JSPL Project

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“A Detailed Study of Pellet
Plant at JSPL Limited.”
Submitted To: Mr. D. Palanisamiy.
H.O.D (MECHANICAL) JSPL LTD., BARBIL, ODISHA
Submitted By: Mr. Abinash sahu.
Bengal College Of Engg. & Tech., Durgapur, West Bengal.

“A Detailed Study of Pellet Plant at JSPL Limited.”
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CERTIFICATE
This is to certify that Mr Abinash sahu, B.Tech student of Bengal
College of Engg. & Tech., Durgapur has undergone a summer Training
at JSPL Ltd during the period 16-06-2014 to 15-07-2014. During this
training he has successfully completed a project on “A DETAILED
STUDY ON PELLET PLANT” under my guidance.

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PREFACE
This report is a sincere effort to reveal the expression of my
experience, observation and study apart from my regular
academic curriculum .This industrial training at JSPL Ltd. Barbil
in the Department of WORKS was the first time real experience
that has helped me to gain practical knowledge of engineering and
learn the discipline and safety of working in industries.
I tried to get an overview of complete working of the company in
this short time.

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ACKNOWLEDGEMENT
I take this opportunity to thank several persons who were a great help in making
this project a success.
I am grateful to Mr Rakesh Parmar for his excellent guidance and co-operation
during my summer training. He gave me sufficient time between his tight
schedules and helped me wherever I needed. I would have never succeeded without
his friendly but disciplined attitude.
I would like to thank Mr Jalal Ahmad Khan, Mr Arghya Sarkar, Mr Prakash
Mahanty and all those employees of JSPL Ltd. whose friendly behaviour never
let me feel an outsider in the industry throughout the whole period.
Finally, I would like to pay my sincere thanks to Mr D.Palanisamiy for his sincere
co-operation. Because of their good relationship with every department in the
organisation, they brought me in contact with several important people in the
organization that helped me a lot.

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ABOUT THE COMPANY
(Mr. Naveen Jindal) (Shri O.P. Jindal)
CHIRMAN FOUNDER
With its timeless business philosophy JSPL is primed to not merely survive but
win in a marketplace marked by frenetic change. Indeed, the company’s
scorching success story has been scripted essentially by its resolve to innovate,
set new standards, enhance capabilities, and enrich lives and to ensure that it
stays true to its haloed value system. Not surprisingly, the company is very much
a future corporation, poised to become the most preferred steel manufacturer in
the country.
JSPL is an industrial powerhouse with a dominant presence in steel, power, mining and infrastructure sectors. Part of the US $ 18
billion OP Jindal Group this young, agile and responsive company is constantly expanding its capabilities to fuel its fairy tale journey
that has seen it grow to a US $ 3.6 billion business conglomerate. The company has committed investments exceeding US $ 30
billion in the future and has several business initiatives running simultaneously across continents.
Led by Mr. Naveen Jindal, the youngest son of the legendary Shri O.P. Jindal, the company produces economical and efficient
steel and power through backward and forward integration.
JSPL operates the largest coal-based sponge iron plant in the world and has an installed capacity of 3 MTPA (million tonnes per
annum) of steel at Raigarh in Chhattisgarh. Also, it has set up a 0.6 MTPA wire rod mill and a 1 MTPA capacity bar mill at Patratu,
Jharkhand, a medium and light structural mill at Raigarh, Chhattisgarh and a 2.5 MTPA steel melting shop and a plate mill to
produce up to 5.00-meter-wide plates at Angul, Odisha.
Expansion Projects
Chhattisgarh
A 7 MTPA integrated steel plant in phases, a 2 MTPA cement plant and a 1600 MW captive power plant is being set up at Raigarh
with a total investment of over US $ 7 billion.

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Jharkhand
A 12 MTPA integrated steel plant with a total investment of US $ 10 billion is being set up in the state. In the first phase, the
company is setting up a 6 MTPA integrated steel plant and a 1320 MW captive power plant at Patratu.
Odisha
A 12.5 MTPA integrated steel plant is being planned in the state. In the first phase, a 6 MTPA integrated steel plant at an
investment of US $ 6 billion is coming up in Angul.
Alongside contributing to India's growth story the company is driving an ambitious global expansion plan with its sights set on
emerging as a leading transnational business group. The company continues to capitalize on opportunities in high growth markets,
expanding its core areas and diversifying into new businesses. In Oman (Middle East), the company has set up a US $ 500 million,
1.5 MTPA gas-based Hot Briquetted Iron (HBI) plant. It has now added a 2 MTPA integrated steel plant.

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BARBIL
The company's pellet plant at Barbil has a total installed capacity
of 9 MTPA production for different grades of pellets. The plant is of
dry grinding, with recuperation type of straight grate technology.
The basic engineering of the plant has been designed by M/s Metso (earlier known
as Aker Kvaerner), USA considering the input raw material quality and product
requirement. The facility houses material handling equipment of wagon trippler,
stacker reclaimer engineered by M/s Mecon based on in-house studies for material
handling and feasible logistics.
The commercial production of the pellet plant commenced at Barbil in December,
2009. As the company is actively engaged in the promotion of alternative fuels, the
pellet production will be through coal gasification, replacing furnace oil as fuel. This is
an innovative initiative, first-of-its-kind in the world using circulating fluidised bed
technology for coal gasification.
In April 2014, the company has started producing pellets from its second unit of 4.5
MTPA iron ore pelletisation plant at Barbil. The plant designed by M/s Metso
(earlier known as Aker Kvaerner) utilizes wet grinding process. The project was
commissioned in a record time of 23 months from the first pilling work.

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LAYOUT PLAN OF PELLET PLANT

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1st • RMHS(Raw Material Handling System)
2nd • DRYER
3rd • BALL MILL
4th • MIXER
5th • BALLING DISC
6th • INDURATING MACHINE
7th • HLS BUILDING
8th • FINAL PRODUCT
PROCESS CHART OF PELLET PLANT:-
PROCESS OF FLOW OF PELLETISATION IN JSPL, BARBIL:–
GREEN BALLS
Oversize and under size
Coal Green balls 9.16 mm
Iron ore fines water
Bentonite
Crushed limestone
Mixing unit Balling SCREENS
Indurating machine
Cooling

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PELLETISATION: -
Pelletisation is a process of compressing or molding a
material into a shape of a pellet. A wide range of different material are pelletized
including chemical compounds, iron ore, animal compound feed and more.
PROCESS:–The process of pelletisation combines mixing of raw material forming the pellets
and thermal treatment baking the soft raw pellets to hard spears. The raw materials is rolled into a
ball then fired in a kiln to sinter the particles into a hard spear.
The configuration of iron ore pellets are packed spheres in the blast furnace allows air to flow in
between the pellets, decreasing the resistance to the air that flows up through layers of material
during the same. The configuration of iron ore powder in the blast furnace is more tightly packed
and restricts the air flow. This is the reason that iron ore is preferred in form of pellets rather than
in form of finer particles. Iron ore fines are generated by crushing and grinding lump ore. If the
lump is of low grade that is low in iron content and higher in impurities such as SiO2 and Ai2O3 ,
the fines must be benefitted before being feed to the blast furnace.

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Steps of Pelletising:-
Iron Ore Pellets
are made from
a variety of
different ores.

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Pelletisation Process Flow with Dry Grinding

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RMHS :-
STOCK YARD

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 Arightamount ofinputfor anindustryis necessary inordertoproduce aneffective
output. In our pellet plant, we are getting the iron ore fines as the input from
SHARDA mines, we need an effective handling system for the passage of the raw
material from NDMC to our plant. Hence we are making use of conveyors for
serving that purpose.
 Generally during mining different sizes of iron ore are being produced with
different quantities of iron content. In this aspect large amount of mines are
produced during mining. These are 9-10 mm fines and these fines comes from
screening plant of SHARDA mines through their conveyors then with the help of
stacker these fines are being dumped at their stockpile.
 There are 4 types of bin classified as below :
 Bin-1-iron ore
 Bin-2-iron ore
 Bin-3-lime stone
 Bin-4-coal
oSpecification of bin:-
 Made: - MS pellet
 Capacity:-2200 tonne
 Speed:-300 to 400 TPH
o Specification of motor:-
 Kw:-7.5
 RPM:-1450

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 Pf:-0.85
 Wt.:-64.0kg
 AMB:-50 degree Celsius
oSpecification of gear box:-
 Input rpm:-7.5
 Oil grade:-460
 Ratio:-112.0
 Output rpm:-13
oLime feeder specification:-
 Pulley centre to centre:-10,000mm
 Drive motor:-1.5 kw
 Total assay weight:-5520 kg
 Total weight of heaviest part:-6100kg
 size of largest part:-10535*1160*770mm
 Feed rate:-20 TPH
 It consist of 8 conveyors. Each bin has 2 conveyor i.e. ,
 CF 1, CF 2 – Coal conveyor
 LF 1 , LF 2 – Lime stone conveyor
 OF 1,OF 2,OF 3,OF 4 - Iron conveyor

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oSpecification of belt conveyor-
RMHS CONVEYOR BELT
DRYER
 TPH-360
 Width- 800 mm
 Belt grade- HRT
 Pulley: - head pulley, snaupe pulley, bend pulley, take-up pulley, pressure
pulley, tail pulley.
 RMHS is a system where the raw materials like iron ore fines, lime stone, coal are
added at the proper or at the required quantity. Here the size of the iron ore fines is
about 7mm.
Then the raw materials are moved to the dryer section through the belt conveyor.
oSpecification of belt conveyor :–
 TPH-360
 WIDTH-800MM
 Belt grade-HRT
 Pulley: - head pulley, Snaupe pulley, bend pulley, take-up pulley, pressure
pulley, tail pulley.
oLime stone specification :–
 Type of weight feeder:–TLD 80/1.1v
 Pulley centre to centre:–1000mm
 Belt width:– 0.8m

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 Drive motor:– 1.5 kw
 Total assay weight:- 5520 Kg
 Total weight of heaviest part:–6100 kg
 Size of largest part :–1035*1160*770 mm cube
 Feed rate :– 20 TPH
 Then, the raw materials are sent to the dryer section.
DRYER :-

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 Thedryerofasinglecomponentconsistingofashellwithendsealsupportedrollers.Dryer
shell is lined with sail hard material liners having a particular profile to suit the of shell
either bolted or welded construction to provide sufficient contact with the hot flue gases
passing through the shell and improve the drying efficiency.
 Essential features of dryer are :-
 A cylindrical dryer shell of welded construction roller from tested quality steel plates.
 The feed end portion consists of a feed chats receiving material from main conveyor. The
feedchuteisfabricatedoutofcarbonsteelplatesandlinedwithsteelwearingliners.Thefeed
end is provided with a sealing arrangement to prevent any material over flowing out of the
shell.
 Two sets of supporting rollers are provided on which the dryer shell is supported with. The
dryer drive is through a reduction gear box and a pinion with girth gear arrangement. Girth
gear is mounted on a shell flange steel and mounted on a counter shaft supported on anti-
friction bearing.
 A discharge end assembly consist of a plate fabricated discharge housing with sealing
arrangement and single flop dompers.An auxiliary drive is provided to facilitate rotation of
the dryer for initial starting maintenance work.

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o DRYER DETAILS :–
 Size – 5.2m*
35m long
 Capacity – 360 TPH
 Feed moisture – 12%
 Product moisture - <1%
 Effective length – 35m
o SHELL:–
 Plate thickness – 36,56,25 mm
 Plate material – IS 2002
o INSIDE OF SHELL :–
 Type :– Lifter and liners
o GIRTH GEAR :–
 Type of gear :- spur
 no. of teeth :– 212
 width of the gear :– 550mm
 module :– 36
 gear material :– cast steel
o SUPPORT ROLLERS :–
 Diameter of roller :– 1400 mm
 Width of the roller :– 575 mm
o MAIN GEAR BOX :–
 Capacity :– 375 kw

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 Reduction ratio :– 42:1
 Make :– fleder
o MAIN MOTOR :–
 speed :– 980 rpm
 Make :– kirlosker
o AUXILARY GEAR BOX :–
 Reduction ratio :– 25:1
 Make :– flender
o AUXILARY MOTOR :–
 Speed :– 980 rpm
 Make :– kirlosker
o PARTS OF DRYER :–
1. Dryer internals
2. Supporting roller
3. Shell with
4. Drive Arrangement
1.DRYER SHELL:–The shell is the main part and at the same time the heaviest
partofthedryer.Theshellbodyismadeofsteelofplatesbyfabricationandwelding.
2. DRYER INTERNALS:–The dryer shell is protected on the inside surface by
a liningconsisting of the liners plates. These liners are of SAIL hard steel materialand are able
to withstand wear in the shell. These liners are secured through bolting arrangement to the

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inside of shell for major part of the total length of shell. At the feed and disc end liners are spot
welding with the shell.
There are lifters ofvariousshapesandsize alongthe lengthofshelltoliftanddropthe
material to provide sufficient contact with hot gases flowing through the shell. This is a spiral
lifter to push the materials feed from the feed and to a sufficient length of the shell.
3. SUPPORTING ROLLERS: – Two sets of supporting rollers arrangements
are provided to support the rotating dryer shell. The tyres are locked into the dryer shell shall
roll on these rollers .These tyres act as two supports for the dryer arrangement during idle and
operating condition of the system.
4. DRIVE ARRANGEMENTS: – The dryer drive arrangement comprises of
a girth gear mounted in the dryer shell by means of spring plates. A forged steel pinion rotates
the girth gear. Pinion is mounted on counter shaft which is supported in spherical roller
bearings. An HT motor through a gear box drives the pinion for details of girth gear box, refer
technical data as dryer sheet.
o DRYER DESCRIPTION: – The rotary dryer is used to reduce or minimize the
moisture content of the material. It is handled by bringing it to direct contact with heated gas. The
dryer slopes slights so that discharge end is lower than the material feed end in order to convey
the material through the dryer under gravity. Material to be dried by the dryer enters the feed end
of the dryer and as the dryer rotates the material is lifted up by an internal peripheral flights
arranged to lift distribute and transport the material. The hot gas induces the evaporation of
moisture. The heat loss to the material and evaporation of vapour reduces the gas temperature
rapidly.
Each rotary dryer consist of a fabricated feed hooper , weigh feeder , rotary dryer , hot air generator belt
conveyor , cyclone and a wet scrubber for de–dusting the system.
Thefeedendportionsconsistofafeedchutereceivingmaterialfromthemainconveyor.Materialfromhooper
will be to dryer in required portion by electric weigh feeder. This feed end is provided with a sealing
arrangement to prevent any material overflowing out of the shell. Two sets of supporting rollers arrangement

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onare provided onwhich the dryer shell is supporting with dryer drive is throughan induction motor through
areductiongearboxandapinionwithgirthgeararrangement.Girthgearismountedonshellflangebymeans
of spring plate arrangement. The pinion is mounted on counter shaft supported on anti-friction bearing. A
discharge and assembly consist of plate fabricated discharge housing with sealing arrangements and single
flap dampers. An auxiliary drive is provided to facilitate slow rotation of dryer for initial starting or during
maintenancework.Theproductofdryerisconvertedtoahopperbyabelt conveyor,enterpre–demistbaffles
and chevron type demister. Slapped bottom minimizes any built up. Slurry is discharged through the bottom
and devatered scrubbed gases are exhausted via the outlet. Set points for temperature is 62 0
c. The slurry
received from scrubber is continuously discharged to thickner.
o HYDRAULIC THRUSTER OPERATION:–During rotation dryer running
scratchmarksareleftonrollersurfacecausingfasterwearoftyreandsupportingrollers.
The sliding of the dryer shell may also cause damage to drier inlet and outlet ends. To
minimizethiseffecthydraulicthrustersareprovidedwhichareinstalledbeneaththeklin
tyre and are equipped with hydraulic cylinders and power pack. Hydraulic thrusters are
used to make kiln forward or backward at very slow speed (approximately 50 to 60 mm
in 8 to 10 hrs.) and thus avoid damage to tyre and supporting rollers.
Hydraulicoilsuppliedtocylindersthroughpipelinebyelectricallyoperatedhydraulicpowerpack.
There are two limit switches are positioned such that of maximum of 100mm of stroke length can
be operated. But normally stroke length of 50 to 60 mm is adequate.
o STARTING PROCEDURE FOR ROTARY DRYER :–
Reading of all drive to start as per above sequence.
Girth gear spray and GB lubrication system.
Material conveying equipment drive.
Material discharge equipment drive.
Availability of iron ore in feed hopper of a least two hours operation of system.

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o START SEQUENCE :–
Product conveyor belt.
Air slide blower.
Cyclone RAVs.
Gear box oil cooling system if provided.
o STARTING AND IDLER RUNNING DRYER:–
Check and tighten all foundation bolts, holding down bolts and fastening bolts.
Check the grade quantityoflubricateateach lubricatingpointandensure that theyare
as per recommendations.
Make certain that all moving parts have sufficient running clearance.
Check the direction of rotation of all motors.
Check also water circulation system for the main gear box.
Inspect all the hopper and receiving SILOs and clean them if necessary.
o NORMAL SHUTDOWN PROCEDURE :–
Reduce the material feed rate gradually.
Stop the material feeding group.
Stop the dryer drive.
Stop the ID fan.
Stop the product transport group.
o SAFETY :–
Ensure functioning of emergency stops.
Ensure no leakage of coal gas, hence otherwise LPG gas.
Use proper safety equipment while on job.

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MIXER :–
In the mixture the iron ore fines is coming from the silo through the shut off bin with
the help of aeration blower. Then the raw material is sent to the paddle mixture. Before
reaching to the paddle mixture Bentonite and oxide fines are added to the iron ore and
also mixed ore slurry is sent to the paddle mixture. After mixing it is sent to the balling
disc.
 The capacity of mixture is 600TPH.
 Belt width – 1000 mm
 Speed – 1.25 m/s
 Materials – ores + additives

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Ball Mill :–

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o SPECIFICATION OF BELT CONVEYOR :-
 TPH – 300
 Width – 950 mm
 No. of belt conveyor used – 2
DESCRIPTION: – Ball mill is used for grinding iron ore to the required pelletizing fines of
80% to 270 meshes. Earlier dried iron ore is ground successively in double compartments by the
principle of impact grinding before discharging to the chart screen which segregates the correct
sizefines.Theproductofairslidethenconveysthesetothebucketelevatorwhichfinallydischarge
to the silo for storage.

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 DIA – 5.486 M
 EGL – 12.8 M
The ball mill is assisted by cyclones and bag filter for dust control. The cyclone discharge rejoins
the product along with elevator. Bag house discharge in elevator while the bag filter discharge is
sent to clean up thickener for reutilization. The control of ball mill is facilitated by DLS
(Distributedcontrolsystem)whichhelpsinoptimizationofgrindingprocessalongwiththestorage
of identical data for future analysis. The ball mill operator is of course a vital link for smooth
operation and finely maintenance of the equipment.
o BALL MILL MAIN DRIVE :–
 Gear box – 2
 Lubrication pump – 15.5 / 10.9
o BALL MILL – 1 MAIN DRIVE :–
 Gear box – 2
 Lubrication pump – 25.5/10.9

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o 3 – PHASE INDUCTION MOTOR :–
 KW (HP) – 3750/5027
 RPM – 994
 Volts – 6600
 Amps – 391
 Fred (HZ) –50
 AMB – 48
 Weight – 19560 kg
o BALL MILL – 2 MAIN DRIVE GEAR :–
 Gear box – 2
 Lubrication pump KW – 5.5
A – 10.9
RPM – 945
o BALL MILL 2 MAIN DRIVE :–
 KW – 3750
 A – 401
 RPM – 994
o BALL MILL 2 INCHING DRIVE :–
 KW – 551
 A – 96
 RPM – 1483
 Debarring – 6317

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Grinding: – The iron ore grinding facility of parallel streams with grinding
capacity of 310 TPH (1% moisture). Each stream comprises of the major equipment as one
ball mill, cyclone, separator, bag filter, and ID fan. Besides those two air slides have been
used to conveying the solid material to the bucket elevator area as final product of the mill.
Bag filter is also supplied to function as dust separation from the main solid product lines.
Each milling unit will be sect ionized, so that it can operate on a standalone basis. The
equipment is tagged under two series namely 321 and 322 denoting mill circuits
respectively.
ABBREVATIONS & DEFINATIONS :–
 DCS – Distributed control system
 PLC – Programmable logic controller
 LCP – Local control panel
 MCC – Motor control Centre
 PV – Process value or present value
 SP – Set point
 MV – Manipulated or controlled variable in a control action
 LBP – Local push button at field operating system
 TPA – Tones per annum
 TPH – Tones per hour
 VFD – Variable frequency drive

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SYSTEM OVERVIEW – The ironore grindingfacility will be the integral component
of the system. The operation of the facility will be undertaken from the PLC/DCS.
Thegrindingfacilitycentralsystemwillbeprimarilyresponsibleforundertakingprocessescontrol
functions. The grinding facility controlsystem shall be fully automated as possible with necessary
for any operator intervention in the normal operation of the plant being kept to a minimum and
even less intervention will be required by field technically. Process control, motor control, device
control, start up and shut down, interlocking to degree commence rate with level of field
instrumentation and I/O devices from the control room.
OPERATIONAL MODES – The main power supply the MCC is from JSPL. The
system is operated in three different modes & these are as follows:–
 REMOTE AUTO
 REMOTE MANUAL
 LOCAL (LPB)
Only one mode of operation is selected at any one point of time.
REMOTE AUTO – Thisisthepreferredmodeofoperationoperatedthroughthecontrol
system. In this mode of operation the mill operator must select auto mode in PLC/ DCS &
issue a start command to DCS/PLC for acknowledgement to start the remote operation from
DCS/PLC.Theoperatorcaninitiatetheorderlystartorstopofarelatedsequenceofequipment
by selecting the appropriate group in control system, up on operator command, the control
system software program willstart all equipment within the selected groupsequence allowing
appropriate time delays to verify conditions of all interlock protective devices.
EQUIPMENT GROUPING – The various sections of the plant have been assigned
group numbers to assist with definition of discrete areas of the plant such that these can be
started up individually in presentation for overall plant startup. These numbers will also be
used for plant startup & commissioning planning activities. Details of the groups are included
in the relevant sections.

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BALLING DISC :–
The balling disc is used to form pre – wetted ore into nominal 1
/2 inch diameter balls called
“green balls” or “green pellets”.
 The strength of green pellet is determined by the natural surface tension of water &
other adhesive forces using capillary action of water in the spaces between the small
particles of the ore.
 Thefineristhematerial,themoreistheadhesiveforceswhicharecapableofforming
strong agglomerates.
 The process parameters necessary for a controlled continuous disc operation are :–
1. Constant disc feed rate
2. Constant disc feed moisture
3. Constant material size (%minus 45 microns)
4. Constant material fineness

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5. Disc speed rate, speed is more dependent for many hematic ores. A speed of
between 6 and 6.5 RPM has yielded the best results and would be a good
starting point to begin the balling.
6. Feed location
7. Water spray location (for additional moisture if needed)
8. Disc side wall height
 In order to sustain controlled continuous operation, it is also necessary to maintain the
bottomandsidescrapperssothatauniformsmoothandlevelcoatingismaintainedonthese
surfaces. Ridges on the bed change the pattern of the material and and cause breakage of
the pellets.
o BALLING DISC SPECIFICATION: –
 No. of disc used – 6
 Gear box – Make – Flender
 Oil type – Servo mesh oil
 Oil capacity – 260 Ltr
 1– n2/ n1 29– 1
 Motor – Make–A–B–B
 Type – 3–phase induction type
 Power – 220 kw / 300 hp
 RPM – 1486/ amp – 370
 Balling disc – Make – Roto auto
 RPM – 0-9
 Dia – 7620 mm
 Angle variation range – From 420
to 510

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 RIM height – 654 mm
 Bearing oil / quantity – Gastrol tribol (1100 / 1500)/ 160 ltr
 Grease for spray – Petron gear shield / 180 ltr
THICKENER: – Thickener is a process of reducing the liquid content and
thereby increasing the solid density within the slurry. The mechanism is all based on
the settling rate. The settling is even controlled by the rotation of the rake arms. The
rotation of rake arms makes the denser particles to be dragged to the central portion of
light particles move to the periphery. Almost clear water is taken as the overflow.
 DIA – 35 M
Thickener is essentially a conical tank like structure. It has a central shaft at the axis of
the conical tank. The rake arms are attached to a sprocket that rotates about the central
shaft. There are four arms (two long and two short) which are 900
apart. The longer arms
are responsible for the settling action. The shorter arms mainly deal with the central
portion. But the central area is a denser portion subjecting to more torque on arms. The
shorter arms handle such denser matter reducing torque on long arms.
There are two motors which rotate the central sprocket. There is hydraulic lifting
mechanism which is used for lifting the rake arms. Whenever the production is stopped,
the denser material settles down and thereby the rake arms experience high torque when
starting again. So the rake arms are lifted such that they are above the high density slurry

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and experience less torque during subsequent start up. When the process is engaged,
slowly the rake arms are lowered.
Theinletforthethickenerisatthecentralportionwheretheslurrypassesbyapipe.There
is a pass way to walk to the central portion of thickener in order to meet the maintenance
of the drive and lifting unit.
COMPRESSOR: – There are 4 types of compressor working in JSPL
plant.
1. Pneumatic conveying compressor
2. Instrument air compressor
3. Atomizing air compressor
4. Pressuring air compressor
o DETAILS – Pneumatic conveying compressor
o LISTS AND PARAMETER OF GA – 132 W – FF LIMITS
COMPONENTS MAXIMUM MINIMUM
COMPRESSOR OUTLET 7.5 BAR
D.P OIL SEPARATOR 0.45 BAR
D.P AIR FILTER - 0.030
OIL INJECT PRESSURE 2.5 BAR
TEMPERATURE
COMPOUND OUTLET
700
C
ELEMENT OUTLET 1000
C
COOLING MEDIUM 400
C
OIL SEPARATOR 1000
C
DRYER P D P 150
C
An air compressor is a device that converts power (usually from an electric motor, a diesel engine
or a gasoline engine) into kinetic energy by compressing and pressurizing air which on command
canbereleasedinquickbursts.Therearenumerousmethodsofaircompressiondividedintoeither
positive or negative displacement types.

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Centrifugal compressor uses a rotating disk or impeller in a shaped housing to force the gas to the
rim of the impeller, increasing the velocity of the gas. A diffuser section converts the velocity
energy to pressure energy. They are primarily used for continuous stationary service in industries
such as oil refineries, chemical and petro chemical plants and natural gas processing plant.
SILO – Silo is a big stock bin where the material coming from the ball mill is kept
in the form of stock so that if the feed is stopped from the feeder due to some system
failure then also we can continue running the plant from stock also. Silo has a capacity of
3MT of materials at a time.
INDURATING MACHINE:-

37
Indurating Furnace

38
Indurating means hardening by means of heat. It is the heating stage in the pellet making process.
The correct sized green pellet coming out of the balling discs are indurated to a compressive
strength of 250kg/sq. Meter on a straight travelling grate having a reaction area of 4m wide*116m
long*. The travelling grate consist of an endless chain of pellet cars that continuously move on
tracks. The feed machine is maintained in the form of the uniform bed height which is ensured by
auto controlof machine speed. Itshould be noted that in order toavoid thermal shock to grate bars
and pellets, green feed is always charged over a layer of already indurated pellets called hearth
layer. As the machine moves, the green pellet on the pellet cars are subjected to various zones for
proper heating and subsequent cooling gradually. There are different zones given as follows:-
1. Up draft zone
2. Down draft zone
3. Pre-heat zone
4. Firing zone
5. After heating zone
6. Cooling zone 1
7. Cooling zone 2
 NO. of pellet cart – 177
 No. of burner – 34(n-17,s-17)
 Pellet car moves,
1. Down – slide bar
2. Upper side – spring seal bar
o FAN USED:-
1. Cooling fan
2. Recuperation fan
3. Udd fan (up daft duct fan)
4. Wind box exhaust fan
5. Hood exhaust fan

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o Up-draft zone: – Here Ducts comes from cooling zone 2 to UDD fan. It blows into
the up daft zone and the duct removed from the up-draft zone by the hood exhaust fan.
 Temperature – 400 0
C
o DOWN DRAFT ZONE: – In down draft zone ducts come from the firing zone.
After use the duct is removed from the DDZ by the wind box exhaust fan, the temperature
is about 4000
c.Both the hood exhaust fan and wind box exhaust are connected to the
corresponding ESPs to be provided to the chimney.
o FIRING ZONE: – There are different types of method used in pellet plant are given
below:-
Gas firing (LPG)
Fuel firing
Co – firing (carbon monoxide gas)
Then the final product will be obtained. This is the method for pelletisation process to get the
pellet.
Process Gas Flow

40
BIBLIOGRAPHY:-
www.wikipedia.com/iron pellet plant
www.jspl.co.in
…THANK YOU…

JSPL Project

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