the indurated

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    This document summarizes the key components and processes involved in a pellet production plant, including: 1) A horizontal mixer that mixes raw materials at 200 tons per hour and feeds balling discs. 2) Four balling discs that form green balls through a rolling and water spraying process at 55 tons per hour each. 3) Screening and sorting of green balls by size on conveyors, with oversized and undersized balls recycled to balling. 4) A rotary kiln that indurates the green balls at 1250-1350 degrees Celsius and outputs pellets to the annular cooler. 5) An annular cooler that cools the indurated

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    34 views4 pages

    Print

    Uploaded by

    Prem Kumar
    This document summarizes the key components and processes involved in a pellet production plant, including: 1) A horizontal mixer that mixes raw materials at 200 tons per hour and feeds balling discs. 2) Four balling discs that form green balls through a rolling and water spraying process at 55 tons per hour each. 3) Screening and sorting of green balls by size on conveyors, with oversized and undersized balls recycled to balling. 4) A rotary kiln that indurates the green balls at 1250-1350 degrees Celsius and outputs pellets to the annular cooler. 5) An annular cooler that cools the indurated

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    of 4

    MIXER

    PROCESS AND DESCRIPTION


    The proportioned materials are Mixed in a Horizontal Mixer ( Made In house, Inspired by Little
    ford)
    having capacity of 200TPH
    This mixed product is now conveyed to Balling Disc Building Storage Bins through BC 20 - BC 21 -
    BC 22
    FEED CHUTE
    VENT
    MOTOR & GEARBOX

    BEARING
    SCRAPPER WITH TOOL
    HOLDER
    DISCHARGE CHUTE

    TECHNICAL PARAMETER
    Type of Mixer : Single Shaft Continuous Rotating Horizontal Mixer
    Cylindrical Drum Dia- 1200mm Length- 3000mm
    The material is mixed by the Scrapping Arrangement Inside Mixer
    There are total 13 no. of Scrappers Mounted on Main Shaft of Mixer
    MOTOR- 250KW, 1500RPM, GEARBOX RATIO-14:01 CAPACITY- 200TPH
    NO. OF SCRAPPERS – 13
    Vibration Limit – 18 to 28 mm/sec
    Residence Time – 8 Second
    Bearing Used- 22317K

    MAINTENANCE
     Preventive Inspection (Daily) and Preventive Maintenance (Twice a Month) are done
    for this machine
     The Internal Checking is done by Checking Scrapper Condition for any kind of wear
    and tear: or bolt looseness, also The Internal Ceramic Liner Tiles were checked as well
    as both sides Mother Plates are also checked for Wear-out findings
    BALLING DISC
    PROCESS AND DESCRIPTION
    It includes 4 no. of Balling Discs having 6m Diameter and Wall Depth 600mm
    Baling Disc Consists a Big Pan with a Peripheral Wall, which rotates with a certain inclination to
    Horizontal , Generally the Inclination kept is 45̊
    The mixed product discharged into Mix Bins with Help Of Hydraulic System Operated V-Plough
    The Material then discharged into Balling Disc through Disc Feeder & Weigh Feeder
    The Ball Formation is a Two Stage Process (i) Seed Formation (ii) Growth
    It works in a close circuit with the Screening Step (which takes place just after ball formation),
    where the desegregated screened material is recirculated to the balling process. As the disc
    rotates, feed material is charged to the bottom of the pan of disc, where water sprayed and by
    rolling action and surface tension, small pellet balls are formed then after that the size of ball
    increases and the co-efficient of friction reduced causing pellets to acquire a centrifugal force. The
    height and width of the trajectory Increases as the ball size increases until the balls hit the
    Scrapper Blades

    DESCRIPTION OF MACHINE
    Disc Diameter- 6000mm, Wall Depth- 600mm
    Drive - 110KW, 1500RPM, Capacity- 55TPH ×4
    Gearbox – Helical Bevel Reducer, Ratio-
    No. of Scrappers – 5, Inclination Angle - 45̊
    Disc is Rotated by Girth Gear arrangement with
    Bevel-Helical Gear Reducer and Pin Bush Coupling
    GREEN BALL SCREENING AREA
    SWING CONVEYOR
    The green balls produced by Balling Disc are discharged onto BC 23, which convey the
    material and transfer it to Swing Conveyor (A conveyor which swings over an arc shaped rail
    through wheels)
    It helps in Uniform Distribution of material on TG Chain Conveyor Bed which helps in
    combustion later inside TG.

    OVERSIZE ROLLER SCREEN


    The Green Balls having mean dia greater than 16mm are screened out and discharge into
    oversize green ball hopper, through which the material falls on to BC 25 which farther
    convey the material upto BC 20
    The material sizes between 6mm – 16 mm, fall into Wide Belt which will take the material to
    Undersize Roller Screen
    There are about nos Rollers mounted on Oversized Roller Screen, runs by Cycloidal Gear
    Reducers

    WIDE BELT
    3 MTR width conveyor belt which convey the sized material and fed it on the undersized
    roller screen
    UNDERSIZE ROLLER SCREEN
    The Green Balls having Mean Dia less than 6mm are screened out and discharge into
    undersize green ball hopper, through which the material falls on to BC 24 which again falls
    onto BC 25, Rest of the Sized materials are automatically fall on tg chain
    Rotary kiln is barrel- like roatry indurating
    equipment for heat
    ANNULAR
    and slurry material.ROTARYCOOLER
    KILN tretment of bulk material
    This equipment is for the
    indurating process of oxide pellet.
    Rotary Kiln is a thin MS Shell installed on a supporting device with acertain inclination and rotated
    by slowly by driving unit. Material go in from the charging end. Due to the inclination of the kiln
    shell, material inside the kiln will move along the axial line while rolling peripherally, and flow
    slowly from the charging end of the kiln cross the whole kiln shell and go out of the kiln shell at the
    discharging end. Fuel will be injected from Discharging End into high temperature zone inside kiln
    for combustion and flow counter-current with material. Material undergo high efficient heat
    exchange and complicated physical and chemical changes and complete induration process while
    rolling and moving inside the kiln shell.
    This Rotary Kiln is used to produce oxide pellet. Preheated pellet from the Travelling Grate is
    charged through charging end of the rotary kiln and discharged from discharging end of the rotary
    kiln after 1250-1350 degree centigrade induration inside the Rotary Kiln and delivere to the
    annular cooler for cooling. Finally the product pellet is obtaine after cooling in Annular Cooler

    EQUIPMENT DESCRIPTION
    Rotary Kiln is comprised of Kiln Shell, Tyre, Returner Ring, Slip Ring, Support Rollers, Hydraulic
    Thruster, Driving Unit, Seal Plates, Fixed Screen, Inlet hood- Outlet hood, Lubrication System Nose
    Cooling, Structure Cooling.

    TECHNICAL PARAMETER
     Diameter of Kiln – 4 meter, Length of Kiln – 32 meter, Capacity – 90 TPH
     Supplier – Jiangsu Hongda Special Steel Machinery Co. Ltd.
     Material Bulk Density – 2.1 t/m3 , Slope – 4.5 %, Speed – 0.15 – 1.7 rpm
     Driving Unit – Girth Gear with Pinion Arrangement (MODULE – 32)
     Motor Power – 250 kw, RPM – 990, Gearbox- 3 Stage Helical Gearbox , Ratio- 61.44
     Girth Gear Reduction Ratio – 194/19= 10.21
     Hyd. Operated Floating Device ie Thruster Operating Pressure – 3000 PSI
     Fixed Screening Size – 100 mm2 , Inclination Of Fixed Screen- 13 Degree

    PROCESS AND DESCRIPTION


    The Rotary Type Annular Cooler is the cooling equipment for oxide pellet that is compatible
    with rotary kiln. The Effective Cooling Area of Cooler is 50 m 2. The rotary direction of this cooler

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