TROUBLESHOOTING AND OPTIMIZATION OF THE VENTILATION NETWORK IN THE CRUSHING SECTOR OF A FERROSILICON FOUNDRY

ISSUE

In the crushing sector of a ferrosilicon foundry, ferrosilicon ingots are broken into coarse pieces by a jackhammer located in a closed area. Once broken, the pieces of ferrosilicon are crushed and sieved before being stored in the loading hoppers. At each of these stages, capture hoods are installed to prevent dust in the area.


THowever, during jackhammer crushing operations, dusts clouds still occur despite the presence of the ventilation system in this area. These clouds are so dense that they force the shutdown of operations while the cloud is dissipating, which causes productivity losses in the sector. A measurement study has demonstrated that the entire ventilation network in this sector only works at 80% of its nominal capacity. This lack of capacity regularly causes ventilation problems on other equipment in the sector.


TECHNOLOGICAL CHALLENGE

  • Identify the cause of the decreased ventilation capacity in the crushing sector.

  • Optimize the dust removal efficiency of the jackhammer area to eliminate dust clouds generated during ingots breaking activities.


RECOMMENDED SOLUTION

An audit of the entire ventilation network of the crushing sector was carried out. Based on the information collected during this audit, a reverse engineering phase of the complete ventilation network of the sector was carried out. This reverse engineering phase identified the causes of the decreased ventilation capacity in different points of the sector, including the ingots breaking area. The corrective measures necessary to restore the ventilation flow rate in the sector as well as those needed to optimize the crushing area ventilation could then be proposed.

RESULTS

At the end of this study, it was determined that the ventilation flow rate of the ingots breaking area had to be multiplied by 3 to prevent dust clouds formation. It also been determined that some modification of the ventilation duck would be necessary in order to restore the ventilation flow rates in the rest of the network since it has been poorly designed. In this context, a modification of the treated distribution flows by dust collectors in this sector has been proposed. This new distribution then made it possible to propose a layout of the duck network more adapted for this area. Simple modifications of the ventilation hood, dust collectors and fans have also been proposed to achieve the new ventilation flow target in the sector.

INDUSTRY

Mines & Foundries

LEVEL OF INTERVENTION

Troubleshooting and Optimization

ESTIMATED COSTS

18500$

YEAR

2017