Implemented Projects

Package Supply of Process Batching Lines and PCS for Material Handing Sector # 42 of Shop # 4
Customer: Aksu Ferroalloy Plant, Branch of AO TNK Kazchrom (Republic of Kazakhstan, city of Aksu)

Purpose

Batching line and PCS for Material Handling Sector #42 are aimed to load ore smelting furnace #42 with multi-component charge materials in accordance with the preset formula as well as for automatic monitoring, analysis and coordination of batching, transportation and loading of charge materials into furnace hoppers in order to provide proper operation of ore smelting furnace #42.

The aim of this upgrade was the replacement of extremely old and worn out process equipment of Material Handling Sector #42 of Shop #4 and fixed control system, thus it became possible to move to a new quality level of monitoring and control of the charge materials batching and loading into the furnace.

Scope of Work and Services 

  • Development of technical requirements to the automated control system for charge materials batching of Material Handling Sector #42 of Shop #4
  • Development of the technical assignment and design documents for PCS process line
  • Development of design documents, manufacturing and supply of intermittent bathers and belt feeders
  • Manufacturing and supply of PCS equipment for Material Handling Sector #42 of Shop #4
  • Installation supervision and commissioning

Basic Technical Parameters of Process Line 

 Accuracy class as per GOST 10223-97, %  

0.5

 Batching mode

by batches 

 Capacity, t/h

48 

Note - MPL - maximum performance limit 

Process Line Components 

- Storage bins
- Belt and vibrating feeders
- Gathering and inclined conveyor
- Batchers of intermittent action
- Car

Functions

  • Automatic batching of charge materials as per the preset formula with the appropriate metrological accuracy
  • Automatic monitoring of charge materials availability in the furnace hoppers
  • Targeted loading of charge materials into furnace hoppers
  • Monitoring of the state of the equipment transporting charge materials
  • Metering material flow from storage bins of batchers, generating reports for a supply and whole shift of furnace #42
  • Displaying of process progress at the video terminal of the control panel
  • Exchanging data with the existing data base of the Shop through Ethernet

Features

  • The accuracy of batching has been enhanced up to 0.5% and the stability of components proportion has been improved due to the adjustment of portion taking into account overdosing (underweight) in the previous portion.
  • The time for a grab car loading with charge components and its discharge into the furnace has been reduced down to 1 minute   due to using the collecting conveyor and collecting batcher.
  • Automatic continuous monitoring has been introduced for Material Handling Sector #42 and Furnace #42, thus the reliability of the batching control system is enhanced. 
  • Now it is possible to obtain electronic data on the process progress, to process, record and display them at work stations.
  • The reliability of the control system has been enhanced due to building up three level PCS for Material Handling System #42.