REFRACTORY MATERIALS PLANT-I

Refractory Materials Plant-I (RMP-I)was installed along with other units in BHILAI while rotary kiln #02 was commissioned on 28/12/66 under 2.5 MT stage STEEL PLANT under 1.0 MT stage. The plant was expanded subsequently under 2.5MT & 4.0 MT stage. RMP-I supplies sintered dolomite, calcined dolomite and various refractory mortars & castables to SMS-I, SMS-II & RED respectively. First unit of the shop, rotary kiln #01 was commissioned on 15/05/60 under 1 MT stage

RMP-I consists of following sections:

1) Raw material storage yard 2) Mortar shop 3) Dolomite shop

BRIEFWORKING OF THE SHOP:

Dolomite shop :
It produces sintered dolomite and calcined, lime/dolomite in two rotary kilns. Sintered dolomite is used for fettling in Twin Hearth Furnaces (THFs) of SMS-1.Calcinea dolomite is used in SMS-II to increase the lining life of Convertors. Annual capacity of Dolomite shop is 70,000MT .Calcined lime is used in sintering plant to improve quality & productivity of sintering plants.

Product detailsSintered dolomite:

CaO MgO Si02 R203 LOI BD

55-56% 36-38% 1.2% 4-5% < 1.0% (Loss On Ignition) 2.8-3.0 g/cc (Bulk Density)

Calcined dolomite:
CaO MgO LOI Reactivity 52-54% 34-36% 4-5% 120-1 50ml of HCI (4N)

Calcined lime:
Cao Mgo LOI Reactivity 88-89% 2-2.5% 4-5% 330-360 ml of HCL(4N)

RAW MATERIALS: (i) Low silica raw dolomite chips (For producing sintered dolomite): Source Mandla area

Size CaO MgO Si02 AI203

8-20 mm 30% min 20% min 1.0% max 2.5% max

(ii) Raw dolomite chips (For producing Calcined dolomite): Source

Size CaO MgO Si02 Al203

Hirri
10-25 mm 30% min 20% min 3.0% max 2.5% max

(iii) Low Silica Limestone

Source Size CaO Si02 Jaisalmer 10-35 mm 53% min 1.6% max

Fuel: Mix of Coke Oven & LD gas along with PCM

REFRACTORY MATERIALS PLANT-l FLOWCHART

DOLOMITE SHOP

RAW DOLOMITE YARD BUNKER

CHARGING SKIP

MIXED CAS

SINTERING/CALCINATlON IN ROTARY KILNS

COOLER QUl ALITY CONTROL

DlSCHARG1NG SKIPS

SILOS BURNT DOLOMITE ELEVATOR

DOUBLE DECKSCREEN

0-2
DUST BUNKER

2-15
HIGH LINE BUNKER

+15
ROLLER CRUSHER

PROCESS DETAILS :

RMP-2

HOPPER TO SMS-1

Dolomite shop can be divided into following major sections Dolomite production units Dolomite dispatch section.

Dolomite production units :

There are two rotary kilns of 60-meter length & 3 meter diameter. The inclination of kilns is 3.5 % towards discharging end. Each kiln is driven by 125 KW motor. Cooler length is 25 meters while its diameter is 2.5 meters. Low silica chips are charged into Rotary kilns by means of the receiving bin, vibratory feeder, skips hoist, charging bunker and Belt Weigh Feeder. The materials are

charged into Rotary kiln-I with the help of charging pipe and scooping device in Rotary kiln -II. Sintered dolomite is produced in Rotary kilns by calcining & sintering the raw low silica dolomite chips at 1620-1650 0C. While calcined lime is produced by calcining the limestone chips at 1300-1350 0 OC. The kiln operates on counter current flow principle. Mixed gas (CO + LD) alongwith air is charged from one end and raw dolomite chips descend from other end. Sintered/calcined dolomite is discharged from the furnace into the cooler. Material is copied to atmospheric temperature in the cooler before it is discharged.

Dolomite Dispatch Section

The end product is transferred to silos via skip hoist. There are four silos, each having a capacity of 800 MT. The sintered dolomite is screened on a double deck screen of 1 mm & 15 mm, (+ i 15 mm fraction is sent to roller crusher for re-crushing into (-) 15 mm fraction. 1-15 mm fraction is conveyed to high line bunker situated in bulk charging yard of SMS-1. It is loaded into hoppers through chutes. Calcined lime From RMP-II, calcined lime is conveyed to SMS-II /SP-3for use. Depending upon the requirement, production of sintered dolomite& lime is carried out in rotary kilns. Under normal circumstances, one kiln produces sintered dolomite while the other produces calcined lime is screened on 5mm screen, undersize goes to dust bunker while + 5mm is passed through impact mill & output is again screened. The material is stored in dust bunker & sent to SP-3 for RMP-2, material is directly loaded from silos into haul packs.

OPERATING PARAMETERS:
The norms of operation parameters are maintained for achieving high productivity & good quality of sintered /calcined dolomite. The important operating parameters of rotary kiln operation are
SI Parameters Sintered dolomite Calcinedl Lime

1 2 3 4 5 6 7

Kiln speed Sintering/calcinations temp. Dust chamber temp Gas flow GCP draft Gas pressure PCM flow

75-80 sec/ rotation 1620-1650 deg C 760-780 deg C 3000 cu M/Hr (-) 4 to (-) 6 mmWC 220-300 Kg/m2 650-750 kg/hr

78-80 sec/ rotation 1350-1400 deg C 700-760 deg C 3200 cu M/Hr (-)4 to (-) 6 mmWC 220-300 Kgim2 __------

Mortar Shop:
Mortar shop produces different types of mortar and castables after crushing, grinding and mixing the refractory materials. Annual capacity is to produce 18000 MT of mortars & castables. The shop started production on 1Oi11 /61.

Products and raw materials used are as below:

Sno. PRODUCT FIRE CLAY MORTAR 1 2 3 4 5

CHROME MORTAR STEEL LADLE MORTAR HAM-70 MOAT AR VAD MORTAR

INGRADIENTS USED
FIRE BRICK/ HIGH ALUMINA BRICK GROG, PLASTIC FIRECLAY (PFC) CHR-MAG BRICK GROG, PFC HIGH ALUMINA BRICK GROG, KYANITE,PFC LOW FERRIC HIGH ALUMINA CAL. BAUXITE (LFHACB), KYANITE, PFC LFHACB, KYANITE, PFC

6 7 8 9 10 11 12 13 14

BT-1 MORTAR BT-2 MORTAR MAGNESITE MORTAR DEAD BURNT MAGNESITE, PFC SP.COR -1 LAUNDER RAMMING MASS 60% ALUMINA CASTABLE (HAM-K) FIRE BRICK GROG (O-1mm) CHR-MAG (0-10mm)

LFHACB, KYANITE, PFC LFHACB, KYANITE, PFC DEAD BURNT MAGNESITE, PFC FIRE BRICK GROG (FBG), KYANITE, PFC FBG, KYANITE, PFC CHR-MAG GROG, DEAD BURNT MAGNESITE, PFC CALCINED FIRECLAY GROG FIRE BRICK GROG

GROG CHR-MAG GROG