Instructional Manual For Clarification Of Startup In Source Categories Affected By New Source Performance Standards - U.s. Environmental Protection Agency - 1979 Page 88
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146 Pre-Startup Operations
Sintering Machine:
The installation and checkout of a sintering machine
is a very complex operation involving many'suppliers and contractors.
This
period of time is called construction and test-out; it may last 3-4 months.
A
major factor affecting the length of this period is the geographical location
of the plant; isolated areas may make
i t
difficult to obtain spare parts thus
delaying startup.
The pre-startup operation is the most hazardous period dur-
ing which component parts may be damaged.
The test-out is done without load
material.
Some of the items checked are:
instrumentation, structure,
electric motors, mechanical clearances, conveyor belts, mixing drums,
sinter breakers, and coolers.
Curing the
w~chine
is a 5-7 day operation.
In-
experienced operators are a major problem in achieving a maximum production
rate within a reasonable time frame.
Upon successful completion of the con-
struction and test-out, the sintering
machi~e
is ready to receive material.
The maximum time period for construction and test-out is 6 months.
Reduction - Blast Furnace:
The blast furnace for lead smelting is unlike
that used in the Iron and Steel industry in that it has no refractory material,
thereby eliminating the curing requirement.
When a lead blast furnace is
installed or reconditioned, each system is checked and reconditioned or re-
placed.
A final checkout is then conducted coordinating the functions of all
systems and units operating at rated capacity.
This test period takes 2-3
hours.
Some of the major systems/units examined are the water packet cooling
system, flange corking, charging, weighing, fuel and all mechanical, electri-
cal, and hydraulic systems in general.
The furnace is now ready to receive
a charge.
Reduction - Dross Reverberat'ory:
Once the furnace is installed and all
connection$ made, pre-startup operations begin.
The pre-startup operaton
takes 2-3 days.
Simultaneously, the
furn~ce
is cured for 4-7 days depending
on the size of the furnace.
Finally, the furnace is, brought up to operating
temperature and stabilized (2-3 days).
The furnace is now ready to receive
material.
The total pre-startup operation consumes 5-7 days.
Reduction - Electric Furnace:
Electric furnaces in the lead smelting
,industry are used for melting rather than smelting.
The energy is too demand-
ing for a smelting operation.
Tw?
to four weeks are allowed for pre-startup
operations.
Manufacturers call this period of time the green tag period
(test-out).
Individual, mechanical, electrical and hydraulic
co~ponents
are
checked.
Special attention is given to electrode rigging, electrical grounds,
shorts and high resistance.
Up,on successful completion of all checks, a low
secondary voltage is applied to the transformer.
If no problems develop, the
primary voltage (Electric Company) energizes the entire system.
Curing the
furnace is either done with electrical or fossil fuel energy.
Curing consumes
a 3-4 day period and is normally done during the green tag period.
The total
pre-startup operations take about 1-2 weeks.
76
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