1

SINTERING PLANT
2
DEFINITION OF SINTERING
Sintering is a process of agglomeration of fine mineral
particles into a porous and lumpy mass by incipient fusion
caused by heat produced by combustion of solid fuel within
the mass itself.
3
TYPES OF SINTER
NON FLUX SINTER
FLUXED SINTER
SELF FLUXED SINTER
SUPER FLUXED SINTER
4
SCHEMATIC DISTRIBUTION OF THE ZONES IN CHARGE DURING SINTERING
ON THE SINTER STRAND
ZONE OF SINTERING
ZONE OF
CONDENSATION
OF MOISTURE
5
Material flow Diagram
Sintering Plant
Hammer
Crusher
Flux
Flux Screen
+
3
m
m

Stock Bin &
proportioning
section

Iron Ore Fines
-
3
m
m

Coke breeze
from C O
PMD
Coke return from B F -25mm
Fuel Storage Coke crusher
-
3
m
m

Sinter
M/c
Hot
screen
SLC
Cold
screen
Sinter
to BF
-8mm
-5mm
-5mm
Hot Sinter return
Cold Sinter return
Cold Sinter return
Waste Material LD Slag, Mill Scale & Flue Dust

Coke breeze
from external
sources
Nut Coke ( 15 -25 mm)
Lime Dust
6


RAW MATERIALS USED FOR SINTERING

1. Iron ore fines
2. Flux ( lime stone & dolomite )
3. Coke breeze
4. Waste Materials:
a). Flue dust ( From Blast Furnace but added in RMHP )
b). Mill scale ( From Slabbing Mill, H.S.M.&CCS)
c). L.D.Slag (From S.M.S.)
d). Lime dust ( From R.M.P.)
5. Sinter return ( Own generation )


7

MAIN SECTIONS OF SINTERING PLANT

1. RAW MATERIAL SECTION.
( For crushing of coke and flux )

2. STOCK BINS AND PROPORTIONING SECTION
( For storing,proportioning & mixing )

3. SINTER MACHINE SECTION
( For sinter making )




8
COKE CRUSHING BY FOUR ROLL CRUSHERS
( 08 Nos. CAPACITY 16 T/Hr. EACH )
MIX COKE FROM C.O. COKE RETURN FROM B.F.
( - 15mm ) ( - 25mm )











+ 15 mm TO B.F.
MIXED WITH SINTER

-15 mm TO FUEL
STORAGE

- 15 mm
- 3 mm
-3 mm TO STOCK BINS
6 mm
2 mm
(NUT COKE SCREEN)
9



FLUX CRUSHING BY HAMMER CRUSHER
( 05 Nos. CAPACITY- 250T/Hr. EACH )
+ 25mm
FLUX FROM RMHP ( + 25 mm )
HAMMER CRUSHER
(36 Hammers in each Crs.
in two rows. )
- 3mm TO STOCK BINS
FLUX SCREEN (10 Nos. ) CAPACITY 150T/Hr.EACH
MOTOR
10
STOCK BINS AND PROPORTIONING SECTION

A. TO STOCK RAW MATERIALS :

There are three similar series of over head bunker and
conveyors to feed three sinter machines at a time. Each series
contains 23 bunkers . Materials are stored in the bunkers in
following order :
BUNKER No. TOTAL BUNKER MATERIAL
1 6 06 Iron ore fines
7 13 07 Crushed flux ( - 3 mm )
14 17 04 Crushed coke ( - 3 mm )
18 01 Waste materials
19 20 02 Cold sinter return
21 01 Hot sinter return
22 23 02 Lime dust


11
B. FIXING OF FEED RATE :

For sending raw mix to sinter machine for sintering, fixation of
feed rate of materials is done considering capacity of the sinter
machine and quality requirement of blast furnace.

Feed rate fixed is :

Iron ore fines 250 T/hr.
Flux 75 T/hr.
( Feeding of Flux depends on available lime in sinter required
in blast furnace.Available lime means CaO SiO
2
in sinter.)
Coke 20 T/hr.
Waste materials 20 T/hr.
Sinter return 60 T/hr.
Lime dust 02 T/hr.


12
PROPORTIONING OF CHARGE

ELECTRONIC
CONVEYOR SCALES
ELECTRONIC
FEEDER
VIBRO FEEDER
O/F FLUX COKE W/M S/R L/D
A 1
CONV.
TO
S/M -1
A 3
CONV.
TO
S/M -2
A 5
CONV.
TO
S/M -3
PRIMARY
MIXING
DRUM
13
RAW MIX
SRC
D/C
D/F
C/S
SHAKER GATE
RAW MIX BUNKERS
ELECTRONIC FEEDERS
BALLING DRUMS
SHUTTLE DISTRIBUTOR
FURNACE
CHARGE HOPPER
DRUM
FEEDER
SINTER MACHINE
WIND BOXES
1 2
25 26
MAIN GAS COLLECTOR
TO EXH.
TO EXH.
DUST POCKETS
(36Nos.)
WATER
DRUM
COOLER
-5mm
+8mm TO BF
-8mm


TO STOCK BINS
-5mm TO STOCK BINS (HOT SINTER RETURN)
SINGLE ROLL CRUSHER
HOT SCREEN
COLD SCREEN
DISC FEEDER
SINTER MACHINE PROCESS FLOW
WATER
WATER
H/S
RAW MIX

14
Sinter Machine Specification for each machine

There are three Sintering machines

Length - 78 M
No. of pallets - 130
Sintering area 252M2
Bed height - 480mm
Exhauster - 02 Nos.
Aspirator - 02 Nos.
Cooler Blower- 06 Nos.
Balling Drum - 02 Nos.
Drum Cooler - 01 No.
Straight line Cooler - 01 No.
15
CRANES Location & Capacity
Name Location Tons
G/Crane Fuel Storage 10
C/Crane C/Crane Building 05
H/Crane H/Crane Building 10
S/B S/B Tops 05
A1/A2 A1/A2 Area 15
B/Drum B/Drum Area 50
Exh. Exh Buld. 50
Sinter Machine Machine Build. 30
Bay 1,4& 5 ARS 15
Bay 6 ARS 03
MDP MDP 05
JN 12 S/B Top 15
Other then these 46 nos. of Telphers are also there.
16
WHAT IS
AGGLOMERATION
Agglomeration is defined as the process to
prepare a suitable Blast furnace feed for
smooth, proper and efficient running of the
Blast furnace operation.
The process of agglomeration can be classified
as follows:
i) Briquetting.
ii) Nodulising.
Iii)Vacuum Extrusion process.
iv) Sintering
v) Pelletizing.
17
ADAVANTAGES OF
AGGLOMERATION
Ability to use all kinds of Raw Materials- like iron ore
fines, iron bearing waste products, flue dust, Steel plant
reverts.
It can be produced into any shapes and sizes.
It can be cured to adequate strength suiting Blast
Furnace needs.
Process designed to suitable small batch operations and
large scale operations.
Excellent blast Furnace charge material in place of
lump ore, reduces the cost of smelting of ore, increases
Furnace permeability there by increasing BF
productivity and lowering cost in terms of lower fuel
rate.
18
WHAT IS SINTER
Sintering is the process of agglomeration of
iron ore fines into a porous mass by
incipient fusion heat generated within the
mass itself.


19
TYPES OF SINTER
Depending upon weather bases have been incorporated in the Sinter mix,
sinters are divided into three broad classes: -

(i) Non Fluxed OR ACID SINTERS: - Those where no flux is present or is
added in the ore.

(ii) BASIC SINTER OR Self Fluxing SINTER: - Those where sufficient
flux has been added in the sinter mix to provide a basicity that is desired
in the final slag, taking into consideration only the burden acids. An extra
flux is added to the BF burden, to take care of coke ash acids.

(iii) SUPER BASIC OR SUPER FLUXED SINTER: - In these type of
sinters an additional flux is added to the mix to provide for the desired
final slag basicity, taking into account the acids content of both ore as well
as the coke ash.


20
THE NEED FOR SINTER
(i) To utilize the fines generated during the mining
operation.

(ii) To utilize different additives like mill scale, flue
dust, hearth slag etc. in an integrated steel plant.

(iii) The need for charging prepared burden in Blast
Furnaces to increase productivity and lower fuel rate.



21
ADVANTAGE OF SINTER
i) Agglomeration of fines into hard, strong and irregular porous lumps which gives
better bed permeability.

ii) Elimination of 60 - 70 % of sulphur and Arsenic (if present) during sintering.

iii) Elimination of moisture, hydrated water and other volatiles on the sinter strand with
a cheaper fuel.

iv) Increased the softening temperature and narrowing down of the softening range.

v) As the calculation of flux takes place in sinter strand, super-fluxing saves much more
coke in the furnace.

vi) It increases the Blast Furnace productivity.

vii) Lime rich bosh slag hinders reduction of silica, absorbs vaporized silicon and
sulphur to produce low- Si, low-S iron.

viii) Increase of sinter percentage in Blast Furnace burden, increases the permeability,
hence reduction and heating rate or burden increases, so the productivity also.

ix) Utilization of solid wastes generate within steel works
22
TYPES OF SINTER MAKING
PROCESS
Huntington and
Heberlein Pot Process-
fpr non-Ferrous metal
Industry.
Batch Sintering-
Greenwalt Single Pan
Process
Allmanns Ingenoirs
Bryans Multi Pan
Process
Dwight-Lloyd
Continuous Sintering
Process
Pelletizing Process- This
consists of sub
operations like
preparation of ore feed,
balling, hardening. Shaft
furnaces are used for
producing small
tonnages. Multiple
Shafts handle larger
production level.

23
Huntington & Heberlein Blast roasting Pot Vacuum Extrusion Process
24
Green walt Single Pan Sinter Machine Pelletizing Process
25
PRINCIPLE OF THE SINTER
MAKING PROCESS
Iron one sintering is carried out by putting GREEN MIX after Mixing and Nodulizing drum (a
mixture of Base mode with iron ore fines, mixed with flux, coke breeze as a solid fuel, other
additions, sinter return fines, lime, moisture) over a traveling gate in form of permeable bed
and permeable bed.

The top layer of this sinter bed is heated to the sintering temp. (1200C-1300C) inside a Ignition
Hood furnace. In the ignition hood the air is drawn downwards, through the grate with the help
of exhaust blowers (Waste Gas Fan) connected by means of Waste gas main.

The narrow combustion zone developed initially at the top layer by layer to the sintering level.
The cold blast drawn through the bed cools the already sintered layer the thereby gets itself
heated. The heat contained in the blast is utilized in drying and preheating the lower layers in
the bed. In advance of combustion therefore each layer gets dried and preheated by the heat
transferred from the upper combustion zones. The lower portion of the bed absorbs much of
the heat in the gases.


In the combustion zone, bonding takes place between the grains and a strong and porous
aggregate is formed. The process is over when the combustion zone has reached the lowest
layer of the bed. The sinter cake is thus tipped from the grate in hot condition . It is then
broken, cooled in sinter cooler cold sized and sent to the Blast furnace.
26
MECHANISM OF SINTERING
2Fe
2
O
3
.CaO + Al
2
O
3
.SiO
2
2Fe
2
O
3
CaO.Al
2
O
3
.SiO
2

(SFCA)
SILICO FERRITE OF CALCIUM
AND ALUMINIUM
2Fe
2
O
3

SLAG BOND
2Fe
2
O
3

2Fe
2
O
3

Heating Cooling
Single
lump
Heating
2Fe
2
O
3

2Fe
2
O
3

+
CaO
2Fe
2
O
3
CaO at 1200
0
C
CALCIUM FERRITE
27
28
GENERAL ARRANGEMENT OF
A SINTER PLANT
Raw material receiving and
proportioning system
Mixing and Nodulizing-
moisture addition
Charging Station-laying of
Green mix on the strand
Ignition

Sintering Process
Sinter Discharging and Hot
breaking
Cooling of sinter in Sinter
Cooler
Treatment of Sinter in terms
of Cold crushing and sizing.
Conveying to BF stock-house
Dust treatment and Waste
Gas system with Waste Gas
Fan and De-dusting Fan

29
EQUIPMENTS IN SINTER
PLANTS
RAW MATERIAL BINS AND
WEIGH FEEDERS
MIXING AND NODULIZING
DRUM WITH WATER
INJECTION SYSTEM
SURGE BIN-SECTOR GATES
WITH SERVO DRIVES AND
FEED DRUM
IGNITION HOOD FURNACE
WITH BURNERS
SINTER MACHINE-PALLETS
with GRATE BARS
WINDBOXES WITH WASTE
GAS MAIN
SPIKE CRUSHER-WITH
CRASH DECK
DOUBLE ROLL CRUSHER
VIBRATORY COLD SCREEN
FOR HEARTH LAYER
VIBRATORY SCREEN FOR
RETURN FINES
CONVEYORS, RECEIVING
CHUTES AND TRANSFER
CHUTES FOR RAW
MATERIAL AND SINTER
WASTE GAS FAN WITH LCI
DRIVE
DEDUSTING FAN FOR PLANT
DEDUSTING
ESPs
LT and HT DRIVES
PNUEMATIC ACTUATORS &
VALVES
30
SINTER PLANT FACILITIES AT
TATA STEEL
F:\Sinter Plant Facilities at Tata Steel.pdf
31
DIFFERENT UNITS OF SINTER PLANT
RAW MATERIAL BEDDING AND BLENDING PLANT

SINTER PLANT 1

SINTER PLANT 2

RAW MATERIAL BEDDING AND BLENDING ( NEW )

SINTER PLANT 3

32
FUNCTIONS OF RMBB
Stacking of Raw materials

Bedding and Blending of various raw
materials and other constituents of Sinter
mix through proportioning

Homogenizing the mix components for
achieving consistent Sinter chemistry



33
R.M.B.B.PLANT LAYOUT

WAGO
N
T/H
C/S
TGH
P
R
O
P

B
U
I
L
D
I
N
G
ROD MILLS
CRUSHER
H/M
COKE SCREEN
FLUX
SCEEN
WOB#2
WOB#1
TBS#1
TBS#2
SP1/SP2
B/R (L&T)
B/R
(ELECON)
P
Y
R
D
U
N
Ld
Slg.
Ret. Sinter fines From G.Fce.
I
O
F
L
S
F
R
P
D
F
34
Material Flow at Sinter Plant
35
Hot Return
Fines
Hearth
Layer
SINTER
STORAGE
Sinter
Screening

Proportioning
Bins
Mix
er

Wate
r
Sinter
Machine
Sinter
Cooler
Waste Gas
Fan
Waste Gas
Esp.
BF HIGH
LINE
Raw
Materials
Return Fines Lime
Dust
Hearth
Layer
Hot Air
Combustion Air
Cold Return
Fines
Ignition Hood
Spike
Crusher
Cooler Fan
Segregati
on
Chute

Doubl
e
Roll
Crusher
Cold
screen
SINTER PLANT
36
OVER VIEW OF SP#3-a typical DWL Sinter
Machine
37
PROGRESS OF SINTERING
COMBUSTION JONE
GREEN MIX
SINTER
SUCTION MAIN
WASTE GAS FAN
WIND BOX
38
BED
HEIGHT
LEVEL SENSOR
FLAP
GATES
IGNITION
HOOD
FEED ROLL
HEARTH LAYER
GREEN-MIX
BIN

GREEN MIX
SHUTTLE CONVEYOR
THERMO-VISION
CAMERA
PROBES
FEDDING SYSTEM
HEAT TREAT
MENT HOOD
HEARTH
LAYER
BIN
CUT-OFF
PLATE
39
QUALITY ASPECT OF SINTER-
WITH RESPECT TO BLAST
FURNACES PERFORMANCE
CHEMICAL
1. Fe% in Sinter
2. CaO % in Sinter
3. SiO2 % in Sinter
4. MgO% in Sinter
5. Al2O3 % in Sinter
6. FeO % in Sinter
7. K2O % in Sinter
PHYSICAL
1. SINTER SIZE
ANALYSIS in terms of
Cum+10mm and -5mm
2. TUMBLER INDEX
3. SHATTER INDEX
4. RDI (Reducibility
Degradation Index)
5. RI (Reducibility Index)
6. Softening and Melting
Test (S-M)
40
FACTORS AFFECTING SINTER
QUALITY
(1) Size of The Charge Mix: The strength of sinter is directly related to the size
distribution of the charge mix. If size is large, the contact area will be less and the
strength of the sinter will be low and conversely if size is too small the contact area of
particles will be large and the strength will be high.

Ideal size of ore Fines -10 mm to + 100 mesh
Coke breeze -3.2 mm 85%
Flux - - 3.2 mm 85%

(2) Fuel content: - Variation in Fuel content in Charge Mix affect the peak Temperature
attained during sintering, the combustion zone will not be uniform leading to poor bed
permeability, This increases return fines generation

(3) Moisture: - The presence of moisture in the Charge mix has several advantages. It
maintains proper permeability in the bed during sintering. This is beneficial from the
point of view of heat transfer during sintering.

(4) Re-circulating load or Return fines addition: - For higher output of the sinter strand
the circulating load should be low. A low circulating load however, reduces the
permeability of the bed. An optimum-circulating load is established for maximum
output of the acceptable sinter to the Blast Furnaces.
41
Parameters Controlling Sintering
Process
Fuel content for heat input

Ignition intensity-
Temperature of Ignition
Hood Furnace

Moisture content of mix to
control its permeability.

Machine speed control to
obtain complete Burn
through

Return Fines Addition


Waste Gas Temperature

Sintering Temperature or
Burn through Temperature

Pressure drop across the
Sinter Bed- Main Suction

Bed Height

Calcined Lime addition- to
improve bed Permeability.




42
IMPROVEMENT IN PERFORMANCE OF
SINTER PLANTS
BY
INTENSIFICATION OF SINTERING
PROCESS
By

Dr M T Raju
Deputy General Manager
RDCIS
SAIL
43


Managing the existing technologies to reach
designed/rated performance

Incorporation of innovations to surpass rated
capacity
44
Reaching rated capacity:

1. MEN (WOMEN)
2. MATERIAL
3. MONEY
4. MINUTES
45
Surpassing rated capacity:
Creative (Innovative) solutions can only
enable to surpass.
Five elements of creativity.
1. FLUENCY
2. FLEXIBILITY
3. ORIGINALITY
4. AWARENESS
5. DRIVE
46
Creative (Innovative) solutions
are possible by

LATERAL THINKING
47
INTENSIFICATION OF SINTERING
PROCESS
Sinter as a prepared burden material
continues to hold its prominent position in
world due to its very good metallurgical
properties such as tumbling strength,
reduction degradation index, reducibility
index, high softening temperature and low
range of softening range

48
PRINCIPAL STEPS OF IRON ORE
SINTERING TECHNOLOGY
The iron ore fines , lime stone fines, dolomite
fines, lime dust, metallurgical wastes and coke
breeze are proportioned based on charge
calculations.
Then this mix is mixed and balled in mixing and
balling drums with the addition of water and then
loaded onto the pallet.
The sinter mix undergoes ignition as well as
suction is applied under the bed.
The top layer gets ignited and sintering proceeds
down wards till the end .
The hot sinter is screened and crushed.
The hot sinter is then cooled on a cooler
The cooled sinter is screened to remove -5mm
fraction and then transported to blast furnace.
49
Need of Intensification of
sintering process

Why?

Intensification of sintering process is required
to enhance the production capacity of existing
sinter machines.

How?

Without sacrificing the quality aspects.
50
What is meant by intensification?
Accelerating sintering process for achieving higher
production without deterioration in quality.

Production = k*A*B*V*Y

k = Constant
A = Sintering Area
B = Bulk Density of mix
V = Vertical sintering speed
Y = Yield
51
Methodology of Intensification of
sintering process

Factors that influence sintering

1) MEN

2) MATERIALS

3) PROCESS PARAMETERS.
52
MATERIALS

1) Iron ore fines size

2) Iron ore fines chemistry

3) Coke breeze

4) Calcined Lime
53

.
The granulometry of iron ore fines, used in
sintering, has a great influence on sinter plant
performance.

Laboratory Experiments were conducted with
different granulometry of iron ore fines to assess its
influence on sinter quality and productivity.

The upper size of the iron ore fines was reduced in
each of the experiments.

GRANULOMETRY OF IRON ORE FINES
54

EFFECT OF IRON ORE FINES SIZE ON
SINTERING
Sl.No Size Lime %yield VSS Prod. T.I
(mm) (Kg/t) (+5mm) mm/min t/m
2
/h %

1 0-15 0.0 70.6 18.6 1.182 69.3

2 0-8 0.0 76.5 19.6 1.272 68.3

3 0-8 20.0 75.6 20.1 1.326 67.2

4 0-6 20.0 80.3 20.3 1.418 67.3

5 0-5 20.0 81.0 21.6 1.489 66.7
55

Chemical Quality
EFFECT OF TOTAL Fe

Results show that lower Fe grade (< 62% Fe) ores and
concentrates will typically form SFCA (SiO2-Fe2O3-
CaO-Al2O3) as part of the final assemblage.

Medium grade (62-65% Fe) ores will form a mixture of
SFCA and SFCA-1..

High grade (65-68% Fe) ores will form largely SFCA-1.

The SFCA-1 phase is the most desirable bonding phase in
iron ore sinter, since microstructures composed entirely of
SFCA-1 show higher physical strength and higher
reducibility than microstructures composed predominantly
of SFCA
56
LOSS ON IGNITION

The higher LOI of iron ore fines has a detrimental
effect on sinter quality and productivity

EFFECT OF Al2O3

An increase in Al2O3 % by 1 % increases the RDI
value by 10%

EFFECT OF SiO2

Higher SiO2 in sinter will induce the formation of
glassy phases in sinter and reduce the strength of
sinter.

57

COKE BREEZE SIZE
The required coke breeze granulometry for
efficient sintering is:

+5 mm < 5 %
- 3 mm = 85-90 %
-0.5 mm < 15 %

Presence of higher % of +5 mm slows down the
coke breeze burning rate and thus reducing
sintering rate.

For reducing the micro-fines generation during
crushing, -3 mm should be screened out before
the crusher.

58

CALCINED LIME
Calcined lime is one of the best intensifier of
sintering process

Preheats the sinter mix

Enhances balling phenomena

Replaces raw lime stone

Calcined lime addition @ 20kg/t was found to be
optimum for SAIL sinter plants.
59

PROCESS PARAMETERS
Mixing and Balling

Segregation of mix

Moisture

Ignition

Under-grate Suction

Preheating of sinter mix

Use of hot air in ignition hood

cooling

60

MIXING AND BALLING REGIMES

Generally most of the sinter plants are provided
with separate mixing and balling drums. But the
latest generation of sinter plants are provided with
a combined mixing and balling drums.

The main purpose of mixing drum is to
homogenize the sinter mix . The diameter of the
drum , the RPM and the space factor play a major
role in achieving higher degree of mixing.
61
The balling drum (Nodulising drum) ensures that
fines are coated on the nuclei particles, thus
produce higher size balls. This facilitates in
improving the mean size of sinter mix and hence
the permeability of mix. Here again the diameter ,
RPM and space factor play a major role in
achieving higher degree of balling.
Very little water is added in mixing drum and
major quantity of water is added in the balling
drum
The amount of water added and the method of
water addition in the balling drum also control the
degree of balling and hence the permeability of
sinter mix.
62






A
Laboratory model of high speed agitating mixer
Lab study at RDCIS showed improvement of strength
index with reference to conventional mixer
63
MOISTURE

As is known, faster the rate of air flow through
the bed faster is the rate of sintering.

The rate of flow of the air through the bed is
controlled by the vacuum under the bed and the
permeability of the bed.

64
SUCTION UNDER-GRATE
The rate of flow of the air through the bed is
controlled by the vacuum under the bed and the
permeability of the bed.

The optimization of the gas dynamics parameters of
the sinter machines enables one to achieve higher
under grate suction and thus substantial
improvements in the techno-economic parameters of
the sinter production.
65
IMPROVING IN SM PRODUCTVITY PER 10 mmwc AS
A FUNCTION OF SUCTION UNDER GRATE
500 600 700 800 900 1000 110 1200 1300 1400 1500
1.2

1.0

0.8

0.6

0.4
SUCTION, mmwc
IN
C
R
E
A
SI
N
G
IN
P
R
O
D
U
C
TI
VI
T
Y,
%
66
IGNITION


To provide the required free oxygen potential in the
zones for faster burning of the fuel and also early
starting of sintering.

Oxygen enrichment in ignition hood

To produce a strong sinter in the upper part of the
layer;

67
PRE-HEATING OF SINTER MIX


Pre-heating of sinter mix helps in reducing the ill effects
of Re-condensation of moisture

Pre-heating of sinter mix can be done by:
* Addition of hot water in balling drum
* Addition of steam in balling drum or raw mix hopper
* Installing gas burners inside the balling drum
* Adding hot return fines
* Addition of calcined lime

68
HOT AIR IN IGNITION HOOD


Hot air recovered from sinter cooler could be used in
the ignition hood.

This will help in not only saving gaseous fuel, but also
increases the free oxygen potential.

69
COOLING OF SINTER


Efficient cooling of sinter will help in improving sinter
strength

Installation of proper waste heat recovery system of
cooler will help in adding hot air in ignition hood

70
Rate
Size
BTP
Temp
Sinter Quality
Temp
Free O
2

Potential
Top layer
Starting of
sintering
Productivity
Rate
Method of
Addition
Balling
Permeability
Re-condensation
Under
Ignition hood
Rest of
machine
Coke
Water
Under grate
suction
Ignition
71
RECENT TRENDS OF INTENSIFICATION OF
SINTERING
High Fe, low Al
2
O
3
iron ore fines
Serpentine replacing dolomite
Good quality and quantity of lime addition
High Intensity mixer
Divided coke addition
Polymer addition in balling drum
Pre-heating of sinter mix
New sinter mix charging system
New ignition furnaces
Taller bed operation
Higher under grate suction
Taller bed circular coolers
Process control models
72