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Sulphur Liberation Test

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

Procedure Test Parameters

Wt. 500 g / Size 11-13 Type of Reactor Vertical

1. Preparation
of Sample mm Drying @ 105 C for 2 Reactor Size 75 mm diameter
hrs.
Sample Weight 500 g
Pellet Fraction 11-13 mm

KIO3 solution for titration Test Temp 815 C

2. Preparation 0.2225 g 1n 900 ml of H2O and Reduction Time 4.0 hrs
of Solution then bring up to 1000 ml.
. Gas Mixture 100% H2
Starch- KI solution : 1.0 g of
soluble starch in 50 ml of boiling Gas Flow rate 3 l/m
water + 1.5 g of KI until dissolved
then dilute with H2O up to 100 ml

3.Heating up Close N2 valve

N2 gas Open H2 valve

2
 Sulphur Liberation Test contd>>>>

4.Start Time : 4.0 hrs. Close reduction gas valve &

Reduction Gas composition: (3lpm) open N2 @ ( 1.0 liters /min)
% lpm Switch off the furnace.
H2 100 3.0

5.Reduction About 2 hr , up to room

temp Keep N2 gas flowing

6.Completion Stop N2 gas supply &

of Reduction take out the pellets .

7.weighing Reducibility, Compressive

and evaluating strength after reduction &
metallization.

8. Calculation Recorded in form #

3
 Linder Reduction Test
Aim Of Test

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

Procedure Test parameters

1. Preparation Wt. 500 g / Size 11-13 mm Type of Reactor Horizontal

of Sample Drying @ 105 C for 2 hrs.
Reactor Size 190 dia/ 220 mm length/
no lifters
2.Heating up Flow rate :15 liters/min until
Sample Weight 500 g
N2 gas reactor temp. = 760C (60
min) add 30 min for Pellet Size 11-13 mm
stabilization Test Temp 760 C
Reduction Time 5.0 hrs
3.Start Close N2 valve & start barrel
rotation @ 10 rpm Open Gas Mixture 55% H2,36%
Reduction
H2,CO,CO2, CH4 valves CO,5%CO2,4% CH4
Gas Flow rate 15 l/m
4.Reduction Time : 5.0 hrs. Rotation Speed 10 rpm
Gas composition: (15 lpm)
% lpm Sieve Size 6.35,3.35 ,0.5 mm
H2 55 8.25

CO 36 5.40
CO2 5 0.75
CH4 4 0.60
4
 Linder Reduction test Contd>>>>

5.Completion Close reduction gas valves

of Reduction & open N2 @ ( 15liters /min)

6.Cooling About 1 hr , up to room temp

Stop the barrel

7.Sample Stop N2 gas supply & take out

Discharge the pellets and fines-record
the Weight of the reduced
pellets

8.Sieving and Sieve size: 6.35,3.35,0.5 mm

evaluating Reducibility, Compressive
strength after reduction &
metallization.

9. Calculation Recorded in form #

5
 Reduction Under Load Test
Aim Of Test

Determination of the clustering properties of Midrex Pellets.

Procedure Test Parameters

Type of Reactor Vertical
1. Preparation Wt. 500 g / Size 11-13 mm
of Sample Drying @ 105 C for 2 hrs. Reactor Size 75 dia
Sample Weight 500 g
Pellet Size 11-13 mm
2.Load Apply the weight 2 kg/cm2
Test Temp 860 C
Application
Reduction Time 3.0 hrs
Gas Mixture 55% H2,36% CO,
Flow rate :20 liters/min until 5%CO2,4% CH4
3.Heating up reactor temp. = 860C (60
N2 gas min) add 30 min for Load Application 2kg/cm2
stabilization Gas Flow rate 20 l/m

4.Start Close N2 valve Open

Reduction H2,CO,CO2, CH4 valves

6
Reduction Under Load Test Contd>>>>>
Time : 3.0 hrs.
5.Reduction Gas composition: (20 lpm)
% lpm
H2 55 11.0
CO 36 7.20
CO2 5 1.00
CH4 4 0.80

6.Completion Close reduction gas valves &

of Reduction open N2 @ ( 20liters /min)
switch off the furnace.
10.weighing Reducibility, Compressive
About 2 hr , up to room temp and evaluating strength after reduction &
7.Cooling metallization.
Keep N2 gas flowing

8.Sample Stop N2 gas supply & take Recorded in form #

out the pellets . Extract the 11. Calculation
Discharge
clustered sample

9.Clustering Put the sample in a rotating

Tester drum @ 30 rpm for 2 or 5
minutes. Then measure the
cluster.

7
 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 Test Parameters
500 g (W1) ,Size 11-13 mm
1. Preparation Drying @ 105 C for 2 hrs. Type of Reactor Vertical
of Sample Place the sample in a vertical Reactor Size 75 mm Dia
reactor & place the reactor
Sample weight 500 g
exactly into the center of the
furnace. Pellet Size 11-13 mm

Flow rate:15 l /min Reactor Test Temperature 550 C

2.Heating up temp. = 550C and 10 min for Reduction Time 0.5 hrs
N2 gas stabilization
Gas Composition
% CO 30 , N2 70
Time: 0.50 hrs.
3. Reduction L/min CO 4.5 N2 10.5
Gas Composition: (15 l /min)
% lpm
CO 30 4.5 Gas flow rate 15 liters / min
N2 70 10.5

4. Completion Switch on the furnace & cool

of Reduction the reactor under a flow of N2
gas at 15 l /min

8
RDI TEST PROCEDURE Contd>>>>

5.Cooling About 2.0 hrs, up to

room temp. Take out the
reduction tube.

7.Discharging After cooling the tube

of Sample to the room temp. take
out the sample.

Weigh the reduced

8. Weighing sample & determine
(W2 )

The reduced sample is

9.Tumbling subjected to tumbling for
11.Calculation Reduction Rate (%) :
30 min @ 30 rpm in the (W1-W2)*10000
tumbling apparatus for W1(0.43*TFe-0.112*FeO)
RDI determination
R.D.I = Wt. (-3.15 mm)*100
The sample is sieved W2
10.Sieving using 6.35 , 3.15 & 0.5
mm sieves. Record data – form #

9
 FREE SWELLING INDEX
Aim 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 Test Parameters

1.Preparation Size 11-13 mm Drying Type of Reactor Horizontal

of Sample @ 105 C for 2 hrs. Reactor Size 30 dia , 360 mm length
Sample 3 pellets
2.Selection of Select 3 3 pellets at Pellet Size 11-13 mm
Sample random, exclude the
cracked ones. Clean the Test Temp 900C
pellets and weighed each Reduction Time 1.0 hrs
(W1).
Gas Mixture 30% CO ,70% N2
L/min 0.15 CO ,0.35 N2
3.Measuremen Measure the volume of
t of volume each pellet using a Gas Flow rate 0.5 l/m
(V1) Mercury densimeter.

4.Placing the Place the pellets in the

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

10
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. V= W1+W3 – W2 V : vol of pellet

Gases: % lpm P W1 :wt. of pellets in the air
CO 30 0.15 W2 : wt. of blank in the mercury.
N2 70 0. 35 W3 : wt. of pellets in the
mercury
7.Cooling Pass N2 gas at a rate of P : Density of mercury
200 ml/min . Remove the
furnace & take out the
reduction tube.

8.Discharging After cooling the tube to

the room temp. take out 10. Measurement V = W1+W3 – W2
of Sample P
the sample. of Volume (V2)

9. Weighing Weigh each pellet again & 11. Calculation

determine W1, W2 & W3 of Swelling S.I. = V2 – V1 x100
Index. V1
Record – form #

11
 REDUCIBILITY TEST PROCEDURE
Aim Of Test

Determination of the total reducibility of blast furnace pellets.

Procedure Test Parameters

1. Preparation 500 g (W1) ,Size 11-13 mm Drying @ Type of Reactor Vertical
of Sample 105 C for 2 hrs. Place the sample in
a vertical reactor & place the reactor Reactor Size 75 mm Dia
exactly into the center of the furnace. Sample weight 500 g

2.Heating up Flow rate:15 l /min Pellet Fraction 11-13 mm

N2 gas Reactor temp. = 900C Test Temperature 900 C
Add 30 min for stabilization
Reduction Time 3.0 hrs
Gas Mixture % CO 30 , N2 70
3. Reduction Time: 3.0 hrs.
CO 4.50 , N2
Gas Composition: (15 l /min)
L/min 10.50
% lpm
CO 30 4.5 Gas flow rate 15 liters / min
N2 70 10.5

4. Weight Loss Record the weight losses at every

5 min interval for the complete
period of reduction. using a
balance & printer.

12
REDUCIBILITY TEST PROCEDURE Contd>>>>

Switch on the furnace &

5. Completion cool the reactor under a
of Reduction flow of N2 gas at 15
l /min
10. Calculation

6.Cooling About 2.0 hrs, up to room

temp. Take out the
reduction tube. a. Reduction Rate (%) :
(W1-W2)* 10000
7.Cooling Pass N2 gas at a rate of W1(0.43*A-0.112*B)
15l/min Remove the
furnace & take out the b. Rate of Reduction (%/min) i.e (dr/dt)40 :
reduction tube. Wt. loss @ t min of reduction (W1-Wt)
Wt. loss upon completion reduction (W1-W2)
8.Discharging After cooling the tube to
of Sample the room temp. take out c. Compressive Strength After Reduction (kg/p)
the sample. (20 reduced pellets were measured for CCS

Weigh the reduced Average , Max. & Min. were reported.

9. Weighing
sample& determine ( W2 )
Record data – form #

13
 HYL REDUCIBILITY TEST PROCEDURE
Aim Of Test

Determination of the reducibility of HYL pellets.

Procedure Test Parameters
500 g ,Size 50%(10-12.50 Type of Reactor Vertical
1. Preparation mm)&50% (12.5-16mm)
of Sample Reactor Size 75 mm Dia
Place the sample in a vertical
reduction tube & close tightly . Sample weight 500 g
Pellet Fraction 10-12.5 mm 50% & 12.5-16
2.Heating up Flow rate:10 l /min for 1.5 hrs mm 50%
N2 gas As the temp. reaches 950C,
Increase the N2 gas to 30 l/min Test 950 C
Temperature
Time: until 95% reduction Reduction Time Until 95 % reduction
3. Reduction attained
Gas Mixture % H2 55, CO 21,CO2 14, N2 10
Gas Composition: (55 l /min)
H2 30.25,CO11.55,CO2
% lpm
7.70,N2 5.50
H2 55 30.25 L/min
CO 21 4.50
N2 10 10.50 Gas flow rate 55 liters / min
CO2 14 9.75

Set the balance &the printer to zero

4. Weight and be sure that the reduction tube
Loss does not touch the furnace. Monitor
the weight losses at continuously
until it reaches 95% of reduction.
14
HYL REDUCIBILITY TEST PROCEDURE Contd>>>>

5. Completion When 95% of reduction

of Reduction attained, replace the
reducing gas with N2
gas at 10 l /min

6.Cooling Open the furnace & let

the reduction tube 9. Calculation
cooled to room
temperature. a. O2 reducible (%) : (Tfe x1.5 – FeO x 0.78 x 0.50) x16 x 100
5585

7.Discharging After cooling the tube . b. O2 to be removed : O2 reducible x 0.95)

of Sample remove the sample and
measure the weight of c. Reduction rate % = Wt. Loss x 100
reduced pellets. O2 Reducible
d. K = Ln(1-1/R)
t
8. CSAR Select 20 pellets of the
e. Compressive Strength After Reduction (kg/p)
Measurement reduced sample& (20 reduced pellets were measured for CCS Average , Max. &
proceed for the CSAR Min. were reported.
test.

15
 MOISTURE DETERMINATION Test PROCEDURE
Aim Of Test

Determination of the moisture content in the sample.

Procedure Test Parameters

1. Heating Oven Maintained @ 105 + 5 C Oven 105 +5 C

Temperature
2.Tray Weight Record as (W1) Sample Weight 1kg
Drying Time 3 hrs. min
3.Sample Take app. 1 kg sample &
Weight record weight of tray with
sample as (W2).

4. Drying of Place the tray in oven for

Sample 3 hrs. min.

5.Weight after Remove the tray from the

Drying oven. Weigh & record (W3)

M.C = W2-W3 x 100 W1= Tray weight

6.Calculation W2= Weight of sample & tray
W2-W1
W3= Weight of dry sample & tray

16
 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 Record the weight of the

Weight cylinder

2.Fill in the Fill the cylinder with the

Sample sample to overflow &
level the top. Record the
weight.

3.Sample Calculate the sample

Weight weight

Fill the cylinder with

4. Fill in water . Record the
Water weight

17
 BULK DENSITY TEST PROCEDURE Contd>>>>

5.Volume of Calculate the volume of

Water water

6.Calculation B.D = W W = Sample Weight

V V = Water Volume

18
 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.

2. weighing Weigh 2 empty pycnometers (W1)

(W1)

3. Xylene Add 20 ml of xylene to the pycnometers and place

Addition in vacuum desicator for 30 min

4. weighing Measure pellet weight in Mercury (W2).

(W3)

5.Calculate Calculate the apparent Specific Gravity.

the Apparent
S.G

19
 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 ( cement
standard 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.

20
 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

21
 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.

22
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.

23
 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 Test Parameters
Drum Size Dia 1000 mm, width 500 mm
1. Sample Wt. 15kg (A) / size + 6.3 mm
Drying @ 105 C for 2 hrs. Sample Weight 15kg
Preparation
Pellet Size +6.3 mm
No. of 200
Charge the sample to the Revolution
2. Drum drum & rotate for 200
Rotation revolution at 25 rpm. Rotation Time 8 min
2 kg/cm2 Rotation Rate 25 rpm
Sieve Size 6.3 mm / 0.5 mm
3. Sample Remove all test sample &
Discharge screen with 6.3 mm & 0.5 mm
sieves.

24
TUMBLE TEST PROCEDURE (ISO)
Contd>>>>

4. Data Record the weights +6.3 mm

Recording (B), -6.3 +0.5 mm (C )

5.Calculation Calculate TI ,wt % +6.3 mm &

AI , wt % - 0.5 mm

T.I = B x100 A: initial weight of + 6.3 mm pellet sample

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

25
 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 Test Parameters

Wt. 23kg (A) / size + 5 mm Drum Size Dia 914 mm, width 457 mm
1. Sample
Preparation Drying @ 105 C for 2 hrs. Sample Weight 23kg
Pellet Size +5 mm

2. Drum Charge the sample to the drum No. of Revolution 200

Rotation & rotate for 200 revolution at 25 Rotation Rate 25 rpm
rpm 2 kg/cm2
Rotation Time 8 min
3. Sample Remove all test sample & screen Sieve Size 5 mm & 1 mm
Discharge with 5 mm & 1 mm Sieves.

26
TUMBLE TEST PROCEDURE (JIS) Contd>>>>

4. Data Record the weights +5mm (B),

Recording -5 +1 mm (C )

Calculate TI,wt % + 5mm &

5.Calculation
AI, wt % -1 mm

T.I = B x100
A A: initial weight of + 5 mm pellet sample
B: weight of pellets retained on 5.0 mm screen after tumbling.
A.I = A- (B+C) x100 C: weight of broken pellets / dust collected between 5.0& 1.0 mm
A

27
 POROSITY TEST PROCEDURE
Aim Of Test

Determination of the porosity of the pellets .

Procedure

1. Sample Record the sample weight

weight (W1)

2.Sample Record the sample weight in

weight in Mercury (W2)
Mercury

3.Calulate App. Specific gravity =

App. Specific W1 x pHg
gravity W1+W2

4. calculate Porosity = P- Papp

porosity x100
P

28
 COLD COMPRESSIVE STRENGTH TEST PROCEDURE
Aim Of Test

Determination of the crushing strength of the pellets .

Procedure

1. Sample Dry the sample @ 105 C

Preparation Select at random (12) pellets from 11-13 mm
for production and (100) pellets for shipment.

2. Machine Select the scale x1.

Preparation Check the calibration of the recorder.

3.Sample Place single pellet at the center of the

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

3.Recording Record the max. load at which the pellet

breaks from the recorder chart.

No. of Pellets 12 or 100

Pellet Size 11-13 mm
Load Cell 1000 kg

29
 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 Sieve the green ball with 11-13 mm screen &

of Green Balls keep in oven (105C) for complete drying. Select
(12) pellets for testing. Balls for testing.

2.Testing of Test each green ball individually using the

Green Ball crushing strength machine.

3.Recording of The DCS of each green ball is recorded on a

Data chart . record all measurements & proceed for
computation.

4. Calculation Calculate the average , maximum & minimum.

form #

Practical Limitation:

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

30
 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 Sieve the green ball with 11-13

of Green Balls mm screen & Select (12) pellets
for testing. Balls for testing.

2.Testing of Test each green ball individually

Green Ball using the crushing strength
machine.

3.Recording of The GCS of each green ball is recorded

Data on a chart . record all measurements &
proceed for computation.

Calculate the average , maximum &

4. Calculation minimum. form #

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

31
 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 of Select (12 nos.) of a suitably sized

Green Balls balls (11-13 mm)

2.Dropping of Drop each ball from 50 cm height

the Balls until fracture occurs

3.Recording of Record the number of drops

data required to cause breakage.

4. Calculation Calculate the average drop nos

and the maximum & minimum
values.

32
 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%

33
 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)

Phenolphthelein Indicator 2 to 3 7. NaOH % = V2 *0.35 X 250

5. COLORING drops – ( pink color) CALCULATION V1
Record – Chemical
Titrate with 0.1 N H2SO4 std analysis result form
6.TITRATION
solution – Pink to Colorless –(V2)

34
MASTER INSTRUMENTS FOR TEST, MEASURING, INSPECTION & CALIBRATION
MASTER INSTRUMENT TYPE OF MEASUREMENT Calibration Frequency of
I.D. No.
DESCRIPTION AND SIMULATION By whom calibration
1700 I1 STOP WATCH Citizen Model LSW Time External 1 year
9107
1700 I2 DIGITAL THERMO METER Temperature External 1 year
ANRITSU MODEL HFT-80
1700 I3 LIQUID IN GLASS THERMO Temperature External 1 year
METER MODEL 0-360 Deg.C
1600 I1 TRUE RMS MULTI METER Voltage, Current, External 1 year
FLUKE MODEL 187 Resistance,
Frequency
1600 I2 MULTI FUNCTION CALIBRATOR Pressure, current, voltage External 1 year
MC-5
1600 I3 INDUSTRIAL SCOPE METER Oscilloscope External 1 year
FLUKE MODEL 123
1600 I4 DEAD WEIGHT TESTER Pressure/ Flow External 1 year
1700 M1 Measuring glass wares: Volume Internal (QC) 6 months
Glass burettes-12862, 12856,
7439, 1266
Pipettes- 10ml, 25ml.
Flasks- 100,250,500,1000ml
1700 T1 Test sieve normal Size Internal (QC) 6 Months
1700 T2 Hand sieve (wooden frame) Size Internal (QC) 6 Months

35
MASTER INSTRUMENTS FOR TEST, MEASURING, INSPECTION & CALIBRATION Contd>>>

MASTER INSTRUMENT MASTER REFERENCE FOR Calibration Frequency of

I.D. No. TYPE OF MEASUREMENT By whom calibration
DESCRIPTION
1708 Platform Scale B-251 (250 KG) Weight External 1 year
(Physical Lab)

1600 Plat form Scale – YAMOTO –EDI-302 Weight External 1 year

W1 (300 KG) / (E/I Work Sop)

1700 D1 CARBON MONOXIDE DETECTOR Gas leakage detector External 1 year

MODEL MINI CO PORTABLE
SL NO – A1 - 12829

1700 D2 CARBON MONOXIDE DETECTOR Gas leakage detector External 1 year

MODEL MINI CO PORTABLE
SL NO – A2 –3173-J97-

1700 D3 CO GAS DETECTOR Gas leakage detector External 1 year

COMA-2 (SL NO 1456)

1700 D4 H2 GAS DETECTOR Gas leakage detector External 1 year

(SL NO 2631)

1700 D5 CH4 GAS DETECTOR Gas leakage detector External 1 year

(SL NO 2632)

1600 I5 VIBRATION ANALYZER 3560C Vibration External 1 year

FRONT END

36
 QUALITY CONTROL SAMPLING &TESTING SCHEDULE
SR. SAMPLE DESCRIPTION COLLECTION PHYSICAL & METALLURGICAL CHEMICAL ANALYSIS
NO FREQUENCY TESTS
1. IRON ORE SHIPMENTS (A) 40-45 Samples (1) Moisture (1)- ---
(1)Increment Sample Per Shipment (2) Size, Blaine Index (B)TFe,SiO2,Al2O3,CaO,M
(2) Lot Sample (B) 1 Lo t= 4 (3) Bulk Density, Specific Gravity, Size & gO, MnO & LOI.
(3)Composite Sample Incremens Cyclosizer Analysis, Blaine Index & Grindability (C)T.Fe,FeO,SiO2,Al2O3,
(as required) CaO,MgO,MnO,P,S,TiO2,V
& LOI
2. BENTONITE SHIPMENTS 4-5 Lots (1) Moisture, Bulk Density, size Blaine & Enslin TFe, SiO2, Al2O3, CaO
(1) Lot Sample value MgO,P,S,Na2O,K20,MnO,
(B) Composite Sample (2) Green Ball Properties LOI -----
3. LIMESTONE FINES 1 / Day - (A) CaO, MgO
(1)Lot Sample (provisional) 20-25/Day - (B) CaO, MgO
(2)Truck Sample Once/Lot Moisture & Size (C) CaO,MgO,SiO2, CO2,
(3)Composite Sample LOI
4. PELLET SHIPMENTS 30-40 Samples per (1) Moisture (A) - - -
(1)Increment Sample shipment (B) Bulk Density, Size, CCS, Porosity, Tumble (B)TFe, FeO, SiO2, Al2O3
(2)Composite Sample &Abrasion Index (JIS/ISO),Specific Gravity, CaO,MgO, MnO P,S
(3)Discharge Port Sample Metallurgical Tests: TiO2,V & LOI
( Hadeed & Perwaja) MIDREX TYPE
TFe &MFe
LINDER, SBR &RULT
(C)Same as (B) above.
HYL TYPE:Reducibility @ 950C, Sticking Index
& LTDT
B.F. Type:
JIS Reducibility, Swelling Index & RDI
5. BIN SAMPLES 1 / Shift • Moisture (1) CaO /MgO (116 only)
(1) Bin 1-4,116, Dried Ore 2/ Day • Blaine index (2) ---
(2) Bin – 4 1/ Week (C) Size & Cyclosizer on fine ore only. (C)T.Fe,FeO,SiO2, Al2O3
(3) Fine Ore & Mixer 1 &2 CaO,MgO,MnO,P & LOI
6. BENTONITE 1/ Shift Size / Blaine SiO2, Al2O3
1/ Week Enslin Value ( on day composite) ------

37
QUALITY CONTROL SAMPLING &TESTING SCHEDULE Contd>>>
SR SAMPLE DESCRIPTION COLLECTION PHYSICAL & METALLURGICAL CHEMICAL ANALYSIS
NO FREQUENCY TESTS
7. RETURN FINES 1 / Week Size -

8. GRINDING MILLS 2 / Mill / Shift Blaine Index -

DISCHARGE
9. FINE ORE (506 DISCHARGE) 4 /Shift Blaine Index -
10. GREEN BALLS 1/ Shift Moisture, Drop No., GCS, DCS -
11. PREHEATED BASKET TEST As Reqd CCS, Fines Generation -
PELLETS
12. PRODUCT PELLET 1/Hr (1)1 HRLY: CCS (1)2 HRLY: TFe
(2)4HRLY:Size,Tumble &Abrasion (2)4HRLY : T.Fe, FeO,SiO2
Index, Porosity. Al2O3, CaO, MgO, Mno &
(C)Weekly: CCS, Tumble &Abrasion LOI, Tio2 & P (every 8hrs)
Index, Porosity &
(3)Weekly :Same as (B)
METALLURGICAL TESTS
TFe&MFe on reduced pellets
(MIDREX, HYL OR BF TYPE).
13. SPECIAL SAMPLES As Required As Required As Required
14 COMMERCIAL PELLET As Required Complete Physical & Metallurgical complete Chemical Analysis
SAMPLES Tests.
15 SPECIAL SAMPLES FOR As Required As Required As Required
OUTSIDE TESTING
16 IN COMING SAMPLES As Required As Required As Required
EXAMPLE : IRON ORES,
BINDERS, ADDITIVES,
SURFACE PROTECTORS ETC
17 RESEARCH WORKS As Required As Required As Required

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Thank you!

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Department

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Email: name@vale.com