AGGLOMERATION HUB: PROBLEMS SOLVED

Capability Development Training

Modern sinter plants face a number of challenges ranging from raw material properties, meeting sinter quality norms, stringent statutory environment norms, cost economy, so on and so forth. In order to meet these challenges, it requires a team of operators who are knowledgeable and updated on each of these aspects and can take right decision at right time. Hence it is most important to develop the capability of the team of operators. They should be updated with the statutory norms, recent developments and what others are doing in the same field. Our Expert team, with four decades of experience, can deliver all of the above and promise to make a team of operators with the requisite knowledge.

Operation system audit

We often miss to identify our own inefficiencies as we:

Otend accept common mistak
fail to compare ourselves with the best in class operation elsewhere
oget used to live with the difficulties

The remedy for all the above is to have an in-depth audit of the system by an expert eye. Our experts possess a vast experience at number of plants at different geography. It will provide the gap analysis, and from there new projects can be taken up.

Raw Material Selection, Preparation & Beneficiation

Selection of good quality raw material depends on number of issues including cost, quality and impact on operation. Hence a broad strategic decision has to be taken by the Senior Management to decide on the choice of Raw Materials. After choice of Raw Material, the right method of processing or pre-processing the same is a matter of time, money and knowledge. Our team of Experts can help you in doing the in-depth Techno-Commercial evaluation and suggest the best possible solution.

Expert Opinion

All sinter plants face some challenge or other. The challenges can be premature failure of equipment, Not meeting the customer specified quality, lack of production numbers, too many interruptions, unsafe conditions, and so on. Our team of expert, with their rich experience and deep understanding of the processes will solve all such worries, for sure.

Process Improvement

As we all know, sintering is a continuous process and the challenge is to produce a homogeneous product using heterogeneous raw materials. Along with the quantity of sinter produced, its consistent quality prepared as per demand of the customer (Blast Furnaces) is of paramount importance. This is taken care by Process Improvement, enabled by the theoretical and practical knowledge of the intermediate stages of converting raw materials into product sinter. A proper process improvement journey can ensure a steady production level ensuring a rock steady quality characteristic – e.g. sinter chemistry, tumbler index, RDI, RI, Mean Size, etc. Fortunately, our team of experts have a track record of improving the processes in many sinter plants – from 60 year old plant to most recent plants. We can also recommend and hand-hold plants to achieve productivity levels of 1.67 t/m2/h (40 t/m2/d) from any such plants.

Productivity & Quality Improvement

Our team of Experts have made many turn-round performances in old as well as new sinter plants in terms of productivity improvement to the level of 1.67 t/m2/h (40 t/m2/h). We are capable of repeating the same at any other sinter plant, by application of scientific knowledge and experience. Along with productivity, the consistency in quality of sinter can be guaranteed.

Cost optimization

Optimum use of resources and cost elements such as fuel rate, iron ore rate, etc can be done without affecting the production and quality. This is in addition to or excluding the choice of raw materials which depend on strategic decisions. We have demonstrated this in number of plants, helping to optimize cost of production (Rs/t of sinter )

Automation, Instrumentation & Optimization

We are living in an era of digitalization in every aspect of life. Gone are the days when sinter plants depended on the experience and efficiency of operators only, to produce desired quality and quantity. However, this had the disadvantage of people’s perception and their skill. Contrary to these, modern sinter plants – young and old – operate with many gadgets such as

(a) Online Moisture probe
(b) Online Permeability Probe
(c) Online Quality Probe
(d) online chemistry probe, etc

All such measurements get logged into a computer system (PLC or DCS), analyse the abnormality and take corrective actions. Many plants use a Digital Twin to prioritise and suggest the right course of action to operators. Thus, the mode of operation has seen a major change and become independent of human intervention. Our team of experts have pioneered many such innovations and are capable to repeat the same at other locations too.

TQM & Daily Management

The role of TQM and Daily Management is well established in keeping the system deviations in check. It is also a good tool to engage the plant operators, supervisors and managers in a systematic time bound way to monitor things and take corrective action at an opportune time. Our Expert team can guide the team to establish such a system which is proven and time tested.

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