This study set out to reduce polycyclic aromatic hydrocarbon pah emissions from the iron ore sintering process by optimizing its operation parameters obtained from the taguchi experimental design. Mathematical modeling and simulation in matlabsimulink of. During the iron ore sintering process, the loose raw materials, mixtures of fine ore, limestone flux and coke breeze, are converted into a porous but physically strong cake, which is generally composed of four main phases. Pdf modeling sintering process of iron ore researchgate. Ironore sintering process optimization optymalizacja procesu aglomeracji rudy zelaza the work deals with examination of the influence of the ratio between iron ore concentrate and iron ore on quality of produced iron ore sinter.
In this study, a model of granule growth was proposed based on two dimensional homogeneous sphere packing theory. Modeling and simulation of iron ore sintering process with. Iron ore sintering plant in the dosing process from the sintering plants will be taken into account the following conditions. This is due to the fact that coke burns to liberate temperature and start agglomeration. Pdf measurement of process conditions present in pilot. The process of sinter making originated from a need to make use of fines generated in mines and in ore beneficiation plants. Oreblending optimization model for sintering process. Us20090078088a1 method of granulating raw material for. One of the possibilities to increase iron content in sinter is the modification of raw materials ratio.
Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed. Theory and practice of sintering of iron ore sintering of iron ore is a generic term which is used to describe the process whereby a sinter mix raw mix or green mix of iron ore fines, fluxes, fuel coke breeze and plant return fines eg mill scale, blast furnace dust, and returned sinter fines etc are converted into a particular form of. Sintering is the most economic and widely used agglomeration process to prepare iron ore fines for blast furnace use. Numerical modeling of the iron ore sintering process. Development of an iron ore sinter process model to predict. The process of iron ore sintering is a nonequilibrium process that takes place within a very short time, and to clarify its process mechanisms, an analytical approach combining a phase diagram of a multicomponent system and insitu observation of hightemperature reactions is effective. In order to conserve these, otherwise waste material, they are compacted together and made into lumps by a process known as sintering. Therefore, sintering and blast furnace processes offer good opportunities to decrease the co 2 emissions. Sintering is a thermal agglomeration process that is applied to a mixture of iron ore fines, recycled ironmaking products, fluxes, slagforming. Agglomeration is the size incensement process of the fines ore. Shuangliang clyde bergemann gmbh, ratingen, nw, germany. Sintering is a thermal process carried out at 0 deg c to 1400 deg c by which a mixture of iron ore, return fines, recycled products of the steel plant industry such as mill scale, blast furnace dusts, etc. High grade iron ore less than 10% of the total reserves.
Study on the effect on sintering mineralization of iron ore. In this paper, the sintering process and sinter structure have been analysed and the key factors affecting the sintering performance of iron ore fines, including productivity and quality, identified. The complexity of the reaction poses difficulties to optimize the process and hence the quality o f the sinter. It constitutes 5 percent by weight of the earths crust, and it is the.
Reducing pah emissions from the iron ore sintering process. Suction temperature will increase with increase in coke fines up to certain limit. The course and a thermal e ect of individual reactions that take place during combustion of carbonaceous fuels coke breeze or charcoal in the agglomeration process were modeled using thermodynamic program hsc chemistry 5. The top left quadrant shows a side view of a steady. This paper analyses the effect of the chemical composition on mineralization characteristics of liquid production. For the utilization of the variable ore, it is necessary to agglomerate the fines into the required size for charging in the blast furnace. Four operating parameters, including the water content wc. An oreblending optimization model for the sintering process is an intelligent system that includes iron ore characteristics, expert knowledge and material balance. Sintering involves heating iron powder to partially, but not completely, melt the iron particles. Sintering is a process by which a mixture of iron ores, fl uxes and coke is agglomerated in a sinter plant to manufacture a sinter product of a suitable composition, quality and granulometry to be. C by which a mixture of iron ore, return fines, recycled products of the iron and steel industry mill scale, blast furnace. In this work, the hematite solid solution with aluminum h ss was prepared and sintered with cao to investigate the effect of alumina on liquid phase formation in sintering process of.
Iron sintering plants rationale for standard unique to ontario, the sintering of ironbearing steel mill secondary materials and ore results in an estimated annual release of 6. A model of the iron ore sintering process has been developed with the objective of being representative of the sinter pot test, the standard laboratory process in which the behaviour of specific sinter feed. Three dimensional mathematical model of the iron ore sintering process based on multiphase theory which includes sintering and blast furnace processes, and only the sintering process represents around 20% of this amount1,5. Thermodynamic modelling of iron ore sintering reactions. Utilization of charcoal in the ironore sintering process.
Reduction of solid fuel consumption in sintering of indian. The sintering process begins with the preparation of a sinter mixture consisting of iron ore fines, fluxes, solid fuel called bonding agents in japan such as coke breeze, and return fines from the sinter plant and blast furnace as well as recycled ferruginous materials. This corresponds to 4 percent of the national total of dioxins and furans emissions documented in the. In this chapter, the sintering process is first described and the key steps of the sintering process, namely, granulation and thermal densification, are identified. The fundamental sintering characteristic of black iron concentrate improved rapidly and fully completed at 70 the assimilation temperature of iron concentrate is much higher than that of fines ores. Romanian iron ore iron ore 1, krivoirog iron ore iron ore 2, brasilian iron ore iron ore 3 and scale iron ore 4, each with its. Utilising of the oiled rolling mills scale in iron ore sintering process. Effect of alumina on liquid phase formation in sintering. Quite different behaviors of different iron ore fines are observed at higher temperatures. Iron ore sintering is an important source of dioxins, polychlorinated dibenzopdioxins and dibenzofurans pcddfs.
Pdf utilising of the oiled rolling mills scale in iron. Compared with sintered ore, pellets have a higher iron and a lower gangcontent, and pelletizing is suitable for treating the very fine ore that will predominate in the future. Variation of granule size has a great influence on the quality of sinter and productivity of the process. Three dimensional mathematical model of the iron ore. Mineralogy of iron ores of different alumina levels from. After the relationships between iron ore characteristics and sintering performance. Investigation on reaction schemes of iron ore sintering process by. Sintering sintering tests were carried out in a batch square shaped sintering unit of 3030 sq. With the development of sintering technology, a sintering plant has become a tremendous success for providing a phenomenal increase in. Due to the density difference between iron ore fines and coke fines, coke fines form layer on the surface of raw mix balls nodules. The purpose of the sintering process is manufacturing a product with the suitable characteristics thermal, mechanical, physical and chemical to be fed to the blast furnace. Automation and control systems are vital tools to assist plant operators in the monitoring of each stage of the sinter production process.
Characteristics and sintering performance of iron ore. Sinter plants agglomerate iron ore fines dust with other fine materials at high temperature, to create a product that can be used in a blast furnace. As an important component of gangue in iron ore, alumina affects the amount of liquid phase by influencing the formation of calcium ferrites. The assimilation temperature of some fines ore is low at about 1260. Modeling and simulation of processes from an iron ore. The sintering fundamental characteristics of black iron. In the present work, 14 indices are proposed to represent chemical composition, granulating properties and high temperature properties of iron ores. Iron ore sintering is a hightemperature, nonequilibrium reaction process that involves the formation of cafeo melt. Steel community and the country demand technological solutions for utilising low grade ores. Granule growth is an important process for iron ore sintering process. In the sintering process, the iron ore corresponds to the mixture of hematite, goethite and other gangue. Rom iron ore with fe less than 58 60% discarded as waste.
Pdf sintering is a thermal agglomeration process that is applied to a mixture of iron ore fines, recycled ironmaking products, fluxes. On dioxin formation in iron ore sintering environmental. However, high quality iron ore resources are being depleted due to the heavy demand, and thus it is necessary to continue improving sintering technology in order to use lower. The main effect on iron ore mineralization performance in the sintering process is the grain size of raw material and chemical composition. Preparation of the mixture for the sintering process the iron ore sintering process serves the preparation of the ironbearing mixture for blast furnace. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Iron ore sintering is a type of powder metallurgy used to pretreat iron before using it in manufacturing applications. After beneficiation iron ore availability can improve by about 50%.
In order to study the process parameters and inner phenomena, a mathematical model. This paper reports on attempts to identify materials, conditions, and mechanisms responsible for pcddf formation i by investigating salient properties of ores viz. Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. Theory and practice of sintering of iron ore sintering of iron ore is a generic term which is used to describe the process whereby a sinter mix raw mix or green mix of iron ore fines, fluxes, fuel coke breeze and plant return fines e. Both the raw mixtures as well as the sinter material should be controlled carefully to obtain the optimal composition that would lead to a good quality of iron in a blast furnace. Theory and practice of sintering of iron ore ispatguru. During the iron ore sintering process, two types of particles are present.
Sintering is a thermal agglomeration process that is applied to a mixture of iron ore fines, recycled ironmaking products, fluxes, slagforming agents and solid fuel coke. Bhagat introduction the process of sinter making originated from a need to make use of fines generated in mines and in ore beneficiation plants. The final product, a sinter, is a small, irregular nodule of iron mixed with small amounts of other minerals. Most steel plants use coal and iron ores from diverse sites as the major raw material for the sintering process. Improvements in the blast furnace process are achieved by technological improvements and a stable supply of high quality iron ores and sinters 1.
Sintering phenomena in fluxed composite iron ore pellets generally deal with. During the iron ore sintering process, the loose raw materials, mixtures of. In sinter process, the fine iron ores are prepared for the blast furnace process by. Iron ore sintering process model to study local permeability control. A raw material for sintering of 100% in total is blended so as to adjust ironcontaining dust andor sludge to 60% or more, and coarse grains having a grain size of 2 mm or larger to 20% or more on the weight basis, onethird or less of the total amount of addition of coke breeze is added as a fuel, the blend is kneaded and granulated using a vibration kneading granulator to thereby produce. Iron ore fines are agglomerated in the sintering process to produce sinter. Expired lifetime application number us449376a inventor william m stewart. Introduction in this chapter, a methodology for simulating th e sintering process of iron ore is presented.
The mathematical modeling of the iron ore sintering process has received much attention since the 1970s, when muchi and higuchi7 proposed the first one dimensional 1d model. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. The exact process used and additional elements involved vary, with some methods using gas or electricity in addition to heat. The process, called sintering, causes the constituent materials to fuse to make a single porous mass with little change in the chemical.
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