Sinter Plant Presentation

December -2018
 Plant Performance
Ground
Description Target Achieved Stock Remark

Production 12000 MT 12136.72M 800 MT 11336.72 MT

(BF consumed)
T
Almost 5%
Return Fines 30 37.00 return fines
Generation generation
(%) increased, when
sinter handled
by loader
Cost
Rs / Ton 4561
 Raw Material Consumption
Material Name Specific
consumption Remark
(Kg/T)
Iron Ore Fines 813
Lime Fines 165
Dolo Fines 108

Coke Fines 99 Fixed carbon is 60 to

80 %

Mill Scale 4
Sinter Return Fines 757
Flue Dust 20

Note – 1. Specific consumption calculated on net Sinter Basis.

 Delay

SP # 1 SP # 2

4.51

48
14.71
55.37 29.5

BF
Hr
Elct Elct
21.15
Mech
Hr
5.41
P.P
6.49
Mech
SCM 24.03

Operation
69.12
23.13

Shutdown
 Delay
SP # 3

0.59
Total Delay (Hrs)
7.75
SP # 1 - 184.39
Elct.
SP # 2 - 117.03
11.58

Hr
SP # 3 - 73.27
P.P. - Power not available.
Mech
S.C.M. - Supply chain
0.6700
00000
00000
52.68 1 Opeartion
management
P.P H.R.- Labour late reporting or
not available
Note - SP # 2 Stopped 95 times
 T.Fe % S.P.-1

55.00
54.00
53.00
52.00
51.00
50.00
49.00
48.00
8 1 8 1 8 1 8 18 1 8 18 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8
.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12
1 2 3 4 5 6 7 8 9 10 1 1 12 1 3 1 4 1 5 1 6 17 18 1 9 2 0 21 22 23 24 2 5 26 2 7 28 29 3 0 3 1

S.P.-2
55.00

54.00

53.00

52.00

51.00

50.00

49.00
18 1 8 1 8 1 8 1 8 1 8 18 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8
1 2 . 1 2 . 1 2 . 1 2 . 12 . 12 . 12 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 .
1. 2. 3. 4. 5. 6. 7. 8. 9 . 1 0 . 1 1 . 1 2 . 13 . 14 . 15 . 16 . 1 7 . 1 8 . 19 . 20 . 21 . 22 . 23 . 2 4 . 2 5 . 2 6 . 27 . 28 . 29 . 3 0 . 3 1 .
 T.Fe. %
55.00

54.00

53.00

52.00

51.00

50.00

49.00
8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 18 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8
.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12
1 2 3 4 5 6 7 8 9 10 1 1 12 13 1 4 1 5 16 1 7 1 8 1 9 20 21 2 2 23 24 2 5 2 6 27 2 8 2 9 3 0 31

Note – T. Fe. In sinter going down after 18th dec. due to high grade
iron fines consumption was low. On 22 and 23rd plant was running
with spillage material and return fines.
 SiO2 % S.P. 1
9.50

8.50

7.50

6.50

5.50

4.50
18 1 8 1 8 18 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8
1 2 . 1 2 . 12 . 12 . 1 2 . 1 2 . 12 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 . 1 2 .
1. 2. 3. 4. 5. 6. 7. 8. 9 . 1 0 . 11 . 12 . 1 3 . 14 . 15 . 16 . 1 7 . 18 . 19 . 2 0 . 21 . 22 . 2 3 . 2 4 . 25 . 26 . 2 7 . 28 . 29 . 3 0 . 31 .
8.50

7.50 SP # 2
6.50

5.50

4.50

8.50

7.50
SP # 3
6.50

5.50

4.50
 CaO %
15.50
S.P.1
14.00
12.50
11.00
9.50
8.00

15.50
14.00 S.P.2
12.50
11.00
9.50
8.00

15.50

14.00 S.P. 3
12.50

11.00

9.50

8.00
 MgO % SP # 1
3.00
2.70
Target – 1.8 Target – 2.1
2.40
2.10
1.80
1.50
1.20

3.00 Target -1.8 Target – 2.1

2.70 SP # 2
2.40
2.10
1.80
1.50
1.20

3.00 Target- 1.8 Target – 2.1 SP # 3

2.70
2.40
2.10
1.80
1.50
1.20
 Al2O3%
SP # 1
4.00
3.90
3.80
3.70
3.60
3.50
3.40

3.90

3.80 SP # 2
3.70

3.60

3.50

3.40

3.90
S.P.3
3.80

3.70

3.60

3.50
 Basicity SP # 1
1.90

1.85

1.80

1.75

1.70

1.90

1.85
SP # 2
1.80

1.75

1.70
8 18 1 8 18 18 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8
.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12
1 2 3 4 5 6 7 8 9 10 11 1 2 13 1 4 1 5 16 1 7 1 8 19 2 0 2 1 22 2 3 2 4 2 5 2 6 2 7 28 2 9 30 31

1.90
SP # 3
1.85

1.80

1.75

1.70
8 18 1 8 18 18 1 8 1 8 18 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8
.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12
1 2 3 4 5 6 7 8 9 10 11 1 2 13 1 4 1 5 16 17 1 8 19 2 0 2 1 22 23 2 4 25 2 6 2 7 2 8 2 9 3 0 31
 SP # 1
75.50
T.I.
74.00

72.50

71.00

69.50
8 18 18 18 18 18 18 18 18 18 18 18 18 18 18 1 8 1 8 18 18 18 18 1 8 1 8 18 18 18 18 18 18 18 18
.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 14 15 1 6 1 7 1 8 1 9 2 0 2 1 2 2 2 3 24 25 26 27 2 8 2 9 3 0 3 1

75.50

74.00

72.50

71.00 SP # 2
69.50
8 1 8 1 8 18 1 8 1 8 1 8 18 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8
.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12 .12
1 2 3 4 5 6 7 8 9 1 0 1 1 12 1 3 1 4 15 16 1 7 1 8 19 20 2 1 2 2 23 24 2 5 26 27 28 2 9 30 31

75.00

73.50
SP # 3
72.00

70.50

69.00
Raw Material Planning For 450 T Net Sinter Per Day Jan19
Sl. No. Material Cost Specific cons. Cons. Per Cons. Per
Name (Rs/ T) (Kg/T) Day (T) month(T)

1 Mill scale 2900 98 44 1323

2 Iron Fines 2800 433 195 5846

(H. Grade)
3 Iron fines 1500 431 194 5819
(L. Grade)
4 Lime Fines 2900 138 62 1863

5 Dolo Fines 2150 94 42 1269

6 Coke Fines 8000 87 39 1175

7 Sinter Return 500 690 311 9315

 Chemistry consider of raw material & Target chemistry of
sinter
Elements Target for Mill scale Iron fines Iron fines Lime Dolo Coke
sinter (H.grade) (L.grade) Fines Fines Fines
T.Fe% 55.15 71.73 62.13 57.00 - - -

SiO2% 5.90 - 3.00 7.00 2.00 3.50 -

Al2O3% 3.6 - 3.25 3.50 - - -

CaO% 10.19 - - - 50.50 28.65 -

MgO% 2.10 - - - 1.50 19.87 -

Basicity 1.73 - - - - - -

LOI% - - 5.00 5.50 42.50 44.31 -

Most% - 4.86 6.70 7.00 2.00 4.00 -

FC % - - - - - - 65.00
 Focus Points
Need to focus on following points
1. Internal delay time need to be reduced by the sinter plant respective
team.
2. External delay time need to be reduced by the respective
department.
3. Logistic department needs to be improved as lot of delay ( bunker
empty ) is observed due to non timely availability of vehicles.
4. HR department needs to concentrate for the timely availability of
manpower.
5. Frequent stoppages of sinter plant # 1 and 3 due to power failure.
6. Frequent stoppage of sinter plant # 2 due to non availability of BFG
7. Minimum raw material stock of 15 days to be maintained by
Procurement department for the consistency of sinter plant
operation.
NOTE : High production cost due to frequent stoppages
 NEW PROJECT
INORDER TO REDUCE THE PRODUCTION
COST, INCREASE THE PROCUCTIVITY AND
SAFETY . THE FOLLOWING MODIFICATION IS
REQUIRED IN PRIORITY.

1. Hearth layer system in auto mode.

2. Car transfer system is required in auto
mode.
THANKS