SINTER PLANT WASTE HEAT RECOVERY PROCESS AND ITS BENEFIT IN INDIAN STEEL INDUSTRY

Sinter waste heat recovery system is a process onwards gainfully utilization of untapped waste heat from sinter plant for generating steam either for process steam requirement or in turn can produce power for plant. The saving in power will reduce the cost of production of sinter and in turn, the cost of steel. Sinter waste heat recovery is a very promising option for the future adoption in Indian steel industry. The current statuses of this technology in various countries are also under adoption. Finally, the potential of implementation in Indian steel has been discussed and its challenges as well as opportunities involved.

MEROS Dust Quality of Different Plants and Its Potential Further Uses

Sintering is a process of agglomeration of fine particles into porous sinters for blast furnaces. During the sintering process, high volumes of sinter plant gas containing high loads of dust, SO2 and NOX and toxic pollutants, such as heavy metals (e.g., Hg, Pb, Cr and Cd) and PCDD/F, are emitted. The objective of this study was to characterize dusts of different plants as the basis for suggestions of reutilization and treatment options. Dusts, eluates and residues were produced and DOC, T-N, ions and heavy metals were analyzed. The results show that dusts from different plants are very similar in terms of DOC, T-N, Mg, Ca and many heavy metals and only differ in criteria such as suspended solids and ions such as K, Na, Cl and SO4. Based on the high levels of alkalis and low levels of iron, direct recycling into the sinter or furnace process is not recommended. The dissolution of the soluble substances in water reduces the MEROS dust by 90% of the weight and extracts the alkalis. The remaining wastewater needs to be treated to reduce DOC, T-N and some heavy metals. The solid residues can be recycled into the sinter to reduce potential PCDD/F, which are attached to the activated carbon.

Usulan Perbaikan Mixing Design Produk Sinter Ore dengan Menggunakan Metode Simpleks

Sinter ore merupakan produk setengah jadi dalam pembuatan baja. Produk ini dihasilkan dari perpaduan (mixing) raw material dibagian sinter plant untuk mendapatkan karakteristik produk baja yang berkualitas. Berdasarkan hasil identifikasi masalah di bagian Sinter Plant, ditemukan bahwa proses produksi produk sinter ore masih belum efisien. Hal ini dibuktikan dari komposisi material hasil mixing design produk cenderung melebihi target properties proses mixing design yang diinginkan oleh perusahaan. Penelitian ini bertujuan untuk mencari nilai efisiensi biaya produksi produk sinter ore dan dapat mencapai target properties produk sinter ore yang ditetapkan oleh perusahaan. Penelitian dilakukan dengan menggunakan data karakteristik produk yang menjadi target properties dalam mixing design produk sinter ore tahun 2019. Perhitungan mixing design dengan menggunakan metode simpleks. Pengolahan data dengan menggunakan metode simpleks dilakukan dengan cara eliminasi secara iteratif sebanyak 5 kali perhitungan sampai diperoleh solusi optimal. Penerapan metode simpleks dalam pengolahan mixing design produk sinter ore menghasilkan nilai efisiensi yang cukup signifikan bagi perusahaan. Nilai efisiensi yang dapat dicapai sebesar 1.050.210 USD berdasarkan penurunan biaya mixing design dari semula sebesar 20.445.600 USD menjadi sebesar 19.395.390 USD. Pencapaian target properties komposisi material hampir mendekati target yaitu fines ore A sebesar 0,8997, fines ore B sebesar 0, fines ore C sebesar 0,0027, concentrate sebesar 0,0201, dan sub material sebesar 0,1627. Hasil penelitian menunjukan bahwa penerapan metode simpleks dapat menghasilkan solusi optimal bagi perusahaan, baik menyangkut pencapaian keuntungan maupun efisiensi biaya.

Bulk Raw Materials Handling and Blending Techniques of Sinter Plant: A Case Study of Ajaokuta Steel Company Limited, Kogi State, Nigeria

Bulk raw materials handling plant and sintering plant preparatory plants are established to receive, blend, stockpile, prepare and supply specified grades of raw materials for smooth operations of iron making plant (Blast furnace), steel making plant (Basic oxygen converter) and lime Plant(calcinations plant). The study discusses bulk raw materials handling and some general problem of scientific analysis and documentation of basic equipment details, stockyard facilities, bulk materials transport systems and sinter processes, for the general knowledge and operational procedures of these plant for effective and efficient operational processes for optical results. Iron ore concentrate supplied from the mines to some extent fluctuate in their chemical composition as a result of the nature of the deposit with various factors controlling beneficiation processes and addition of metal-bearing materials collected as a waste product from the Rolling Mills, Blast Furnace and Sinter Plant which must be recycled through Iron ore concentrate stockyard. The part of the sinter mixture is melted at a temperature about 1300-1480 ° C and a sequence of reactions shaping the sinter cake to be loaded into the blast furnace to produce iron from a pig.

Hydrometallurgical Processes for the Recovery of Metals from Steel Industry By-Products: A Critical Review

The state of the art for the recovery of metals from steel industry by-products using hydrometallurgical processes is reviewed. The steel by-products are different slags, dusts, and sludges from a blast furnace (BF), basic oxygen furnace (BOF), electric arc furnace (EAF), and sinter plant, as well as oily mill scale and pickling sludge. The review highlights that dusts and sludges are harder to valorize than slags, while the internal recycling of dusts and sludges in steelmaking is inhibited by their high zinc content. Although the objectives of treating BF sludges, BOF sludges, and EAF dust are similar, i.e., the removal of zinc and the generation of an Fe-rich residue to be returned to the steel plant, these three classes of by-products have specific mineralogical compositions and zinc contents. Because wide variations in the mineralogical composition and zinc content occur, it is impossible to develop a one-size-fits-all flow sheet with a fixed set of process conditions. The reason for the interest in EAF dust is its high zinc content, by far the highest of all steel by-products. However, EAF dust is usually studied from the perspective of the zinc industry. There are not only different concentrations of zinc, but also variations in the all-important ZnO/ZnFe2O4 (zincite-to-franklinite) ratio. In many chemical processes, only the ZnO dissolves, while the ZnFe2O4 is too refractory and reports to the residue. It only dissolves in concentrated acids, or if the dust is pre-treated, e.g., with a reductive roasting step. The dissolution of ZnFe2O4 in acidic solutions also brings significant amounts of iron in solution. Finally, due to its high potassium chloride content, sinter-plant dust could be a source of potassium for the fertilizer industry. Graphical Abstract

Pengaruh Budaya 5R dan Kinerja Karyawan terhadap Lingkungan Kerja di Sinter Plant PT.XYZ

Abstract— PT. XYZ is one of the large and multinational companies engaged in steel production in Indonesia and in the first half of 2019 PT. XYZ faces a challenge that is the many employees in the sinter plant do not implement the 5R culture. Sinter plant is the main supplier plant for the blast furnace plant at PT. XYZ which functions to combine a raw material mixture at high temperatures to produce a product known as sinter ore. This research was conducted at PT. XYZ. The data obtained was then processed and analyzed using the SPSS version 26 program. Based on the results of data processing and analysis, it was found that all indicators used in this study had good validity and reliability. The results of data processing and analysis in this study also found that 5R culture (X1) and employee performance (X2) had an influence on the work environment (Y).Keywords— 5R Culture, Employee Performance, Work Environment. Abstrak— PT. XYZ adalah salah satu perusahaan besar dan multinasional yang bergerak di bidang produksi baja di Indonesia dan pada semester pertama tahun 2019 PT. XYZ menghadapi tantangan yaitu banyaknya karyawan di sinter plant yang tidak melaksanakan budaya 5R. Sinter plant merupakan plant pemasok utama untuk blast furnace plant di PT. XYZ yang berfungsi untuk menggabungkan suatu raw material mixture pada temperatur tinggi sehingga menghasilkan produk yang dikenal dengan nama sinter ore. Penelitian ini dilakukan di sinter plant PT. XYZ. Data yang didapat kemudian diolah dan dianalisis menggunakan program SPSS versi 26. Berdasarkan hasil pengolahan data dan analisa tersebut didapat bahwa semua indikator-indikator yang digunakan dalam penelitian ini memiliki keabsahan (validitas) dan keandalan (reliabilitas) yang baik. Hasil pengolahan data dan analisa dalam penelitian ini juga mendapatkan bahwa budaya 5R (X1) dan kinerja karyawan (X2) mempunyai pengaruh terhadap lingkungan kerja (Y).Kata kunci— Budaya 5R, Kinerja Karyawan, Lingkungan Kerja.

ANALISA EFEKTIVITAS PROSES SINTER PLANT DENGAN PENDEKATAN LEAN MANUFACTURING

Divisi sinter plant adalah perusahaan yang memproduksi sinter ore sebagai bahan baku utama pembuatan hot metal. Dalam proses produksinya divisi sinter plant masih terdapat pemborosan sehingga proses produksi menjadi tidak efektif. Penelitian ini bertujuan untuk mengidentifikasi pemborosan yang terjadi dalam proses sinter ore dan memberikan rekomendasi perbaikan mengurangi pemborosan yang terjadi. Penelitian ini menggunakan konsep lean manufacturing dengan menggunakan Value Stream Analysis Tools berdasarkan kuesioner yang diberikan kepada empat supervisor dan Root Couse Analysis. Berdasarkan hasil penelitian didapatkan pemborosan (waste) yang paling dominan dan mempengaruhi proses pencampuran material yaitu over process (60 %) dan motion (40 %). Perbaikan dalam over process dilakukan dengan cara mengganti fasilitas mixing dengan belt conveyor pada proses pencampuran material mampu meningkatkan efektivitas proses. Pergantian ini juga berdampak pada hilangnya proses motion dan berdampak pada peningkatan nilai process cycle efficiency. Penerapan lean manufacturing secara terus akan menghilangkan pemborosan yang terjadi pada proses produksi yang berdampak pada peningkatan kinerja operasional prusahaan.