FIELD OF THE INVENTION:

The present invention relates to a system for Centralized measurement, monitoring and control system for Pot Sintering unit equipped with hot air generator and steam generator. More particularly the present invention relates to controlled injection of steam or hot air during the sinter making with impact on the process as well as sinter quality,

BACKGROUND OF THE INVENTION:
A pot sintering equipment is used to carry out pilot scale sinter making, by simulating the real plant conditions. The results of the sinter pot test can also be used for sinter process optimization. In general a pot sintering unit comprises of a cylindrical mild pot where the sinter mix is fed, means to ignite the mix from top, a system for creating suction so that the combustion zone moves gradually from top to bottom of the mix enabling uniform sinter formation. Sinter pot experiment involves measurement of parameters such as temperature, pressure, air filtration velocity, gas flow and component analysis. Once the sinter is made the same is tested for quality and thereafter the quality achieved can be correlated with the operation parameters measured, thereby help in improving the actual process of sinter making.

In a prior art, a Chinese specification CN104198522A discloses on-line iron ore sintering test device and test method respectively. The invention discloses an on-line iron ore sintering device which comprises an ignition device, wherein the ignition device can be used for temperature regulation and is connected with a semitransparent sintering pot; a double temperature detection thermocouple is arranged at the bottom of the semitransparent sintering pot; a plurality of temperature thermocouples are arranged in a height direction of the semitransparent sintering pot at equal intervals; the semitransparent sintering pot is connected with a smoke discharge reducing pipeline; the smoke discharge reducing pipeline comprises a smaller-diameter section at the front end and a larger-diameter section at the rear end; the smaller-diameter section is internally provided with a thermocouple, a flow meter, a pressure transmitter and a dust concentration meter; a smoke component analyzer sample connection is arranged on the larger-diameter section; the smoke discharge reducing pipeline is connected with a diffusion cyclone dust collector; an air outlet of the diffusion cyclone dust collector is connected with a tubular heat exchange; the tubular heat exchange is connected with a dehydrator; the dehydrator is connected with a variable frequency multistage centrifugal fan; and the multistage centrifugal fan is provided with an analog regulating valve and connected with an exhaust funnel.

In another prior art a Chinese utility model specification CN203259486U discloses improved sinter pot test device, which belongs to the technical field of sinter pot test equipment and is used for a sinter pot test in a metallurgical laboratory. According to the technical scheme, a thermocouple is mounted in an igniter; another thermocouple is mounted on a position above an air bellow and near a pot body of a sinter pot; two layers of sinter pot grates are mounted in the pot body of the sinter pot; a plurality of thermocouples are mounted on the body wall of the pot body of the sinter pot; the front ends of the thermocouples are respectively inserted into sintering materials; a primary mixer is provided with a horizontal regulating device and a vertical regulating device; a spray gun is used for spraying water in an atomization mode under the pressure of an air compressor at a slantly-downward angle of 45 degrees in the horizontal direction; the igniter is provided with an automatic igniter positioning device. The sinter pot can be used for imitating the sinter pot test at various material layers, controlling the ignition temperature and the final sintering temperature and detecting the temperature of a burning layer. With the additional arrangement of the water spray gun, the bonding of mixed materials on the barrel wall of the mixer is reduced, so that the mixed materials are accurate and reliable in moisture. By utilizing the automatic igniter positioning device, the igniter can be aligned with a pot opening of the sinter pot accurately, so that the accuracy and the comparison of the test are improved.

In the previously known pot sintering systems, the recording of the parameters is carried out manually using portable instruments or stand alone on-line systems having sensors connected to recorders.

Controlled injection of steam or hot air during the sinter making process has salient impact on the process as well as sinter quality. In the plant scale operation steam and hot air injection facilities are an added advantage. However, no previously known pot sintering equipment has been found to have the provision of steam and hot air injection or real-time monitoring of the same.

OBJECTIVE OF THE INVENTION:
The objective of the invention is to design and implement a centralized measurement, monitoring and control system for a pot sintering equipment equipped with hot air generator and steam generator for carrying out improved scientific experiment with real time data interface and reporting

BRIEF DESCRIPTION OF ACCOMPANYING DRAWING:
Figure 1 illustrates the overall schematic representation of the centralized measurement, monitoring and control system for pot sintering unit equipped with Hot Air generator(HAG) and Steam Generator(SG) in accordance with the present invention;
Figure 2 illustrates selection of data logging rate from central location for carrying out experiment in accordance with the present invention;
Figure 3 illustrates on-line HMI Interface for control and monitoring of an experiment in accordance with the present invention;
Figure 4: illustrates experiment data recording in real time for analysis in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION:
The invention pertains to an improved system for online measurement, monitoring and control of key parameter during sintering process in a sintering pot equipped with hot air generator and steam generator. This system has an integrated instrumentation scheme specially designed for on-line acquisition of key parameters from sintering experiment. This system has the facility of centralized monitoring of the experiment through a user friendly HMI screens. This system also has provision for on-line monitoring of temperature and pressure of steam injected into the sintering Pot. This system also has the facility of control and on-line monitoring of hot air injection during the sintering process.
Figure 1 gives the overall schematic of the system. Provision is made for measurement and recording of the following parameters in real-time during the experiments:
Temperature measurement from three points on sinter bed and one point in wind box (0 to 1200/1600°C, continuous measurement using K/J type thermocouples and temperature transmitters), Pressure measurement from three points in pot and one point in wind box (0 to ±2000 mm H2O suing sensors and pressure transmitters) , Flow measurement of flue gas (Using Orifice Plate and Differential pressure measurement), Measurement of O2/CO/CO2in flue gas (0-25%, 0-10,000ppm, 0-20% range respectively for flue gas temperature of 700degC), Air filtration velocity measurement using anemometer (0 to 40 m/s)
Flow measurement for steam (flow: 5-50 kg/hr and temp. 100- 200 oC) and Hot air (flow: 0-4.5 Nm3/min and temp.:30- 400oC) injected during experiment is also interfaced with the control system

All the measurement data are converted to standard current signal (4-20mA) and thereafter connected to a standard controller having Analog input and output cards as well as digital input and output cards. The measurement signals are connected to the analog input cards and digital control signals such as start and stop of experiment are connected to the digital inputs. Panel displays are provided for critical parameters using analog output cards and digital output card. Thus all measurement signals are centrally brought into a Data acquisition system for monitoring and control in real time.

All the measurement sensors are connected to the experimental pot using specially designed quick connect interfaces so that the experiment can quickly be set up and the data is available in real time to the central system

Central controller is in turn interfaced with the central HMI station through network for control and monitoring of experiment.

The system facilitates a flexible data logging rate depending on the application (up to 15 minutes at an interval of 5 sec) (Ref: Figure 2). Once all the connections are done, material is loaded and system is ready for experiment, the user can select the data logging interval before initiating the experiment.
An on-line HMI Interface for control and monitoring of an experiment has been designed and developed (Figure 3) and the same is interface with the central controller through ether net. The screen gives the detailed visual overview of the experiment including for all the regimes all regimes of operation from ignition to completion of the sintering process. Before start of experiment, provision has been made to make a manual entry of details such as experiment number, application, client, raw mix composition etc. After ignition of the mixture, the operator can select from the central console when to start the data logging from the various instruments. Once started, all the data are continuously updated and displayed on the HMI screen live and also stored in the computer memory in a specially designed format for report generation. The data will be continuously logged till the operator selects the stop button.

Experiment data recording is carried out in real time in format given in Figure 4. Further the experiment data is exported to a spreadsheet in a format that also contains the data entered manually for reporting and records.

The typical design specifications of various components of the centralized measurement monitoring and control system:
Temperature measurement for sinter bed and wind box • Sensing element: K/S type Thermocouple with SS sheath suitable for fitting in the hole of sinter pot, Measurement: Continuous signal to Temp Transmitter and then central controller, Operating temp: For K-type 0-1200°C (Max.), For S-type 0-1600°C (Max.), Standard degree of protection: IP-65, Thermowell Material: Stainless steel
• Temperature transmitter: Measurement Continuous, with Cold junction compensation, Type2-wire, output signal4 to 20 mA, Ambient temp 50degC, Maximum operating temp0 to 1600°C, Protection Class IP-65, Accuracy ±0.1 % of full scale
Pressure measurement for sinter bed and wind box • Sensing element: Diaphragm type
• Pressure transmitter: Measurement Continuous, local indication & Analogue Signal transmission, Pressure range ( mm H2O) 0 to ±2000 mm H2O , Accuracy ± 0.2 % of full scale, Max temperature during sintering (Inside pot) 1400°C, Temperature of flue gas 7000C (Max.), Application Positive or negative (vacuum) pressure measurement in sintering process, Type 2-Wire, Output Signal 4-20mA, Protection Class IP-66, Ambient temp 50°C
Flow measurement for wind box • Sensing element: Orifice place material SS316 with Differential Pressure Transmitters
• Type2-wire, Output signal4 to 20 mA, Ambient temp 50°C (Max.), Maximum Operating Pressure 0 to ±2000( mm H2O), Maximum Operating Flow rate 4.5 Nm3/min(max), Temperature of flue gas700 0C (Max.), Protection ClassIP-66, Accuracy+/- 1% of span
Flow measurement for Steam • Type: Vortex Flow Meter (With Temperature& Pressure compensation), Size DN15, Medium Steam, Accuracy ± 1.0%, Temperature, -10°C to 250°C, Pressure 20 Bar, Signal Output 4 – 20 mA, Body & Sensor Material SS304, Flow Rate 24 to 400 kg/h, Process Connection DN 15 PN 16 Flange, Environment Humidity 85% RH, Protection Class IP65
Flow measurement for Hot Air • Type: Vortex Flow Meter (With Temperature& Pressure compensation), Size DN15, Medium Heated Air, Accuracy ± 1.0%, Temperature, -10°C to 250°C, Pressure 20 Bar, Signal Output 4 – 20 mA, Body & Sensor Material SS304, Flow Rate 24 to 400 kg/h, Process Connection DN 15 PN 16 Flange, Environment Humidity 85% RH, Protection Class IP65
Flue Gas Analysis • Temperature of flue gases 700 0C (Max.), Measuring sensor for O2,CO,CO2, Ambient temp 500C , Output 4-20 mA, Data logging Continuous
Air filtration velocity measurement above the bed • Vane type Anemometer, Air velocity range 0 to 40 m/s, Accuracy ±1 % of MV, Resolution 0.01 m/s, Temperature -30 to +60°C, Data logging Continuous
Controller & HMI • Programmable modular controller with Analog and Digital I/O modules and Ethernet port for communication (In the system Thermo fisher make DT85 was used for the purpose), Windows OS based PC with HMI developed using dot NET programming tools for display and recording of experimental data
Communication protocols • All instruments to Central Controller: 4-20mA
• Digital signals: 24 Vdc
• Controller to HMI PC: Ethernet TCP IP

USEFULNESS OF THE INVENTION:
The improved system for monitoring and control of the experimental pot sintering equipment enables real time recording of the experimental data automatically as against manual recording of data in existing systems. The on-line pictographical view of the experiment in the HMI terminal is very operator friendly and gives an overall view of the on-going experiment. The system can be implemented over any general purposes Data controller and instrumentation making it versatile and open. The quick connect facility given for the various sensors enable setting up of the system for carrying out the experiment within short span of time. The on-line measurement and recording of the steam flow and hot air flow and temperature enable complete simulation of the industrial scale sintering operation.
INDUSTRIAL APPLICABILITY:
Other plants (Iron & Steel plants, Cement Plants) and R&D organizations in India.

Although the foregoing description of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration by way of examples and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. The particular embodiments and applications were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, variations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

WE CLAIM:

1. A system for centralized measurement, monitoring and control system for Pot Sintering unit equipped with hot air generator and steam generator comprising of :
a plurality of temperature measurement means for sinter bed and wind box;
a plurality of pressure measurement means for sinter bed and wind box;
a flow measurement means for sinter material in sinter bed and wind box;
a flow measurement means for Steam for wind box;
a flow measurement means for Hot Air;
a flue Gas Analysis means;
an air filtration velocity measurement above the sinter bed;
a central controller & HMI; and
a communication protocol means for continuously update and display real time data on the HMI screen and store for report generation.

2. The system as claimed in claim 1, wherein temperature measurement means includes sensing element of K/S type and thermocouple with SS sheath suitable for fitting in the hole of sinter pot configured for continuous measurement and signal to Temperature Transmitter and then central controller.

3. The system as claimed in claim 2, wherein said temperature transmitter is configured for measurement continuously in real time with Cold junction compensation with features of Type 2-wire, output signal 4 to 20 mA, Ambient temp 50degC, Maximum operating temp 0 to 1600°C, Protection Class IP-65, Accuracy ±0.1 % of full scale.

4. The system as claimed in claim 1, wherein the said pressure measurement means include sensing element of Diaphragm type and pressure transmitter with features of: Measurement Continuous, local indication & Analogue Signal transmission, Pressure range (mm H2O) 0 to ±2000 mm H2O, Accuracy ± 0.2 % of full scale, Max temperature during sintering (Inside pot) 1400°C, Temperature of flue gas 700 0C (Max.), Application Positive or negative (vacuum) pressure measurement in sintering process, Type 2-Wire, Output Signal 4-20mA, Protection Class IP-66, Ambient temp 50°C.

5. The system as claimed in claim 1, wherein the said flow measurement means include sensing element of orifice place material SS316 and Differential Pressure Transmitters with features of Type 2-wire, Output signal 4 to 20 mA, Ambient temp 50°C (Max.), Maximum Operating Pressure 0 to ±2000 (mm H2O), Maximum Operating Flow rate 4.5 Nm3/min (max), Temperature of flue gas 700 0C (Max.), Protection Class IP-66, Accuracy +/- 1% of span

6. The system as claimed in claim 1, wherein the said flow measurement means for steam is a Vortex Flow Meter (With Temperature& Pressure compensation), with features of Size DN15, Medium Steam, Accuracy ± 1.0%, Temperature, -10°C to 250°C, Pressure 20 Bar, Signal Output 4 – 20 mA, Body & Sensor Material SS304, Flow Rate 24 to 400 kg/h, Process Connection DN 15 PN 16 Flange, Environment Humidity 85% RH, Protection Class IP65

7. The system as claimed in claim 1, wherein the said flow measurement means of hot air is a Vortex Flow Meter (With Temperature& Pressure compensation), with features of Size DN15, Medium Heated Air, Accuracy ± 1.0%, Temperature, -10°C to 250°C, Pressure 20 Bar, Signal Output 4 – 20 mA, Body & Sensor Material SS304, Flow Rate 24 to 400 kg/h, Process Connection DN 15 PN 16 Flange, Environment Humidity 85% RH, Protection Class IP65.

8. The system as claimed in claim 1, wherein the said flue gas analysis means is configured for measuring temperature of flue gases 700 0C (Max.) and measuring sensor for O2, CO, CO2, Ambient temp 500C , Output 4-20 mA with continuous data logging.

9. The system as claimed in claim 1, wherein the said air filtration velocity measurement above the sinter bed is of Vane type Anemometer, with features of Air velocity range 0 to 40 m/s, Accuracy ±1 % of MV, Resolution 0.01 m/s, Temperature -30 to +60°C, with continuous data logging.

10. The system as claimed in claim 1, wherein the said controller & HMI is a Programmable modular controller with Analog and Digital I/O modules and Ethernet port for communication (In the system Thermo fisher make DT85 was used for the purpose), Windows OS based PC with HMI developed using dot NET programming tools for display and recording of experimental data .

11. The system as claimed in claim 1, wherein the said communication protocols include: 4-20mA Digital signals, 24 V dc Controller to HMI PC and Ethernet TCP/IP.