Steel Batching System

• Stand alone batching controller and PLC based systems
• SCADA/ HMI interface, Customized reports
• In batch accuracy and overall batch accuracy is achieved during process
• Batch actions available like wait /timer/ agitator ON/OFF / two speed batching.
• ERROR correction in the same batch and number of batches is possible.
• Connectivity to master system by all communication methods  

• Capacity ranges from 10 kg to 10 tons
• Use of batch hoppers from 1 to 12 nos
• Control of feeding devices like valves, single / twin screw feeders, vibrofeeders, belt feeders
• Overall batching accuracy 0.1 % achievable
• Class iii systems for industrial use
• Usable for explosive / non explosive atmosphere

• Indoor application in glass
• Ceramics
• Chemicals
• Steel
• Soaps & detergents
• Food & beverages
• Pharmaceuticals
• Ferro alloy
• Ready mix concrete & building products

Auto mode

PLC programming is done as per the composition of batching operation to have a flexibility in selecting random component recipe. The PLC, SCADA is integrated with program Total plant batching operations can be monitored from the PC screen with required reports.

Semi Auto Mode:

The Batch controllers having facility to program for individual set points timers, discharge, manual component, etc, inputs, outputs. Batch house panel will have Mimic diagram of the complete Batch system to know the status  of the field Instruments.

Manual mode:

The required switches are provided on the panel for operations. Operator can feed No. of batches to be taken in the day/shift. This continuous Batching can be stopped by pressing “Stop” switch or by switching OFF the conveyer. This cycle runs for 365 days without any manual intervention. The Batching system can generate Batch report automatically after every Batch. Also it gives production & consumption report on demand.

Owing to our technological advancement, we have been able to offer Ferro Alloy Flux Addition Batching Systems. These systems are made using latest tools and machines installed at our unit. Our batching systems are designed as per the application requirements of our clients. Some of the features of these systems are durability, longer functional life and easy maintenance. The use of these systems ensures reliable usage and superior performance at the clients' location.

With the efforts of our team mates, we have been able to offer Sinter Plant Batching Systems. These systems are manufactured using latest technologies as per industrial norms and standards. Before the delivery, we test these systems to ensure hassle-free performance at the clients' end. Our plant batching systems are extensively used for the industrial applications owing to the reliable performance.

The melt shop is prepared to use cold DRI. The continuous DRI feeding system has already been designed to handle cold DRI and uses number of silos, EM vibro feeders, and few conveyor belts.The capacity of the DRI bins on top of the EAF can be scaled using weighing system when DRI feeding. As a rule, it is common to have the amount needed for one heat or little more.

The cold DRI is received from storage yards at any time as is needed by the EAF.  The handling system is designed with enough capacity to have the required amount of DRI and the same is stored before the EAF heat cycle starts.

The DRI storing silos will be installed on load cells. The load cells are of type shear beam or compression. The load cell signal will be summed in JB and connected to batching controller with special extension cable to transmitter modules, transmitter modules will be connected to batching controller. Through which it receives weight of each DRI silo. Provision is there to calibrate for required full scale.

These Transmitter modules are connected on LOCAL bus to the batching controller. The controller is state of the art and designed to handle up to six weigh silos .The controller has 16 digital outputs, 16 digital input and 4 nos. of analog outputs .The Controller has 6” touch screen and inbuilt power full PLC. The controller is programmed for batching of DRI in discharge batching mode as per the set point entered by the user.The controller has provision to control the feeding rate. The user needs to enter set point for feeding rate.The feeding rate is assumed continuous. If needed this rate can be made constant by varying the amplitude of EM/Motorized vibro feeders by calculating flow rate if user wishes.

The controller gives out 4..20 mA or 0…10Vdc to control feed rate of the EM vibro feeders. The same will be connected to existing EM vibro feeders .The controller is incorporated with 2 serial ports from port-2 it can print a batch report on local serial printer. It also stores data of 1000 heat cycles for record purpose.

The Continuous Feeding of cold DRI

When feeding cold DRI into an EAF, the rate at which it is fed depends on the available power, electrical and chemical.Typically, the amount fed is controlled by the specific feeding rate given by the ratio of the amount of DRI per unit time fed and the total power available inside the furnace as is shown in equation.

Specific Feeding Rate = DRI per unit time (kg/min) Total power (Mw)

This ratio indicates the amount of DRI that can be fed into the EAF without causing DRI

Accumulation or liquid bath overheating for a given furnace and a given metallic charge quality, DRI and scrap.If the ratio is greater that this number, it means that there will be accumulation in the furnace since there is not enough energy to melt the DRI being fed? On the other hand, if the ratio is less that the equilibrium ratio, it means that there will be more energy to heat the liquid bath since there is not enough DRI to melt.

We are a prominent firm engaged in offering AOD Feeding Systems that hold a huge demand in the market. We fabricate these systems using premium quality components procured from trusted vendors of the industry. These are designed and developed as p[er the exact needs of our clients. Further, we ensure that these are made in compliance with international quality standards. Our clients can avail these systems at affordable prices from us.

Our clients can avail from us a quality-assured range of RMHS Batching Control Systems. Fabricated using latest technologies and tools, these control systems are known for their reliable usage. These systems are manufactured in compliance with the industrial norms and standards. Some of the features of these systems are durability and superior performance. These systems are available in the market at competitive prices as per their requirements.

Batching System:

Batching hoppers are provided below storage hoppers (first Batch hopper for Chrome fines / Lime and second for Molasses). Batch hoppers are installed on 3 Nos.of imported Load cells below the storage hoppers. The Vibrofeeder/Conveyer, screw feeder and Ball valve is provided below storage hoppers for charging the raw material in to Batching hoppers. Batch hoppers have Gate valve and Ball Valve to discharge the batched materials in to the Mixer. Load cells are connected to Batch controllers, which are mounted in Batching system Panel for Weight Indication and batching operations. The Batch controllers having facility to program for individual set points and manual component, inputs such as starts, stop and abort the batch, outputs for VFD of Conveyer/screw feeder and Ball/Gate valves, timer and discharge sequence. Batch house panel will have switches, lamp, timers, power supply, relays, VFD for conveyer/screw feeder, etc for Automatic/Manual operation and Mimic diagram of the complete Batching system to know the status (ON/OFF, Coarse/Fine, Overload, etc) of the field Instruments like Screw feeder, Conveyers, Gate/Ball Valves, Mixer and Mixer gate.

Following timings are settable:

• Dry Mix Time
• Wet Mix Time
• Mixer Discharge gate OPEN time

In Manual Mode, switches are provided for Screw-feeder, conveyer and Ball Valve. Operator can take the batch with help displayed weight and switches.