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FINES
Chapter 1. Preface
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Sintering plants are normally associated with the production of hot metal in blast
furnaces in integrated steel pants. The process of sintering is basically a pre-treatment process
step during iron making to produce charge material called sinter for the blast furnace from iron
ore fines and also from metallurgical wastes (collected dusts, sludge and mill scale etc.).
The sintering technology was originally developed for the purpose of using the iron the
metallurgical waste of a steel plant and iron ore fines in the blast furnace. But currently the focus
has changed. Now the sintering process aims to produce a high quality burden for the blast
furnace. Today sinter is the main metallic burden for a large blast furnace.
The principle of sintering involves the heating of iron ore fines along with flux and coke
fines or coal to produce a semi-molten mass that solidifies into porous pieces of sinter with the
size and strength characteristics necessary for feeding into the blast furnace.
It is basically an agglomeration process achieved through combustion.
The product of the sintering process is called sinter and is having good following quality
characteristics
Chemical analysis
Grain size distribution
Reducibility
Sinter strength
Sinters are classified into acid sinter, self-fluxing sinter and super fluxed sinter.Selffluxing sinter brings the lime required to flux its acid components
(SiO2, Al2O3). Super-fluxed sinter brings extra CaO to the blast furnace. For self-fluxing and
super-fluxed sinter, the lime reduces the melting temperature of the blend and at relatively low
temperature. Incase ofself-fluxing and super-fluxed sinter, the lime reduces the melting
temperature of the blend and at relatively low temperatures (1100 Deg C to 1300 Deg C) strong
bonds are formed in the presence of FeO. The following are the advantages of adding flux to
the sinter
It generates slag with the impurities present in the iron ores and solid fuels producing a
suitable matrix for cohesion of the particles
It promotes the calcination reaction of the limestone (CaCO3 =CaO + CO2) outside of
the blast furnace hence saving heat consumption in the blast furnace.
The flexibility of the sintering process permits conversion of a variety of materials, including iron
ore fines, captured dusts, ore concentrates, and other iron-bearing materials of small particle
size (e.g., mill scale) into a clinker-like agglomerate.
Sinter machines
Sinter machines are of two types i) circular and ii) Straight line. Straight line
Machines are also being known as Dwight and Lloyd machines. Dwight and
Lloyd constructed the first continuous sinter plant in 1906.Circular sinter machines are normally
suitable for blast furnaces having useful volumes of 650 Cu m and less. The man parameters of
some of the circular machines are given
in Table 1.
Table 1 Main Parameters of Circular Sinter machines
12 Sqm
17 Sqm
25 Sqm
33 Sqm
Subject
Unit
machine
machine
machine
machine
Annual Production 1000 tpa
172
253
404.5
556
Total Power
requirement
kW
700
1500
1750
2400
Land needed for
plant
Sqm
8000
9000
10000
12000
Land needed for
building
Sqm
800
3400
35000
3600
Various features of the circular machines are as below.
When compared with the straight line machines the capital investment costs are low and
the construction periods are short.
Sealing is better and air leakage is less in these machines since the wind boxes move
synchronously with grates and since water sealing is adopted.
Discharging system makes the size of cold sinter such that there is no need of an
additional crusher.
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Chapter 3. Conclusion
The sintering process is the combination of the blended ore, flux, coke breeze, after
mixing and granulation, then charged into the sintering machine and completed the sintering
process by the suction fan, then through cooling and screening process, the product of sinter
will be transported to BF as the main source of iron-contained material .