Sinter bars

Steel • Dąbrowa Górnicza, Polska, PL

APPLICATION (+1 pts)

APPROVED

Basic Information

Overview

What is sinter? Sinter is a product of the ore sintering process (e.g., in ironmaking), in which fine particles fuse together into larger, hard lumps under high temperature. What are sinter breaker bars used for? Bars in a sinter breaker: break large sinter lumps into smaller pieces, working together with the sinter stars enable achieving the proper material size (important, for example, for the blast furnace) help ensure uniform feeding of the material further in the process How do they work? Most often: they are massive steel components, they cooperate with moving parts (sinter stars), the sinter impacts the bars and is compressed in cooperation with the stars → causing it to crack and break the bars wear is caused by abrasion at elevated temperatures

Industry

Steel

Location

Dąbrowa Górnicza, Polska, PL

Component/Workpiece

Sinter bars

Business Type

Integra - Workshop

Job Type

New

Type of Wear

Abrasion

Impact

Problem Description

The challenge the customer was facing

There are two sinter lines with equal production on each line. Each line produces approximately 3.5 Mt per year. The hourly production is 600 t, with 30% recirculation. The client wanted to reduce the total cost of ownership by increasing service life (limiting the number of shutdowns for replacement and reducing the number of spare parts). Previously, they used steel beams—either cast or cast with 2D hardfacing. The service life of a beam, depending on its position in the sinter breaker line, was about 6 months (including its rotation).

Previous Service Life

6mo

Competitor

Steelworks, Pioma, ArcelorMittal SSC; Małapanew, etc.

Welding Alloys Solution

How WA solved the challenge

Welding Alloys Polska proposed the solution, and Welding Alloys Integra France designed and manufactured the bars using 3D Carb technology with an external hardfacing layer. In the initial versions, the service life reached 8–9 months (after rotation). With subsequent orders, the bars were redesigned (adjusting the distribution of 3D Carb inserts and changing the base material grade to P355 to minimize the risk of bars-end distrotion). The latest version of the bars, after modifications, is capable of lasting up to 12 months.

Product Category

Integra Services

Product Description

Sinter bars, base steel P355 + 3D Carb

Job Duration

Technical Advantages

The service life has nearly doubled. The number of maintenance shutdowns has decreased from four to two per year. Each shutdown lasts approximately 24 hours. The replacement is carried out by an external contractor -> the risk of potential accidents during replacements has been reduced (non-quantifiable). The number of spare parts has decreased fourfold.

Service Life