PRIVATE JOINT-STOCK COMPANY DNEPROHYDROMACH

5/2 Plekhanov str. | Dnepropetrovsk 49000 | Ukraine

Tel./fax: +38 (056) 370-34-88; 370-34-89; 238-69-63
e-mail: info@dneprohydromach.com
web: www.dneprohydromach.com

Customer

Country

SHYAM GROUP OF INDUSTRIES

INDIA

TP No. 150814

GENERAL TECHNICAL OFFER

FOR MANUFACTURING AND SUPPLY OF
THE BF HYDRAULIC CHARGING UNIT HydroMech Top

PJSC DNEPROHYDROMACH, 2014

1. GENERAL
This technical offer describes the Blast Furnace charging unit HydroMech Top (HMT), developed by
DNEPROHYDROMACH.

The proposed HMT is the long-term development result of DNEPROHYDROMACH specialists.

Technical solutions considering modern requirements to process of loading and distribution of

furnace charge by blast furnace bell and hopper section are applied in design of new bell-less top.

Installation of bell-less top equipment is executed during blast furnace construction. All project
designs are executed in relation to conditions of blast furnace.

HMT equipment set allows to solve problems directed to achievement of high technical and
economic rates of unit operation.

HMT installation will provide reliable and steady loading of blast furnace with charge materials of
high-quality distribution. Precise center charge materials loading, without stream dispersion, allows
to form gas permeability of axial zone of the furnace over a wide range, so to regulate a course of
domain melting irrespective of charge materials initial structure, and also in the conditions of
pulverized coal fuel use (PCF).

BLT is executed for operating with top pressure of gases up to 2.5 kgf/cm at design pressure of blast
furnace 1.5 kgf/cm;

2. ESTIMATED TECHNICAL SOLUTIONS
HMT distributor gear is taken out of furnace space, has water and nitrogen cooling. Admissible working
temperature of furnace top gases 500 . The distributor chute is executed in the form of conical tube with
angle range from 0 to 53 that does not provide any of the existing charging units. Such range gives the
possibility of realization of the directed loading of portions of furnace charge by all throat sections, and also
the concentrated layer of furnace charge precisely on the center that allows formation of axial "outlet" over a
wide range.

The intermediate storage bunker is executed with loading of 1 portions of furnace charge.

Pressure equalization system in the intermediate bunker provides work both on inert gas (nitrogen),
and on the cleared blast-furnace gas. Use of steam is provided, as a reserve, for neutralization of
explosive mixture.

HMT control system allows to make loading of materials in various sequence and at any combination
(at the discretion of technological personnel).

Offer TCO - TP No. 150814

Technical proposal

MAIN ADVANTAGES OF HYDROMECH TOP

The original design of distributive chute suspender gives the possibility of axial "outlet" formation
over a wide range.

There is no possibility of uncontrollable material "over spilling" at grate distributor angle rates and
charge consumption at loading to the furnace.

Simplicity and reliability of design.

Compactness of device.

Wide working range of distributive chute discharge angle.

Increased accuracy and discharge angle positioning speed of the distributor of furnace charge due to
hydraulic actuator use.

Gas-sealing valves are executed without rubber or other any non-metal sealing (firmness is provided
with ground-in surfaces of seat and retainer) that allows to work at uncool row material.

Possibility of various energy carriers use in the cooling system.

The increased resource of charge distributor operation.

3. EQUIPMENT SUPPLIED
Before issue of design documentation to HydroMech Top production the Supplier agrees with the Customer
"Specification for development" where requirements for equipment scope and its technical parameters are
defined. The present technical offer provides the following scope of equipment, specified in the Table.
No.
item

Equipment name

Quantity,
pcs.

Mass, t.

Note

1.

Hopper

2.

Upper storage lock

3.

Upper gas-sealing valve

2.5

4.

Intermediate bunker

12

5.

Bottom storage lock

4.4

6.

Bottom gas-sealing valve

2.5

7.

Compensator

8.

Process latch

0.8

9.

Hopper

5.5

10.

Hopper mechanism with chute

10.1

11.

Accumulator station

7.0

12.

Pressure equalization system

up to 5

13.

Lubrication system

14.

Cooling system

15.

Automatic process control system (APCS)

Offer TCO - TP No. 150814

Technical proposal

4. MAIN TECHNICAL CHARACTERISTICS AND FUNCTIONAL PURPOSE OF EQUIPMENT

4.1. Distributor (Fig. 1) is intended for distribution of charge materials at furnace top according to the set
program.
Rotation speed of chute is changed from 4 to 8 rev/min.

The resource of distributor gear is designed for operation, without repairs, during 5 years.

The resource of chute and hopper is designed for 12 18 months.

Chute replacement is executed through central hatch of distributor unit.

Calculated time of chute replacement does not exceed 6 hours.

Flow section of chute bottom part makes 450 mm.

HMT distributor drive gear is the electric motor and differential reducer, executed chute rotation
concerning HMT axis and blast furnace. All distributor assemblies are set in motion simultaneously.
From the main differential reducer rotation is transferred to two opposite conical reducers which
transfer rotation to the planetary reducers changing by chute discharge angle.

Change of chute discharge angle happens at the expense of rotation speed mismatch of two swing
bearings. The mismatch of speeds is carried out by hydraulic drive gear, via the special module with
hydraulic cylinder that gives the chance of exact positioning of discharge angle. Chute angle change
rate contains 0.51.5 /sec

Fig. 1 Distributor HydroMech Top

Offer TCO - TP No. 150814

Technical proposal

4.2. Gas-sealing valves (Fig. 2) are intended for prevention of blast-furnace gas output to the atmosphere
at materials loading to the furnace.

Valves drive hydraulic, flow section 600 mm.

Valves are equipped with nitrogen supply system to the blow of contact areas.

Fig. 2 Gas-sealing valve

Offer TCO - TP No. 150814

Technical proposal

4.3. Storage locks (Fig. 3) are intended for prevention of charging material pouring out from hopper to the
bunker and from the bunker to the furnace at the closed corresponding gas-sealing valves.

The bottom storage lock with which the intermediate storage bunker is equipped, has additional
function of regulation of charge flow control. The quantity of storage lock opening positions is set by
agreement with the Customer.

Gate drive hydraulic, flow section 450 mm.

Fig. 3 Storage lock

4.4. Intermediate bunker is intended for accumulation and sluicing of materials before loading to the
furnace.
Useful capacity of bunker has to provide reception of materials not less than 1 portion and makes
11m3.
Storage bunker is equipped with the bottom storage lock and bottom and top gas-sealing valves.
Intermediate storage bunker is equipped with loaded materials weighing system by agreement with
the customer.
Storage bunker is connected to the furnace charge distributor by means of the bellows-sealed
compensator bar having a cut-off goggle valve in the bottom.

4.5. Hopper is intended for charging materials' moving direction at pouring out from conveyor to storage
bunker.
Hopper has the volume min 5.5 m3.
Hopper is equipped with storage lock (latch).

4.6. Accumulator station (AC) of hydraulic actuator is intended for operation providing and control of all
executive hydraulic gears (gas-sealing valves, storage locks, nitric valves, filling and output valves, etc.).
AC is equipped with two hydraulic pumps, liquid storage tank, accumulator unit, filtration unit, oil
cooling and heating unit, hydraulic control racks.
Working pressure 200 kgf/cm2.


Offer TCO - TP No. 150814
Technical proposal

4.7. Pressure equalization system is intended for pressure equalization in the intermediate storage bunker
with working space of the furnace, at materials loading to the furnace and with atmosphere, at materials
loading to the bunker.
The system includes pipe ducts, equalizing valves (input and output) and shut-off valves.
Use nitrogen and semipure blast-furnace gas for pressure equalization. Detailed description of
system operation is submitted in Maintenance Manual.
System is equipped with shut-off valves and at lack of nitrogen, allows the use of steam, as converter
of explosive gas mixture in intermediate storage bunkers.
It is strictly forbidden to execute the blowing of gas-sealing valves contact surfaces by the steam.
4.8. Control system of HMT operation is intended for operation control of all gears according to program, set
by process personnel. The system is executed on the basis of modern computer facilities with use of
industrial controllers and computers, in function of applied at blast furnace.

5. REQUIREMENT OF ENERGY CARRIERS FOR STEADY WORK OF HMT

5.1. Nitrogen general expenses

during pressure balance
Requirements to nitrogen:
oxygen content
pressure at feed floor
temperature
5.2. Overall flow of steam

- constant 5000 m/h;

- peak (3 5 sec.)
up to 10,000 m/h.

- max 3.0 %;
- min 4.0 kgf/cm;
- max 45C.
- up to 3.0 t/h;

With pressure at feed floor

5.3. Overall flow of water
With pressure at feed floor

- min 2.5 kgf/cm.

- up to 8.0 m/h;
- min 3.5 kgf/cm.

6. THE APPLIED STANDARDS AT DESIGN

GOST (interstate standard)
DSTU (State Standard of Ukraine)
Enterprises standards.

7. SCOPE OF DELIVERY AND SERVICES OF DNEPROHYDROMAH

7.1 DNEPROHYDROMAH gives to the Customer the design documentation necessary for operation of
equipment (Certificate, maintenance instruction, drawings of HMT general views and assembly units, electric
circuit diagrams), and also drawings of spare parts and fast-wearing-out details.

Offer TCO - TP No. 150814

Technical proposal

7.2 DNEPROHYDROMAH provides:

coordination of design documentation to the delivered equipment;

delivery of construction tasks for HMT binding and installation to blast furnace;
control assembly of HMT and organize acceptance with participation of the Customer;
participates in HMT commissioning and putting into operation.

8. CUSTOMER SCOPE OF WORK

Customer executes:

Project works by Supplier assignment for HMT binding and installation.

Equipment mounting at the furnace.
External cable run
Equipment and materials supply according to Project Documentation by item 1.
The customer provides performance of all installation and construction works connected with BLT
equipment installation.

Offer TCO - TP No. 150814

Technical proposal