Claims:1. A system for sealing air leakage in an under-suction type sintering machine, the system comprising:
a plurality of metal wires, each having a fixed end and a free end; and
a metallic channel having a first end and a second end, wherein the channel comprises a recess extending longitudinally from the first end to the second end, and wherein the fixed ends of the plurality of metal wires are fixedly mounted in the recess of the metallic channel.

2. The system according to claim 1, wherein the metallic channel is made from mild steel.

3. The system according to claim 1, wherein the recess of the metallic channel has a U-shaped cross section.

4. The system according to claim 1, wherein the plurality of metal wires are made from stainless steel.

5. The system according to claim 1, wherein the plurality of metal wires are made from spring quality steel.

6. The system according to claim 1, wherein each of the plurality of metal wires has a diameter of from 0.1mm to 2mm.

7. The system according to claim 1, wherein the metallic channel has a length of from 100mm to 5000mm.

8. The system according to claim 1, wherein the plurality of metal wires extend 10mm to 150mm from the metallic channel.

9. The system according to claim 1, wherein the plurality of metal wires are fixedly mounted in the recess of the metallic channel in a form of bundles.

10. The system according to claim 9, wherein the bundles of metal wires have a density of at least 30 wires per cm2.
, Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the technical field of metallurgy sintering. In particular, the present disclosure pertains to a system for arresting air leakages in an under-suction type sintering machine.

BACKGROUND OF THE INVENTION
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Sinter machines are used to agglomerate the fines of iron ore, manganese ore and the like. Air is drawn down through the grate to produce downdraft combustion. Thus, for the downdraft sintering machine, suction pressure, below the grates, plays a very important role in the sintering operation. Under grate suction is created by exhausters. The assembly of components from exhausters to pallet bottom is called suction track, which consists of stationary parts, namely, wind boxes, vacuum chambers, sleeves, heat compensators, wind main etc. The sealing plate acts as a coupling between the stationary wind box and moving pallets, where the wind box is situated under the grate by means of blower fans at the bottom of sintering machine. In general, track mounted and pallet mounted sealing systems are used in the sinter machine. Further, the sealing system consists of Seal bars with spring and the wear bars.
[0004] In the sintering process, out of total leakage across suction track, around 40% is through sealing system. In early ‘70s, the air leakage of the sinter machine was more than 60%.The air leakage is generally lower in the newly built sinter machines. However, as reported with application of all recently developed measures such as the high minus pressure contact air-sealing technology and self-adjustable flexible sealing device, the all-metal soft magnetic sealing device and double plate spring sealing device etc., the air leakage of sinter machine can be reduced to between 20% to 30%, which enables more air being sucked through the grates.
[0005] In an older sinter plant, continuous abrasion and thermal deformation generates multiple mechanical leakage points along the track and maximum leakage occurs through the sealing system. These leakage points become easy paths causing ambient air ingress into suction track, instead of air being sucked through packed sinter bed. Hence sinter machine productivity reduces gradually.
[0006] At sinter plants, especially the old ones, the problem of air leakages through track sealing is quite common. To make these sinter plants more efficient, a considerable amount of electrical power is wasted just to suck leaked atmospheric air across the suction track. As such, this reduces the effective suction at under grates, resulting in reduced volume of air being sucked through the bed. This in turn reduces the vertical sintering speed and hence affecting the productivity and quality of sinter output. To maintain the health of the sealing, frequent unplanned shutdowns are required, which further leads to reduced production. Further, the sinter plant where gap between moving and stationary part of sinter machine is higher, air is leaked through the gap.
[0007] There is therefore a need for a provision to block/ hinder the leakage points that cause ambient air ingress into suction track (easy paths) so that more air is sucked through the packed sinter bed and sinter machine productivity is improved significantly.
[0008] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0009] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about”. Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0010] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0011] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0012] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

OBJECTS OF THE INVENTION
[0013] A general object of the present disclosure is to provide a system and method for arresting air leakage through track sealing at sinter plants.
[0014] Another object of the present disclosure is to provide a simple and robust design to fabricate a sealing system.
[0015] Yet another object of the present disclosure is to design a sealing system that can be easily fabricated.
[0016] Yet another object of the present disclosure is to design a sealing system that can be easily installed in sinter machines.
[0017] Another object of the present disclosure is to design a sealing system that can minimize side leakages and fresh air ingress through track sealing.
[0018] Yet another object of the present disclosure is to design a sealing system that requires a negligible sinter machine downtime during installation.
[0019] Yet another object of the present disclosure is to design a sealing system that can be retrofitted in a deform track in a sinter machine, thereby making a leak proof system.

SUMMARY
[0020] Aspects of the present disclosure relate to a system for arresting air leakage through track sealing at sinter plants. The disclosed sealing system can be fixed on the inner side of gap between the moving and stationary part of a sinter machine in order to block/seal the leakage of air through the gap during under-grate suction created by exhausters.
[0021] In an aspect, the present disclosure provides a system for sealing air leakage in an under-suction type sintering machine, the system can include: a plurality of metal wires each having a fixed end and a free end; and a metallic channel having a first end and a second end, wherein the channel comprising a recess extending longitudinally from the first end to the second end, and wherein the fixed ends of the plurality of metal wires are fixedly mounted in the recess of the metallic channel.
[0022] In an embodiment, the metallic channel of the sealing system can be made from mild steel. In another embodiment, the recessed metallic channel can have a U-shaped cross section.
[0023] According to embodiments of the present disclosure, the dimensions of the disclosed sealing system can be designed specifically based on the gap between the moving and stationary part of the suction track of a deformed sinter machine. In an exemplary embodiment, the metallic channel can have a length ranging from 1900mm to 2300mm.
[0024] In another exemplary embodiment, the plurality of metal wires can extend 10mm to 150mm from the metallic channel. In a more preferred embodiment, the plurality of metal wires can extend70mm to 100mm from the metallic channel.
[0025] In an embodiment, the plurality of metal wires can be fixedly mounted in the recess of the metallic channel in a form of bundles to form a brush like assembly. In another embodiment, the bundles of metal wires mounted in the recess of the metallic channel can have a density of at least 30 wires per cm2.
[0026] In an embodiment, the plurality of metal wires can be made from stainless steel, preferably from spring quality steel. In another embodiment, each of the plurality of metal wires can have a diameter ranging from 0.1mm to 2mm.
[0027] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0029] FIG. 1 illustrates schematic view of a conventional prior art sinter machine.
[0030] FIG. 2 illustrates under-grate air leakages across a gap between the moving and stationary part of a conventional sinter machine.
[0031] FIG. 3 illustrates schematic view of a sealing system in accordance with embodiments of the present disclosure.
[0032] FIG. 4 illustrates an exemplary diagram showing the wind box arrangement of a sinter machine in accordance with embodiments of the present disclosure.
[0033] FIG. 5 illustrates exemplary configuration of a sealing system according to one embodiment of the present disclosure.
[0034] FIG. 6 illustrates exemplary configuration of a sealing system according to an embodiment of the present disclosure.
[0035] FIG. 7 shows an exemplary sealing system constructed in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION
[0036] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0037] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0038] Unless the context requires otherwise, throughout the specification which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense that is as “including, but not limited to.”
[0039] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0040] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0041] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable.
[0042] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein.
[0043] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0044] The headings and abstract of the invention provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
[0045] Various terms as used herein. To the extent a term used in a claim is not defined, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0046] Reference will now be made in detail to the exemplary embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
[0047] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
[0048] The present disclosure relates to a system for arresting air leakage through track sealing at sinter plants. Due to continuous abrasion, thermal deformation, ageing, a gap can be created between the moving and stationary part of suction track of a sinter machine, resulting in the deformation of the sinter machine. This gap can become easy leakage points causing ambient air ingress into the suction track when air is sucked through a packed sinter bed. The air leakage through the gap drastically degrades the effectiveness and efficiency of the deformed sinter machine.
[0049] A schematic view of a conventional prior art sinter machine is shown in FIG. 1. The suction track, here, is in a bad shape and the sinter machine is deformed. Subsequent to continuous abrasion, thermal deformation, ageing, an inevitable physical gap is created between the moving and stationary part of suction track of the sinter machine. FIG. 1 shows the leakage of air through the gaps 202a and 202b, collectively called gap 202 during the under-grate suction created by exhausters.FIG. 2 illustrates under-grate air leakage across a gap between the moving and stationary part of a conventional sinter machine-3, SP2 and BSP.
[0050] In an aspect, the present disclosure provides a system for sealing air leakage in an under-suction type sintering machine, the system can include: a plurality of metal wires each having a fixed end and a free end; and a metallic channel having a first end and a second end, wherein the channel comprising a recess extending longitudinally from the first end to the second end, and wherein the fixed ends of the plurality of metal wires are fixedly mounted in the recess of the metallic channel.
[0051] According to embodiments of the present disclosure, the dimensions of the disclosed sealing system can be designed specifically based on the gap between the moving and stationary part of suction track of a deformed sinter machine. In an exemplary embodiment, the metallic channel of the sealing system can have a length ranging from 100mm to 5000mm, preferably from 1900mm to 2300mm. In another embodiment, the metallic channel can have a width in the range of 20 mm to 40 mm, height in the range of 20 mm to 40 mm and thickness in the range of 3 mm to 6 mm.
[0052] In an embodiment, the metallic channel can be made from mild steel. In another embodiment, the recessed metallic channel can have a U-shaped cross section. The metallic channel can be painted with a red oxide primer, or any suitable paint, to minimize corrosion. The metallic property of the channel can enable it to serve for prolonged durations.
[0053] In an exemplary embodiment, the plurality of metal wires can extend 10mm to 150mm from the metallic channel. In a more preferred embodiment, the plurality of metal wires can extend70mm to 100mm from the metallic channel.
[0054] In an embodiment, the plurality of metal wires can be fixedly mounted in the recess of the metallic channel in a form of bundles to form a brush like assembly. In another embodiment, the bundles of metal wires mounted in the recess of the metallic channel can have a density of at least 30 wires per cm2.
[0055] In an exemplary embodiment, the bundles of metal wires mounted in the recess of the metallic channel can have a density of 33 wires per cm2.
[0056] In an embodiment, the plurality of metal wires can be made from stainless steel, preferably from spring quality steel. However, the metal wires can be made up of any other metal that can be corrosion resistant and that can withstand temperature, dust, wind, water, wear and tear and the like. Further, the wire bunch/bundle can be capable of withstanding compressive forces and remain intact in the channel.
[0057] In another embodiment, each of the plurality of metal wires can have a diameter ranging from 0.1mm to 2mm. In an exemplary embodiment, each of the plurality of metal wires can have a diameter of 0.5mm.
[0058] Referring to FIG. 3 that shows exemplary configuration of a sealing system 100 in accordance with embodiments of the present disclosure. As shown in FIG. 1, the sealing system 100 can include a plurality of metal wires 102 made from spring grade stainless steel. The wires 102 can be packed together and rigidly fixed in a recess of the metallic channel 104 to form the sealing system 100 in a form of brush like assembly. The sealing system 100 can be fixed on an inner side of gap between the moving and stationary part of a sinter machine. As a result, the steel wires in the brush assembly can cover the gap between the moving and the stationary part of the sinter machine. The thickness of overall brush and density of stainless steel wires can be able to block (also referred to as hinder or prevent or resist or obstruct hereinafter) the passage of air through it.
[0059] FIG. 5 illustrates exemplary configuration of a sealing system 300 having a length of 2300mm constructed in accordance with one embodiment of the present disclosure. FIG. 6 illustrates exemplary configuration of another sealing system 400 having a length of 1960mm constructed according to an embodiment of the present disclosure. FIG. 7 shows a fully constructed sealing system 500 designed in accordance with one preferred embodiment of the present disclosure.
[0060] Referring to FIG. 4 that illustrates an exemplary diagram of a sinter machine200 that incorporates the sealing system 100a and 100b in accordance with embodiments of the present disclosure. The sealing systems 100a and 100bcan be instances of the sealing system 100 as described in FIG. 3. During the operation of the sinter machine 200, when air is sucked through the packed sinter bed by exhausters (not shown), the sealing systems 100a and 100b can create a blockage to air leakage through the gaps 202a and 202b, resulting in more air being sucked through the packed sinter bed. As a result, the deformed sinter machine becomes very effective and efficient again. As shown in FIG. 4, the sealing systems 100a and 100b can perfectly match the physical gap between the moving and stationary part of the sinter machine 200 and can help achieve optimum benefits from the deformed sinter machine. Further, the sealing systems 100a and 100b can be fixed on the inner side of gaps 202a and 202b such that they do not affect the relative motion between the moving and the stationary part of the sinter machine during operation. Further, the sealing systems 100a and 100b can be dimensioned based on the physical gap 202 between moving and stationary part of the sinter machine to ensure optimum benefits. Since, the sealing systems 100a and 100b can be able to cover the gaps202a and 202bbetween the moving and the stationary part of the sinter machine 200, they can be able to block air leakage. This is achieved due to appropriate thickness and density of the metal wires 102, and overall structure of the sealing system 100 acting together to block the gaps and minimize the air ingress through the gaps 202a and 202b.
[0061] According to embodiments of the present disclosure, the disclosed sealing system can be installed very easily and quickly, thus minimizing the downtime of sinter machines. Further, the sealing system of the present disclosure can be very cheap and can be installed at all deformed sinter machines, thus helping them to be more efficient and effective again.
[0062] In an exemplary implementation, the disclosed sealing system was installed at sinter machine-3, SP#2 and BSP to evaluate the performance of the sealing system 100. It was observed that (a) the leakage through the sealing at the discharge side were significantly reduced as tested by the anemometer, (b) the air filtration velocity at the top improved by over 50%, from 0.19 m/sec to 0.30 m/sec, after the installation of the sealing system 100 and side leakages through track sealing were reduced, which was also indicated by reduction in suction loss of under grate to wind leg segment, (c) the productivity improved by 2.034%, from 1.346 t/m2/hr to 1.374 t/m2/hr, (d) improvement of 4 units was observed in DTI of machine-3 sinter compared to DTI of machine-2 sinter and (e) yield of the product sinter was improved by 1% in machine-3 sinter compared to other sinter plant 2 machines. As observed, the sealing system 100 can be implemented at any sinter plants and the sinter plant productivity and quality can be improved significantly.
[0063] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0064] The present disclosure providesa sealing system for arresting air leakage through track sealing at sinter plants.
[0065] The present disclosure provides a simple and robust design to fabricate a sealing system.
[0066] The present disclosure provides a sealing system that can be easily fabricated.
[0067] The present disclosure provides design a sealing system that can be easily installed in sinter machines.
[0068] The present disclosure provides a sealing system that can minimize side leakages and fresh air ingress through track sealing.
[0069] The present disclosure provides a sealing system that requires a negligible sinter machine downtime during installation.
[0070] The present disclosure provides a sealing system that can be retrofitted in a deform track in a sinter machine.