Large-scale Raw Materials Handling at Bushan Steel's Integrated Steel Plant

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Wagon Unloading System

Run-of-Mine (ROM) coal, imported coal, limestone, dolomite and iron ore are unloaded by five Rotaside wagon tipplers (three by others) and the truck unloading system and are sent to stock yard through series of belt conveyors. In hauling of loaded wagons, placement and out hauling of empty wagons is done by rack and pinion type side arm charger (one for each tippler). The raw materials unloaded from each wagon tippler are drawn by two nos. Apron feeders installed below the hoppers and fed on to the conveyors below.

ROM coal is also unloaded at two track hopper complexes (twin type, 210 m long) with four traveling type paddle feeders in each complex, see Fig. 4. The track hopper unloads material from bottom discharge type wagon by opening gates pneumatically/manually and the same is fed onto four underground belt conveyors at the bottom of track hopper complexes.

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The material received from both the track hopper and wagon tippler stream will be fed onto conveyors for transportation to stockyard via junction towers.

Stockyard and Yard Machines

Stockyard and the yard machines are designed to cater the raw material needs for the 6 million tonnes per year stage. The stock yard is serviced by eight stacker/reclaimers and three bucket wheel reclaimers (see Figs. 5 and 6). Out of the total eleven yard machines, ten machines have been supplied and erected by L&T including one stacker/reclaimer which comes within a covered storage area. The brief specifications of the yard machines are furnished in Fig. 7.

Sinter Base Blending System

This circuit comprises of the raw material preparation and handling system for feeding raw materials from stock yards to sinter plants SP2 and SP3, conveying product sinter to the blast furnace stock house, coke and lump ore to blast furnace stock house and handling coke/sinter fines generated in stock house.

The primary reason of adding sinter in the blast furnace is to increase its efficiency. Sinter is produced using base mix in the base blending system and the course of raw materials is given in the following sections.

Iron ore fines reclaimed from the yard will be discharged on to eight bins in the base bin building through reversible shuttle conveyor and charging hatches.

Limestone and Dolomite Circuit

The limestone and dolomite reclaimed from the stock yard is fed on to the surge bins in the flux crushing and screening building. The flux (+25 to 50 mm) is crushed to predominantly (-3 mm) with the help of three reversible hammer mill crushers (2W+1S) and the oversize material (+3 mm), screened using flip flop screens, is crushed with the help of three secondary reversible hammer mill crushers (2W+1S). The flip flop screens ensure recirculation of (+3 mm) size to the secondary crushers. Thus (-3 mm) flux produced during closed loop crushing and screening system is transported to the four bins in the base bin building through four high angle conveyors (vertical conveying system) due to space constraint and reversible shuttle conveyor. Vibro feeders are used to regulate the feed to crushers and screens.

Coke Circuit

Coke fines arising from the existing plants and purchased coke unloaded in the ground hopper are conveyed to six bins in the coke fines bunker building through a series of conveyors. Coke from the coke fines bunker building is fed to the coke crushing building through high angle conveyors. The coke is screened for 3 mm separation using flip flop screens and the oversize material (+3 mm) is discharged into four surge bins with the help of a reversible shuttle conveyor. Coke stored is crushed with the help of rod mills (2W+2S) installed below respective surge bins. Crushed coke (-3 mm) and screened out (-3 mm) is conveyed to the four bins in the base bin building.

Mill scales brought to the underground hopper by truck and sinter fines stored in stock house are conveyed to the four bins in the base bin building (two, each).

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