Sinter plants agglomerate iron ore fines (dust) with other fine materials at high temperature, to create a product that can be used in a blast furnace. The final product, a sinter, is a small, irregular nodule of iron mixed with small amounts of other minerals. The process, called sintering, causes the constituent materials to fuse to make a single porous mass with little change in the chemical properties of the ingredients. The purpose of sinter are to be used converting iron into steel.

2. • Visakhapatnam Steel Plant is the first integrated Steel Plant located at coastal
areas of Andhra Pradesh, India.
• Bestowed with modern technology VSP has a installed capacity of 3 million tons
per annum of liquid steel and 2.656 million tons of saleable steel.
• At VSP, there is emphasis on total automation, seamless integration and efficient
up-gradation, which result in wide range of long and structural products to meet
stringent demands of discovering customers within India and abroad.
• VSP exports quality Pig iron & steel products to Lanka, Myanmar, Nepal, Middle
East, United States of America and South East Asia.
INTRODUCTION TO VIZAG STEEL PLANT

3. MAJOR DEPARTMENTS
• Raw Material Handling Department(R.M.H.P)
• Coke Oven & Coal Chemical Plant(C.O.C.C.P)
• Sinter Plant
• Blast Furnace
• Steel Melting Shop(S.M.S)
• Continuous Casting Department(C.C.D)
• Light Medium & Merchant Mill(L.M.M.M)
• Medium Merchant & Structural Mill(M.M.S.M)
• Wire Rod Mill(W.R.M)

4. STEEL MANUFACTURING PROCESS FLOW CHART
Iron Ore , Fluxes , Coking and Non-Coking coal R.M.H.P
C.O.C.C.P
C.C.D S.M.S Blast Furnace Sinter
Plant
Rolling Mills Slab, Bloom, Billets Beams, Wires,
Sheets
And other
additives
(Semi-finished
products)
(Finished
Products)

5. SINTERING
• Sintering is a process during which material is transformed from
dispersive(powder state) to compact state without reaching to the melting point.
• It is the thermal process of consolidating powder particle into a coherent
structure via mass transport on the atomic scale.
• Sinter, a hard & porous ferrous material is a better feed material to Blast Furnace
in comparison to Iron Ore lumps and its usage in Blast furnaces that helps in
increasing productivity, decreasing the coke rate & improving the quality of Hot
Metal produced.

6. RAW MATERIAL USED IN SINTER
• Iron ore fines
• Flux ( lime stone & dolomite )
• Coke breeze
• Waste Materials:
a) Flue dust ( From Blast Furnace but added in RMHP )
b) L.D. Slag (From S.M.S.)
d) Lime dust ( From Refractory Mixing Plant through the lime
tanker)
• Sinter return ( Own generation )

7. COKE
QUARTZITE
LD SLAG DOLOMITE
LIME STONEMN ORE
IRON ORE
SINTER

8. SINTER PLANT
• In VSP (Visakhapatnam Steel Plant), Sinter plant agglomerate iron ore fines(dust)
with other fine materials (lime stone, dolomite, coke breeze, metallurgical waste
produced all over the plant in different processes) is done to reuse the fines.
• This forms 80% of Iron bearing charge in blast furnace that increases
productivity at lower fuel rate.
• The sinter plant has three sinter machines each having 312 square meters of
grate area with a total production capacity of 5.256 million tons per annum.

9. MAJOR SECTIONS IN SINTER PLANT
Raw Material Bins(R.M.B)
• This is a section which deals with handling of all raw
materials to production of base mix (a raw material of
sinter preparation).
• There are 12 bunkers present in the raw material bins
to receive different kind of raw material to make base
mix.
Bunker 1 : Metallurgical Waste Bunker 9&10 : Coke-
Breeze
Bunker 2 : Quartzite Bunker 11&12 : Lime
Dust
Bunker 3-6 : Iron Ore Fines
Bunker 7 : Lime stone
Bunker 8 : Dolomite
Sinter Machine Building(S.M.B)
• This is a section which deals with sinter preparation.
• There are total of 8 bunkers in S.M.P.P. in which raw
materials are stored.
Bunker 1: Lime Stone (-3 mm)
Bunker 2 : Coke (-3 mm)
Bunker 3 & 4 : Sinter Returns (-5 mm)
Bunker 5-8 : Base Mix

10. SINTER MACHINE (DWIGHT LLOYD TYPE)
• In Dwight Lloyd Sinter Machine, there are 135 pallet beds are present
surrounding the machine rotor and in each pallet there are 90 grate bars.
• Firstly, the bed material is filled up to 50mm height (10-20mm sinter are used as
bed material. Then the burden material (sinter mix) is fed up to 450mm.
• There are total of 10 burners are present in the sinter machine out of which 8 are
used for burning and remaining two is to maintain the heat.
• There are 26 vacuum chambers in the machine for suction.
• Capacity of Dwight Lloyd Sinter Machine is 450 tons per hour.

11. SINTER PLANT PROCESS FLOW CHART
RAW MATERIAL BINS PRIMARY MIXING DRUM BASE
MIX
SECONDARY
MIXING
YARD
PELLETISING PLANT
(PELLETS ARE FORMED)
SINTER MACHINE BUILDING
(SINTER IS
FORMED)

12. CONCLUSION
• Sinter plant is used for the consumption of waste from all the departments of
the steel plant.
• Sinter process helps to reduce the amount of slag produced in blast furnace.
• Sinter helps in reducing the coke consumption in Blast Furnace which increases
the productivity economically.
• Sintering helps in elimination of moisture, hydrated water and other volatiles on
the sinter strand with a cheaper fuel.

13. REFERENCES
• Powder Metallurgy: Science, Technology, and Materials By Anish Upadhyaya,
Gopal Shankar Upadhyaya
• www.vizagsteel.com/infrastructure
• www.iitg.ac.in/engfac/ganu/public_html/Powdermetallurgy

14. THANK YOU