44451175 Test Procedures

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2

Sulphur Liberation Test

Aim Of Test

Determination of the amount of Sulphur liberated during the reduction of pellets with Hydrogen .

Procedure

1. Preparation of Sample

Wt. 500 g / Size 11-13 mm Drying @ 105 C for 2 hrs.

2. Preparation of Solution.

KIO3 solution for titration0.2225 g 1n 900 ml of H2O and then bring up to 1000 ml.Starch- KI solution : 1.0 g of soluble starch in 50 ml of boiling water + 1.5 g of KI until dissolved then dilute with H2O up to 100 ml

Close N2 valve Open H2 valve

3.Heating up N2 gas

Type of Reactor Vertical

Reactor Size 75 mm diameter

Sample Weight 500 g

Pellet Fraction 11-13 mm

Test Temp 815 C

Reduction Time 4.0 hrs

Gas Mixture 100% H2

Gas Flow rate 3 l/m

Test Parameters

3

Sulphur Liberation Test contd>>>>

Time : 4.0 hrs.Gas composition: (3lpm) % lpm H2 100 3.0

4.Start Reduction

Close reduction gas valve & open N2 @ ( 1.0 liters /min) Switch off the furnace.

5.Reduction About 2 hr , up to room temp Keep N2 gas flowing

6.Completion of Reduction

Stop N2 gas supply & take out the pellets .

7.weighing and evaluating

Reducibility, Compressive strength after reduction & metallization.

8. Calculation Recorded in form #

4

Linder Reduction Test

Aim Of Test

Determination of the fine generation tendency of Midrex Pellets during reduction.

Procedure


Wt. 500 g / Size 11-13 mmDrying @ 105 C for 2 hrs.

2.Heating up N2 gas

Flow rate :15 liters/min until reactor temp. = 760C (60 min) add 30 min for stabilization

3.Start Reduction

Close N2 valve & start barrel rotation @ 10 rpm Open H2,CO,CO2, CH4 valves

4.Reduction Time : 5.0 hrs.Gas composition: (15 lpm) % lpm H2 55 8.25 CO 36 5.40CO2 5 0.75CH4 4 0.60

Type of Reactor Horizontal

Reactor Size 190 dia/ 220 mm length/ no lifters

Sample Weight 500 g

Pellet Size 11-13 mm

Test Temp 760 C


Gas Mixture 55% H2,36% CO,5%CO2,4% CH4

Gas Flow rate 15 l/m

Rotation Speed 10 rpm

Sieve Size 6.35,3.35 ,0.5 mm

Test parameters

5

Linder Reduction test Contd>>>>


Close reduction gas valves & open N2 @ ( 15liters /min)

6.Cooling About 1 hr , up to room tempStop the barrel

7.Sample Discharge

Stop N2 gas supply & take out the pellets and fines-record the Weight of the reduced pellets

8.Sieving andevaluating

Sieve size: 6.35,3.35,0.5 mm Reducibility, Compressive strength after reduction & metallization.


6

Reduction Under Load TestAim Of Test

Determination of the clustering properties of Midrex Pellets.

Procedure


Wt. 500 g / Size 11-13 mmDrying @ 105 C for 2 hrs.

3.Heating up N2 gas

Flow rate :20 liters/min until reactor temp. = 860C (60 min) add 30 min for stabilization

4.Start Reduction

Close N2 valve Open H2,CO,CO2, CH4 valves

2.Load Application

Apply the weight 2 kg/cm2


Reactor Size 75 dia

Sample Weight 500 g


Test Temp 860 C


Gas Mixture 55% H2,36% CO, 5%CO2,4% CH4

Load Application 2kg/cm2

Gas Flow rate 20 l/m

Test Parameters

7

Reduction Under Load Test Contd>>>>>

5.ReductionTime : 3.0 hrs.Gas composition: (20 lpm) % lpm H2 55 11.0 CO 36 7.20CO2 5 1.00CH4 4 0.80


Close reduction gas valves & open N2 @ ( 20liters /min)switch off the furnace.

7.Cooling About 2 hr , up to room tempKeep N2 gas flowing

8.Sample Discharge

Stop N2 gas supply & take out the pellets . Extract the clustered sample

10.weighing and evaluating

Reducibility, Compressive strength after reduction & metallization.


9.Clustering Tester

Put the sample in a rotating drum @ 30 rpm for 2 or 5 minutes. Then measure the cluster.

8

RDI TEST PROCEDURE

Aim Of Test

Determination of the disintegration tendency of blast furnace pellets at low temperature under reducing condition similar to those prevailing in the upper part of the blast furnace.

Procedure


500 g (W1) ,Size 11-13 mm Drying @ 105 C for 2 hrs. Place the sample in a vertical reactor & place the reactor exactly into the center of the furnace.

2.Heating up N2 gas

Flow rate:15 l /min Reactor temp. = 550C and 10 min for stabilization

3. ReductionTime: 0.50 hrs.Gas Composition: (15 l /min) % lpmCO 30 4.5N2 70 10.5

4. Completion of Reduction

Switch on the furnace & cool the reactor under a flow of N2 gas at 15 l /min


Reactor Size 75 mm Dia

Sample weight 500 g


Test Temperature 550 C


Gas Composition % L/min

CO 30 , N2 70CO 4.5 N2 10.5

Gas flow rate 15 liters / min

Test Parameters

9

RDI TEST PROCEDURE Contd>>>>

5.Cooling About 2.0 hrs, up to room temp. Take out the reduction tube.

7.Discharging of Sample

After cooling the tube to the room temp. take out the sample.

8. WeighingWeigh the reduced sample & determine (W2 )

11.Calculation Reduction Rate (%) : (W1-W2)*10000 W1(0.43*TFe-0.112*FeO)

R.D.I = Wt. (-3.15 mm)*100 W2

Record data – form #

9.TumblingThe reduced sample is subjected to tumbling for 30 min @ 30 rpm in the tumbling apparatus for RDI determination

10.SievingThe sample is sieved using 6.35 , 3.15 & 0.5 mm sieves.

10

FREE SWELLING INDEXAim Of Test

Determination of the swelling properties of blast furnace pellets. The test is based on free swelling, i.e. the sample holder allows free expansion of each individual pellet without mutual physical contact.

Procedure

1.Preparation of Sample

Size 11-13 mm Drying @ 105 C for 2 hrs.

2.Selection of Sample

Select 3 3 pellets at random, exclude the cracked ones. Clean the pellets and weighed each (W1).

3.Measurement of volume (V1)

Measure the volume of each pellet using a Mercury densimeter.

4.Placing the pellets

Place the pellets in the boat , spacing 10 mm. Place the boat into the reducing tube.

Type of Reactor Horizontal

Reactor Size 30 dia , 360 mm length

Sample 3 pellets


Test Temp 900C


Gas Mixture L/min

30% CO ,70% N2 0.15 CO ,0.35 N2

Gas Flow rate 0.5 l/m

Test Parameters

11

FREE SWELLING INDEX Contd>>>>

5. Heating up Pass N2 gas at a rate of 200 ml/min Heat the sample up to 900 C and maintain the temp. for 30 min.

6.Reduction Time : 1 hr.Gases: % lpmCO 30 0.15N2 70 0. 35

7.Cooling Pass N2 gas at a rate of 200 ml/min . Remove the furnace & take out the reduction tube.



9. Weighing Weigh each pellet again & determine W1, W2 & W3

V= W1+W3 – W2 V : vol of pellet P W1 :wt. of pellets in the air W2 : wt. of blank in the mercury. W3 : wt. of pellets in the mercury P : Density of mercury

10. Measurement of Volume (V2)

V = W1+W3 – W2 P

11. Calculation of Swelling Index.

S.I. = V2 – V1 x100 V1Record – form #

12

REDUCIBILITY TEST PROCEDURE

Aim Of Test

Determination of the total reducibility of blast furnace pellets.

Procedure


500 g (W1) ,Size 11-13 mm Drying @ 105 C for 2 hrs. Place the sample in a vertical reactor & place the reactor exactly into the center of the furnace.

2.Heating up N2 gas

Flow rate:15 l /minReactor temp. = 900CAdd 30 min for stabilization

3. Reduction

4. Weight Loss Record the weight losses at every 5 min interval for the complete period of reduction. using a balance & printer.

Time: 3.0 hrs.Gas Composition: (15 l /min) % lpmCO 30 4.5N2 70 10.5



Sample weight 500 g

Pellet Fraction 11-13 mm

Test Temperature 900 C


Gas Mixture % L/min

CO 30 , N2 70CO 4.50 , N2 10.50


Test Parameters

13

REDUCIBILITY TEST PROCEDURE Contd>>>>


Switch on the furnace & cool the reactor under a flow of N2 gas at 15 l /min

6.Cooling About 2.0 hrs, up to room temp. Take out the reduction tube.

7.Cooling Pass N2 gas at a rate of 15l/min Remove the furnace & take out the reduction tube.



9. Weighing Weigh the reduced sample& determine ( W2 )

10. Calculation

a. Reduction Rate (%) : (W1-W2)* 10000 W1(0.43*A-0.112*B)

b. Rate of Reduction (%/min) i.e (dr/dt)40 : Wt. loss @ t min of reduction (W1-Wt) Wt. loss upon completion reduction (W1-W2)

c. Compressive Strength After Reduction (kg/p) (20 reduced pellets were measured for CCS

Average , Max. & Min. were reported.

Record data – form #

14

HYL REDUCIBILITY TEST PROCEDURE

Aim Of Test

Determination of the reducibility of HYL pellets.

Procedure


500 g ,Size 50%(10-12.50 mm)&50% (12.5-16mm)Place the sample in a vertical reduction tube & close tightly .

2.Heating up N2 gas

Flow rate:10 l /min for 1.5 hrs As the temp. reaches 950C,Increase the N2 gas to 30 l/min

3. Reduction

4. Weight Loss

Set the balance &the printer to zero and be sure that the reduction tube does not touch the furnace. Monitor the weight losses at continuously until it reaches 95% of reduction.

Time: until 95% reduction attainedGas Composition: (55 l /min) % lpmH2 55 30.25CO 21 4.50N2 10 10.50CO2 14 9.75



Sample weight 500 g

Pellet Fraction 10-12.5 mm 50% & 12.5-16 mm 50%

Test Temperature

950 C

Reduction Time Until 95 % reduction

Gas Mixture % L/min

H2 55, CO 21,CO2 14, N2 10 H2 30.25,CO11.55,CO2 7.70,N2 5.50


Test Parameters

15

HYL REDUCIBILITY TEST PROCEDURE Contd>>>>


When 95% of reduction attained, replace the reducing gas with N2 gas at 10 l /min

6.Cooling Open the furnace & let the reduction tube cooled to room temperature.


After cooling the tube . remove the sample and measure the weight of reduced pellets.

8. CSAR Measurement

Select 20 pellets of the reduced sample& proceed for the CSAR test.

9. Calculation

a. O2 reducible (%) : (Tfe x1.5 – FeO x 0.78 x 0.50) x16 x 100 5585

b. O2 to be removed : O2 reducible x 0.95)

c. Reduction rate % = Wt. Loss x 100 O2 Reducibled. K = Ln(1-1/R) t e. Compressive Strength After Reduction (kg/p) (20 reduced pellets were measured for CCS Average , Max. &

Min. were reported.

16

MOISTURE DETERMINATION Test PROCEDURE

Aim Of Test

Determination of the moisture content in the sample.

Procedure

1. Heating Oven

Maintained @ 105 + 5 C

3.Sample Weight

Take app. 1 kg sample & record weight of tray with sample as (W2).

4. Drying of Sample

Place the tray in oven for 3 hrs. min.

5.Weight after Drying

Remove the tray from the oven. Weigh & record (W3)

2.Tray Weight Record as (W1)

6.Calculation M.C = W2-W3 x 100 W2-W1

W1= Tray weightW2= Weight of sample & trayW3= Weight of dry sample & tray

Oven Temperature

105 +5 C

Sample Weight 1kg

Drying Time 3 hrs. min

Test Parameters

17

BULK DENSITY TEST PROCEDURE

Aim Of Test

Determination of the bulk density of the sample .

Bulk Density is the weight of a representative unit volume of a particulate material including the voids within and between the Particles expressed as weight units per unit volume.

The maximum particle size should not exceed 40 mm.

The moisture content and the size distribution are the two main factors which affect bulk density.

Procedure

1. Cylinder Weight

Record the weight of the cylinder

3.Sample Weight

Calculate the sample weight

4. Fill in Water

Fill the cylinder with water . Record the weight

2.Fill in the Sample

Fill the cylinder with the sample to overflow & level the top. Record the weight.

18

BULK DENSITY TEST PROCEDURE Contd>>>>

5.Volume of Water

Calculate the volume of water

6.Calculation B.D = W V

W = Sample WeightV = Water Volume

19

TRUE SPECIFIC GRAVITY TEST PROCEDURE

Specific Gravity is the ratio of weight of the sample to the weight of same volume of water at 4 C .

Aim Of Test

Determination of the true specific gravity of iron ore , bentonite , limestone and petcoke samples as and when necessary to measure blaine index of raw material and porosity for pellets.

Procedure 1. Preparation

Put 500 ml of xylene & distilled water in 2 beakers & transfer to a desicator for 20 min.

3. Xylene Addition

Add 20 ml of xylene to the pycnometers and place in vacuum desicator for 30 min

2. weighing(W1)

Weigh 2 empty pycnometers (W1)

4. weighing(W3)

Measure pellet weight in Mercury (W2).

5.Calculate the Apparent S.G

Calculate the apparent Specific Gravity.

20

BLAINE INDEX Test PROCEDURE (P-PBL)

Aim Of Test

Determination of the surface area of particles in a unit mass of the material (cm2/g) , which is an alternative parameter to size analysis in expressing the fineness of the material.

The principle of the blaine test is that for a given weight of material compacted to a known porosity , the time for a specific volume of air to pass through the material is a function of the surface area of a constituent particles.

Procedure

1. Determine volume (V) of the measuring cell using a primary standard sample ( cementstandard sample of known blaine, specific gravity & porosity ) and record. This vol shall be used for calculating the blaine index on test samples on regular basis .

NOTE : The cell volume shall be checked periodically to check for any variation and if the variation is found then the new value shall be used for calculation further.

2. T o measure blaine index on a test sample, place the perforated metallic plate inside the cell and place two sheets of filter paper on it and record the weight

3. Place approximate quantity of the sample in to the cell on the perforated metal plate and one filter paper , then place the second sheet of filter paper on the sample and record the weight.

Then insert the plunger in to the cell softly and press to confirm that the the rim of the plunger is stuck to the rim of the cell to confirm the sample quantity is not excessive.

21

BLAINE INDEX Test PROCEDURE (P-PBL) Contd>>>>

4. Insert the cell into the manometer and press it gently to prevent air leak.

5. Open the cock and raise the monometer liquid up to the mark A , and the shut the cock .

6. Slowly remove the plunger from cell. The fluid in the column starts descending from the mark A

7. Measure the time (sec) required for the monometer liquid to descend between the marks B and C

8. Repeat measurement three times and take the average value (to).

9. Calculate the Blaine Index. S = So Po * t * 1-e * e3

P to eo3 1-e e = PV-W / PV

W = PV ( 1 – e)

Where:

S : Specific surface area of ore sample

So : Specific surface area of cement standard sample

Po : Specific gravity of the standard sample

P : Specific gravity of the sample

to : Time required for the standard sample

t : Time required for the sample from B to C

e : Porosity of the ore bed

V : Volume of the cell ( from calibration)

W : Weight of sample used

22

CYCLOSIZER TEST PROCEDURE

Aim Of Test

Determination the presence of ultra fines ranging from app. 30 microns to 6 microns in the powder sample .

Five cyclones calibrated at the standard and operating parameter has the size of 46.7, 31.5 , 22.2, 15.7 and 12.4 microns are arranged in descending order.

Procedure

• Take 20 g of (–) 105 mic. Sample which has been prepared from a representative sample dried and sieved @ 105 mic and place it into a beaker (500 ml) and add water to make slurry.

• Transfer the above sample into the sample container and close the valve.• Fix the sample container in position at the cyclosizer apparatus and close the flow

control valve.• Start the water pump and adjust the water flow pressure to 230 mmH2O.

23

CYCLOSIZER TEST PROCEDURE Contd>>>>

• Open vortex valve slowly and remove air bubbles one at a time starting from cyclone # 1. Open the valve fully.

• Set the timer for water pump for 5 minutes.

• Open sample container’s valve gradually in order that all sample passes in 5 minutes.

• Adjust water flow pressure to 180 mm H2O and set timer to 20 minutes and allow it to continue until the set time is elapsed. Increase flow to 230 mm H2O after buzzer sounds.

• Collect all the samples from the 5 cyclones starting from 5 to 1 each in a separate beaker.

• Allow the beakers to stand for 20 minutes , and decant excess water and dry the sample.

• Record weight of the material obtained from each cyclone

• Calculate the amount of material of particular size in microns that is passing through each cyclone as per the procedure.

24

TUMBLE TEST PROCEDURE (ISO)

Aim Of Test

Determination of the resistance of pellets to breakage during handling. The pellets need to posses sufficient degradation

resistance to withstand transportation without breakage. Breakage can either take the form of fractured bits of whole pellets or dusting caused by abrasion of the pellets against each other and other contact surfaces

Procedure

1. SamplePreparation

Wt. 15kg (A) / size + 6.3 mmDrying @ 105 C for 2 hrs.

2. DrumRotation

Charge the sample to the drum & rotate for 200 revolution at 25 rpm. 2 kg/cm2

3. SampleDischarge

Remove all test sample & screen with 6.3 mm & 0.5 mm sieves.

Drum Size Dia 1000 mm, width 500 mm

Sample Weight 15kg

Pellet Size +6.3 mm

No. of Revolution

200

Rotation Time 8 min

Rotation Rate 25 rpm

Sieve Size 6.3 mm / 0.5 mm

Test Parameters

25

TUMBLE TEST PROCEDURE (ISO) Contd>>>>

4. Data Recording

Record the weights +6.3 mm (B), -6.3 +0.5 mm (C )

5.Calculation

T.I = B x100 A

A.I = A- (B+C) x100 A

Calculate TI ,wt % +6.3 mm &AI , wt % - 0.5 mm

A: initial weight of + 6.3 mm pellet sample B: weight of pellets retained on 6.3 mm screen after tumbling. C: weight of broken pellets / dust collected between 6.35& 0.5 mm

26

TUMBLE TEST PROCEDURE (JIS)

Aim Of Test

Determination of the resistance of pellets to breakdown on handling. The pellets need to posses sufficient degradation resistance to withstand transportation without breakage. Breakdown can either take the form of fractured bits of whole pellets or dusting caused by abrasion of the pellets against each other and other contact surfaces.

Procedure

1. Sample Preparation

Wt. 23kg (A) / size + 5 mmDrying @ 105 C for 2 hrs.

3. SampleDischarge

Remove all test sample & screen with 5 mm & 1 mm Sieves.

2. DrumRotation

Charge the sample to the drum & rotate for 200 revolution at 25 rpm 2 kg/cm2

Drum Size Dia 914 mm, width 457 mm

Sample Weight 23kg

Pellet Size +5 mm

No. of Revolution 200

Rotation Rate 25 rpm

Rotation Time 8 min

Sieve Size 5 mm & 1 mm

Test Parameters

27

TUMBLE TEST PROCEDURE (JIS) Contd>>>>

4. Data Recording

Record the weights +5mm (B),-5 +1 mm (C )

5.Calculation

T.I = B x100 A

A.I = A- (B+C) x100 A

Calculate TI,wt % + 5mm &AI, wt % -1 mm

A: initial weight of + 5 mm pellet sample B: weight of pellets retained on 5.0 mm screen after tumbling. C: weight of broken pellets / dust collected between 5.0& 1.0 mm

28

POROSITY TEST PROCEDURE

Aim Of Test

Determination of the porosity of the pellets .

Procedure

1. Sample weight

Record the sample weight (W1)

3.Calulate App. Specific gravity

App. Specific gravity = W1 x pHg W1+W2

4. calculate porosity

Porosity = P- Papp x100 P

2.Sample weight in Mercury

Record the sample weight in Mercury (W2)

29

COLD COMPRESSIVE STRENGTH TEST PROCEDURE

Aim Of Test

Determination of the crushing strength of the pellets .

Procedure

1. Sample Preparation

Dry the sample @ 105 CSelect at random (12) pellets from 11-13 mm for production and (100) pellets for shipment.

3.Recording Record the max. load at which the pellet breaks from the recorder chart.

3.Sample Testing

Place single pellet at the center of the lower platen of the testing machine . Apply with the load cell (1000kg) at a speed of 10 mm/ min

2. Machine Preparation

Select the scale x1.Check the calibration of the recorder.

No. of Pellets 12 or 100


Load Cell 1000 kg

30

Green balls Dry Compressive Strength Test Procedure

Aim Of Test

Determination of the compressive strength of green balls after they are dried at (105C) for 3 hrs.

Procedure

1. Preparation of Green Balls

Sieve the green ball with 11-13 mm screen & keep in oven (105C) for complete drying. Select (12) pellets for testing. Balls for testing.

3.Recording of Data

The DCS of each green ball is recorded on a chart . record all measurements & proceed for computation.

4. Calculation Calculate the average , maximum & minimum.form #

2.Testing of Green Ball

Test each green ball individually using the crushing strength machine.

Practical Limitation:

Complete loss of moisture is required before proceeding to the test.

31

Green balls Compressive Strength Test Procedure

Aim Of Test

Determination of the compressive strength of green balls in order to assess whether the green balls being fed to traveling grate have acquired adequate strength to withstand the pressure of green balls from upper layers.

Procedure

1. Preparation of Green Balls

Sieve the green ball with 11-13 mm screen & Select (12) pellets for testing. Balls for testing.

3.Recording of Data

The GCS of each green ball is recorded on a chart . record all measurements & proceed for computation.

4. Calculation Calculate the average , maximum & minimum. form #

2.Testing of Green Ball

Test each green ball individually using the crushing strength machine.

Practical Limitation: Green balls must be subjected to the test with a minimum loss of moisture as much as possible.

32

DROP STRENGTH TEST PROCEDURE

Determination of the green balls strength to withstand the drops involved on transfer from balling to the travelling grate .

A low drop value indicates that the balls are brittle possibly due to insufficient moisture whereas plasticity attributes to an excess of water.

Procedure

1. Selection ofGreen Balls

Select (12 nos.) of a suitably sized balls (11-13 mm)

3.Recording of data

Record the number of drops required to cause breakage.

4. Calculation Calculate the average drop nos and the maximum & minimum values.

2.Dropping of the Balls

Drop each ball from 50 cm height until fracture occurs

33

TEST SIEVES CALIBRATION

Aim Of Test

Calibration of test sieves used for size analysis with the help of master sieves.

Procedure

1. Use the Mater sieves as reference standard for calibration of test sieves .

2. Carry our size analysis of standard product pellet , Iron ore sample using the Master sieves.

3. Note down % ret and compute % passing on each master sieve. ( A)

4. With the same product pellets , Iron ore carry out size analysis using regular test sieves which need Calibration check.

5. Note down % ret and compute % passing on each sieve (B)

6. Compare above results (A) and (B). Compute (A)-(B) =C

7. Acceptance criteria C = +/- 2%

34

CAUSTIC SODA ANALYSIS

Aim Of Test

Determination of the NaOH % in Caustic soda. One sample per batch to be drawn from Caustic soda consignment

Procedure

1. SAMPLING

5O ML

2.WEIGHING 1 ml sample to be taken by micro burette.

3.DILUTION Dilute in 250 ml Measuring flask with distilled water.

4.PARTITION 10 ml + 100 ml distilled water. (V1)

5. COLORINGPhenolphthelein Indicator 2 to 3 drops – ( pink color)

6.TITRATION Titrate with 0.1 N H2SO4 std solution – Pink to Colorless –(V2)

7. CALCULATION

NaOH % = V2 *0.35 X 250 V1Record – Chemical analysis result form

35

MASTER INSTRUMENTS FOR TEST, MEASURING, INSPECTION & CALIBRATION

I.D. No.MASTER INSTRUMENT DESCRIPTION

TYPE OF MEASUREMENTAND SIMULATION

Calibration By whom

Frequency of calibration

1700 I1 STOP WATCH Citizen Model LSW 9107

Time External 1 year

1700 I2 DIGITAL THERMO METERANRITSU MODEL HFT-80

Temperature External 1 year

1700 I3 LIQUID IN GLASS THERMO METER MODEL 0-360 Deg.C

Temperature External 1 year

1600 I1 TRUE RMS MULTI METER FLUKE MODEL 187

Voltage, Current, Resistance,Frequency

External 1 year

1600 I2 MULTI FUNCTION CALIBRATOR MC-5

Pressure, current, voltage External 1 year

1600 I3 INDUSTRIAL SCOPE METER FLUKE MODEL 123

Oscilloscope External 1 year

1600 I4 DEAD WEIGHT TESTER Pressure/ Flow External 1 year

1700 M1 Measuring glass wares:Glass burettes-12862, 12856, 7439, 1266Pipettes- 10ml, 25ml.Flasks- 100,250,500,1000ml

Volume Internal (QC) 6 months

1700 T1 Test sieve normal Size Internal (QC) 6 Months

1700 T2 Hand sieve (wooden frame) Size Internal (QC) 6 Months

36

MASTER INSTRUMENTS FOR TEST, MEASURING, INSPECTION & CALIBRATION Contd>>>

I.D. No.MASTER INSTRUMENT DESCRIPTION

MASTER REFERENCE FOR TYPE OF MEASUREMENT

Calibration By whom

Frequency of calibration

1708 Platform Scale B-251 (250 KG)(Physical Lab)

Weight External 1 year

1600 W1

Plat form Scale – YAMOTO –EDI-302(300 KG) / (E/I Work Sop)

Weight External 1 year

1700 D1 CARBON MONOXIDE DETECTOR MODEL MINI CO PORTABLESL NO – A1 - 12829

Gas leakage detector External 1 year

1700 D2 CARBON MONOXIDE DETECTOR MODEL MINI CO PORTABLESL NO – A2 –3173-J97-


1700 D3 CO GAS DETECTORCOMA-2 (SL NO 1456)


1700 D4 H2 GAS DETECTOR (SL NO 2631)


1700 D5 CH4 GAS DETECTOR (SL NO 2632)


1600 I5 VIBRATION ANALYZER 3560C FRONT END

Vibration External 1 year

37

QUALITY CONTROL SAMPLING &TESTING SCHEDULE

SR. NO

SAMPLE DESCRIPTION COLLECTION FREQUENCY

PHYSICAL & METALLURGICAL TESTS

CHEMICAL ANALYSIS

1. IRON ORE SHIPMENTS(1)Increment Sample(2) Lot Sample (3)Composite Sample

(A) 40-45 Samples Per Shipment(B) 1 Lo t= 4 Incremens

(1) Moisture(2) Size, Blaine Index(3) Bulk Density, Specific Gravity, Size & Cyclosizer Analysis, Blaine Index & Grindability (as required)

(1)- ---(B)TFe,SiO2,Al2O3,CaO,MgO, MnO & LOI.(C)T.Fe,FeO,SiO2,Al2O3,

CaO,MgO,MnO,P,S,TiO2,V

& LOI

2. BENTONITE SHIPMENTS(1) Lot Sample(B) Composite Sample

4-5 Lots (1) Moisture, Bulk Density, size Blaine & Enslin value(2) Green Ball Properties

TFe, SiO2, Al2O3, CaO MgO,P,S,Na2O,K20,MnO, LOI -----

3. LIMESTONE FINES(1)Lot Sample (provisional)(2)Truck Sample(3)Composite Sample

1 / Day20-25/DayOnce/Lot

--

Moisture & Size

(A) CaO, MgO(B) CaO, MgO(C) CaO,MgO,SiO2, CO2,

LOI

4. PELLET SHIPMENTS(1)Increment Sample (2)Composite Sample(3)Discharge Port Sample( Hadeed & Perwaja)

30-40 Samples per shipment

(1) Moisture(B) Bulk Density, Size, CCS, Porosity, Tumble &Abrasion Index (JIS/ISO),Specific Gravity,Metallurgical Tests: MIDREX TYPE LINDER, SBR &RULTHYL TYPE:Reducibility @ 950C, Sticking Index & LTDTB.F. Type:JIS Reducibility, Swelling Index & RDI

(A) - - -(B)TFe, FeO, SiO2, Al2O3

CaO,MgO, MnO P,S

TiO2,V & LOI

TFe &MFe (C)Same as (B) above.

5. BIN SAMPLES(1) Bin 1-4,116, Dried Ore(2) Bin – 4 (3) Fine Ore & Mixer 1 &2

1 / Shift 2/ Day1/ Week

• Moisture• Blaine index(C) Size & Cyclosizer on fine ore only.

(1) CaO /MgO (116 only)(2) ---(C)T.Fe,FeO,SiO2, Al2O3

CaO,MgO,MnO,P & LOI

6. BENTONITE 1/ Shift1/ Week

Size / Blaine Enslin Value

SiO2, Al2O3

( on day composite) ------

38

QUALITY CONTROL SAMPLING &TESTING SCHEDULE Contd>>>SR NO

SAMPLE DESCRIPTION COLLECTION FREQUENCY

PHYSICAL & METALLURGICAL TESTS

CHEMICAL ANALYSIS

7. RETURN FINES 1 / Week Size -

8. GRINDING MILLS DISCHARGE

2 / Mill / Shift Blaine Index -

9. FINE ORE (506 DISCHARGE) 4 /Shift Blaine Index -

10. GREEN BALLS 1/ Shift Moisture, Drop No., GCS, DCS -

11. PREHEATED BASKET TEST PELLETS

As Reqd CCS, Fines Generation -

12. PRODUCT PELLET 1/Hr (1)1 HRLY: CCS(2)4HRLY:Size,Tumble &Abrasion Index, Porosity.(C)Weekly: CCS, Tumble &Abrasion Index, Porosity & METALLURGICAL TESTS (MIDREX, HYL OR BF TYPE).

(1)2 HRLY: TFe(2)4HRLY : T.Fe, FeO,SiO2

Al2O3, CaO, MgO, Mno &

LOI, Tio2 & P (every 8hrs)

(3)Weekly :Same as (B) TFe&MFe on reduced pellets

13. SPECIAL SAMPLES As Required As Required As Required

14 COMMERCIAL PELLET SAMPLES

As Required Complete Physical & Metallurgical Tests.

complete Chemical Analysis

15 SPECIAL SAMPLES FOR OUTSIDE TESTING

As Required As Required As Required

16 IN COMING SAMPLES EXAMPLE : IRON ORES, BINDERS, ADDITIVES, SURFACE PROTECTORS ETC

As Required As Required As Required

17 RESEARCH WORKS As Required As Required As Required

Thank you!

Name of presenterDepartment

Phone: 00 0000 0000

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Documents

44451175 Test Procedures