M/S PEACOCK ENGINEERING (INDIA) EQPTS.

OBJECTIVES

The Purpose of this project is to achieve the minimum criteria for continuous production of Washed Iron ore For and Of Different specific sizes.

a)     Blast Furnace

b)    D.R.I or Sponge Iron

c)    Sinter plants

d)    Pelletization

i)    (-40+18) mm

ii)    (-18+10) mm

iii)    (-10+6) mm

iv)    (- 6+3) mm

v)     (- 3+0.05) mm

FEED MATERIAL

Material: Iron Ore

Feed Size: <40mm

PLANT CAPACITY

80 Ton/Hour (Max 100 tph)

40 Ton/Hour (Max 50 tph)

LAND REQUIREMENT

PEIE Ore Washer system 380 m²  without stockpile (detail Matrix below)

PEIE Ore Washer system 180 m²  without stockpile (see detail Matrix)

WATER REQUIREMENT

In circuit 250 m³ /hr;  Top‐up  ~25 m³/hr, hold up: 200m^{3 ,} (Quality: treated)

In circuit 100-120 m³ /hr;  Top‐up  ~30 m³/hr, hold up: 200m^{3 ,} Quality: Non-specified

POWER REQUIREMENT

245KW max (detail list below)

160 KW max (detail list below)

MAJOR EQUIPMENTS

DELIVERY SCHEDULE

12 weeks from date of Drawing approval

12 weeks from date of Drawing approval

SCOPE OF WORK

• Design/development of process flow & layout, Selection of equipments.
• Manufacture, Shop test & Supply.
• Detailed Engineering with Civil Foundation details.
• Supervision, Fabrication, Erection & Trial run of PEIE Supplied equipments.

Using of Iron Ore

Grades and particle sizes.

a) Blast-Furnace             

b) D.R.I or Sponge Iron

c) Sinter plants

d) Pelletization

a)     normally (-40+10) mm.        somewhere (-40+6)mm

b)    normally (-18+6)mm           somewhere (-18+3)mm

c)     normally (-10+3)                 somewhere (-6+3)mm

d)    normally < 0.5 mm.             somewhere (-3+0.5)mm

OBJECTIVE

A) Desired : To achieve a high FE grade value (>62%) and low values for unwanted contaminants for cost effective processing.

B) Not desired : Low FE value of the ore (< 62%) burn off with unwanted contaminants into F/C or Kiln ~ cost ineffective production Ore Oxide (Fe2O3) ~ increasing production costs.

PEIE-100 Iron washing plant introduction example

Increase in Iron from 58.24% to 63.2% ↑which delivers significant  efficiency savings in downstream processes.

↓results

37% reduction in Alumina from 4.3% to 2.7% and a 32% reduction in Silica from 6.6% to 4.5%.

↓results

Reduction in Coal consumption of around 5%

↓results

significant efficiency gain in steel production processes

SCOPE

• Design/development of process flow & layout, Selection of equipments.
• Manufacture, Shop test & Supply.
• Detailed engineering with civil foundation details.
• Supervision, Fabrication, Erection & Trial run of PEIE supplied equipments

Supply ( PEIE’s Scope)

above

Manufactured items

above

Fabricated items

At site

Electrical Items

above

Optional Items

Details later

Noted Exclusions

1)All Civil foundation, building, control room, settling pond, pump house, water channel.

2)All electrical cable and accessories,

3)Factory illumination,

4)Crane, Winch and any handing equipment,

5)Any item not specified in the scope of supply

INSTALLATION  FACILITIES NEEDED

1)Civil clearance for equipment erection.

2)Site facilities like un-interrupted power, Temporary storage and Fabrication space , Industrial LPG and oxygen gas, Hydra to lift 4 ton etc., have to be arranged by you

3)Permit for our welding work at night

STEP 1 (FEEDING SYSTEM): Ore to be fed into Hopper, fitted with Vibro feeder to feed @80 tph of Iron ore to the circuit. The Hopper is fitted with Grizzly of 100 mm²  size to eliminate oversized material to Screen.

A belt weighing system is fitted. The Vibro feeder transfers the ore to the feed conveyor#1.

The feed conveyor #1 feeds to Double deck Dewatering screens #1  to separate (40+18) mm, (-18+10) mm and  (‐10) mm from the feed material.

STEP 2: (DEWATERING SCREEN)

The Top Polyurethane deck will wash, separate (+18)mm and to be stockpiled through conveyor #2 . The Screen has Water spray jets which improve screening efficiency and soil removal. The (-18+10) mm bottom panel overflow product of the screen will be fed to PEIE log washers for further scrubbing. The under‐flow of the screen i.e. (‐)10mm and slurry water is sent to the PEIE-50 OreWasher sump.

STEP #4 (DESLIMING CIRCUIT):

The undersize slurry is collected at the sump of the PEIE-50 OreWasher system integrated with hydrocyclone, sump & pump, dewatering screen. The slurry is pumped to the cyclone and all the ultra‐fines of <50 microns particles taken out of the circuit as overflow of the cyclone. The underflow of the cyclone is dewatered through dewatering screen and gives ‐ 3+0.05mm low moisture final product which stockpiled by using ae stock piled conveyor #4.

STEP#3 (ORE SCRUBBING, DEWATERING )

 PEIE log washer apply attrition to the material to make the surface of Ore from free of fines. The overflow of the PEIE log washer is then dewatered through a Dewatering Screen #2 . The underflow of Log washer and prograde with any <6mm fines is collected in the sump of the PEIE-50 Ore washer.

Washed overflow material passes through Prograde dry size separation screen #2 to separate (-10+6)mm & (-6+3) mm final washed product.

All the underflow slurry materials of dewatering screen will pump to the sump of the  PEIE-50 Ore washer.. The final two products will be stock pilled with the help of through conveyor #3 & Conveyor #4.

STEP#5(WATER RECYCLE CIRCUIT):

The overflow ‐0.045mm slurry from the cyclone will pass to an Thickener to rapidly settle and control the tailings. Dense sludge of circa 800g/litre will be issued from the integrated heavy duty pump for discharge to a  designed settlement area.

STEP#6(WATER RECYCLE CIRCUIT : SETTLING PIT WITH TANK

The underflow of Thickener or overflow of cyclone’s  sludge to be sent to Parallel Settling Pits to settle. Overflow water of it has to be collected to Settling clear water tank which to be pumped from attached Pump house to water spray for application of this circuit. Thickened and semi solid sludge after semi drying to be removed by pay-loader.

1 Hopper & Feeder : PEIE- 30

1b  Bin Vibrator with Grizzly 100 MM² spacing.

1c  Belt feeder and 5 kw direct drive motor & Gearbox with VF Drive

1d  1000/800 mm wide belt for conveyor

1e  Self Supporting structure

1f  Belt scraper with PU blade

2 inclined Conveyor #1:  (feeding to Dewatering screen# 1)

2a  1000 mm wide Conveyor of 20 m long

2b  Feed Chute to receive material

2c  Self Supported Structure walkways, stair

2d  Troughing & carrying idler , Return roller, Guide Roller

2e  Head & tail Pulley (12 mm rubber lagged).

2f  15 kw drive motor & Gearbox

3 Dewatering/ Rinsing /Sizing Screen # 1

3a  Unbalanced motor Double deck Screen with PU panel, size 1.5m wide X 5.0 m long

3b  Self ‐supported Structure, walkways, stair .

3c  Series of spray lines with 5 nozzles in each

3d  20 m3/ hour water spray

3e Rubber lining for the front chute and funnel to improve life and reduce noise.

3f  10 Kw X2 motor

4  LogWasher scrubbing system

4a  Fitted with 82 Nos full set of heavy‐duty chrome molybdenum blades

4b  Single gearbox and motor driving twin shaft

4c  ABB/Siemens electric motor 45 Kw with synchronised drive mechanism for maximum efficiency

4d  Mild steel body; electro welded steel full guard over top of machine

4f  Main bearings mounted on outside of machine for ease of maintenance

4g  Injects water through the floor of the machine as well as the roof to fluidise  material bed

4h  Side and rear discharge points for removal of water and sand / silt so that minimal fines reach the main discharge point

4i Valves  to control water requirement

5 dewatering Screen #2

5a  Dewatering Screen Size – 1.2 mtr wide x 2.4 mtr long

5b  Fully modular dual density 0.8mm / 0.5 mm slotted aperture polyurethane panels – non bolted,

5c  Replaceable modular polyurethane liners along screen sides

5d  Sump for collection of screen underflow slurry

6  Feed Conveyor #2: (feeding to Screen#2)

6a  800 mm wide Conveyor of 18 m long

6b  Feed Chute  to receive material

6c  Self‐supported Structure, walkways,  stair

6d  Troughing & carrying Roller, Return roller, Guide Roller

6e  Head & tail pulley with 12 mm rubber lagging.

6f  7.5 kw drive motor & Gearbox

7 size separation Dry Screen

7a  Circular Motion double deck Screen with PU panel, size 1.8m wide X 4.8 m long

7b  Self Supported Structure ,  walkways, stair .

7c  Fully lined integral feed‐on plate

7d  Rubber lining for the front chute and funnel to improve life and reduce noise.

7e  15 Kw motor

7f  Adjustable stroke length

8  PEIE -50 Orewasher

8a  Fully modular dual density 3.2mm slotted aperture polyurethane panels –non bolted,

8b  Dewatering Screen Size – 1.8 mtr wide x 2.4 mtr long

8c  Replaceable modular polyurethane liners along screen sides

8d  Sump for collection of screen underflow slurry

8e  Creative Pump– 45 kW  27% Chrome alloy impeller for maximum wear resistance property

8f  Support structure with hydrocyclone , PEIE500 dia hydrocyclone – 1 no

9  Conveyors : Model PEIE-15

9a  15 m stockpiler for washed products - 6 Nos

9b  Feed boot to receive material

9c  600mm belt

9d  Fully adjustable skirting rubbers

9e  Troughing rollers as standard

9f   Direct coupled motor and gearbox

9g  Radial pneumatic wheels

9h  Polyurethane spring tensioned primary belt scraper

9i  Lagged head drum

9j  Crowned tail and head drums to assist belt tracking

10 Thickener : Model PEIE- 6100

10a  Thickener of 6m dia. for Concentrate

10b  3.0 kw Direct drive motor and gearbox and heavy duty shaft

10c  Peripheral launder for collection and discharge of recycled water to recycled water storage point

10d  Transfer pipe between thickener and your water storage

10e  Central diffuser drum for receiving pre-dosed effluent

10f  De-aeration chamber fitted to side Thickener for primary treatment

10g  Conical bottom section complete with flushing valves, connections, and pipework

10h  Scraper support bridge and walkway

10i   Manual  Valve for slurry flushing line

10j   Access stairs and all necessary handrails

11 Flocculants Station Poly electrolyte Dosing Unit

11a  Poly electrolyte dosing system

11b  water mixing & dosing tank

11c  Transfer pump1.5KW to convey polyelectrolyte to storage tank

11d  Mixing tank with lid incorporating stirrer unit twin propeller 0.75KW

11e  Transfer pump 0.45KW

12 Water Pumping system

12a  Make up water tank of 55 M3 holding capacity

12b Cylindrical steel Emergency water tank

12c  1 nos Creative pump 45 kW motor for high pressure and low pressure water distribution mounted on steel stanchions/skid base  incorporating pump base

12d  S.S Float fitted for control make up and measuring water level

12e Pre-wired isolator and emergency stop

12f  Manual drain off valves 20

13 Electrical

13a  MCC with proper Copper bus-bar and MCCB/MPCB, contactor, Bimetallic relay etc. and switch gears.

13b   Power cable - XLPE aluminium armoured cable as per required length and size and Control cable - copper, PVC, armoured etc.

14 Additional items

14a Pipe-work and connections between Sump(s) and cyclone(s)

14d Pipe-work and connections between Cyclone(s) and Thickener

14c Pipe Work for flushing of Thickener discharge line

15 Settling Pit

15a Inter-connecting trays (Civil tank and pit Customer scope with PEIE design)