## Minntac Agglomerator Process Description

Review the files in the below order. 1. Agglomerator Presentation.ppt a. General Overview of the entire Agglomerator process 2. Agglomerator Overview.pdf a. Process Flow diagram of the Agglomerator process 3. S3 Isometric.jpg a. Overview of how the equipment is laid out in the Step 3 Agglomerator building. It also provides relative sizing of the equipment involved in the agglomerator process. The above three files is a general overview of the Agglomerator process. The files below will go over indurating process and the low NOx burners. 4. Step 2 Grate Kiln with Airflow. pdf (page 1) a. Process Airflow is key to the indurating process. The diagram shows that airflow runs against the flow of the pellets. i. Traveling Grate: 1. In the DD1 (d own draft) section of the grate, the green balls are dried. The airflow from the preheat section of the grate is pulled into DD1 and the air temperature of DD1 is approximately 600 o F. The air is pulled through the DD1 section by the waste gas fan. 2. The green balls continue to increase in temperature in the DD2 section
. When making flux pellets, the calcinations reaction (endothermic) starts. The air temperature in the DD2 section is approximately 1400 o F. The DD2 section heat is obtained from the cooler recoup air. The air is pulled through the DD1 section by the waste gas fan. 3. The air temperature in the preheat section is approximately 2200 o F. The preheat section is heated using low NOx preheat burners and air from the kiln. In the preheat section, th e greenballs complete the calcinations reaction and start the oxidation reaction (exothermic)
. The air is pulled through the preheat section by the 1A and 1B fans (which is then put into DD1)
. a. Pre heat burners: i. Line 3
– 8 burners ii. Lines 4
- 7
– 14 burners ii. Kiln 1. The kiln can be heated by the following fuels:

a. Natural Gas b. Biomass c. Fuel oil d. Coal (only Line 6 and 7)2. At the end of kiln , the pellets are heated to approximately 2300 o F. iii. Cooler 1. Pellets are dumped from the kiln into the annular cooler. Outside air is pushed upward through the pellets with the 3A and 3B fans. The air from the 3A fan goes into the kiln through the lineal flow duct. The temperature of this air is approximately 2000 o F. The air from the 3B fan goes into the DD2 section of the grate. b. Ge neral process comments i. The process is run negative. This is to ensure that no process gas is released in the plant and also for safety reasons as the process air temperature is very hot. The general idea with a low NOx burner is to add combustion air (outside air) to reduce the temperature of the fl ame which then reduces NOx. The addition of combustion air affected the airflow balance on the line. The waste gas fan removes air from the process and before the low NOx b urner was installed, it was running at 100% capacity. Therefore, the waste gas fan capacity was increased in order to be able to exhaust the additional ai r that was added. 5. Line 6 and 7 Kiln area 3D model. pdf a. This file is a working model that is to scale
. Left click and drag to rotate the drawing. Right click and drag to zoom in and out of the drawing. b. When opening the file, you will see kiln and associated equipment for Line 6 and 7. Line 6 is located on the right side and line 7 on the left side. c. For the Line 6 burner, an extension was made to the building (building is located above the pink colored roof). Currently, this building houses two blowers which are used on Line 6. In the future, an additional fan will be for Line 7. With this layout, th e 3 blowers will supply the air for both Line 6 and 7 (one blower running for each line and on spare swing fan that could be used for either line). T he dimensions of the building are 40’

- 6” x 39’

- 2” x 26’ tall.