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Emission reduction for iron ore sinter plants

Article · January 2008

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Efficient Reduction of PM 10 / 2.5 emissions at Iron Ore Sinter Plants

A. Fleischanderl1, T. Plattner1 and C. Lanzerstorfer2

1
Siemens VAI Metals Technologies, Turmstraße 44, A-4031 Linz, Austria
2
Upper Austria University of Applied Sciences, Stelzhamerstraße 23, A-4600 Wels, Austria

1
Tel.: ++43-70-6592-77125; Fax.: ++43-70-6980-77125; alexander.fleischanderl@siemens.com
2
Tel.: ++43-7242-72811-3220; Fax.: ++43-7242-72811-93220; c.lanzerstorfer@fh-wels.at

Abstract
Iron ore sinter plants are major sources of PM10 / 2.5 emissions. Typical off-gas flows
of sinter machines are in the range of 500.000 to 2.000.000 m³ (STP) per hour and
emission limits for dust are usually 50 mg/m³ (STP). Annual operation hours above
8400 together with the high amount of PM 10 / 2.5 in the emitted dust result in PM 10 /
2.5 emissions of a typical sinter plant operated in compliance with actual dust emission
limits of 200 – 800 tons per year. The emission limit for dust in the TA-Luft (2002) has
been reduced to 20 mg/m³ (STP). In the IPPC document “Best Available Techniques
Reference Document on the Production of Iron and Steel” (2001) fabric filters installed
downstream of electrostatic precipitators are considered as one possible BAT
technique for off-gas cleaning of sinter plants.

The special properties of dust from sinter plants, in particular the small size of the
particles, require careful attention with regard to the selection of fabric filter material.
The results of extensive tests on fabric filter materials for sinter plant off-gas cleaning at
an industrial scale are presented. Ageing of different fabric material was characterised
by break strength, pressure drop and infiltration of fabric material with dust were
investigated in long-term tests. Considerable differences regarding expectable service
time of filter bags were found.

Keywords
Fabric filter, Sinter plant, PM 10 emission, PM 2.5 emission

-1-
Introduction
In the last decades, the iron and steel industry has undergone a technical revolution
introducing new technologies, increasing productivity and reducing emission of pollutants.
Although new production routes for steel have been established, especially the electric-arc
furnace route, the blast furnace route at integrated steel mills is likely to remain the
backbone of worldwide steel production. In this production route, the iron ore fines, which
account for the greater part of iron feed to the blast furnace, are agglomerated in a sinter
process. If iron ore in powder form would be charged into the blast furnace, the inside of
the blast furnace would become impermeable, preventing the flow of reducing gas through
the ore/coke bed. Additionally, the sinter plant serves as a recycling unit, where iron-rich
fine by-products e.g. dust from various de-dusting plants as well as mill scale is recycled to
the process.
Due to the high temperature during sintering, components with a noticeable vapour
pressure like alkali and heavy metal chlorides are volatilised. Re-condensation of these
components in the off-gas system of the sinter machine results in a high fraction of
PM 10 / 2,5 in the dust emission of sinter plants [1, 2, 3].

The dust emission limit for sinter plants is usually 50 mg/m³ (STP). In the new TA-Luft
2002, the general dust emission limit has been reduced to 20 mg/m³ (STP) [4]. However,
for existing sinter plants an exception has been made. Typical off-gas flows of sinter
machines are in the range of 500.000 to 2.000.000 m³ (STP) per hour. Annual operation
hours above 8400 together with the high fraction of PM 10 / 2.5 in the emitted dust result in
PM 10 / 2.5 emissions of a typical sinter plant operated in compliance with actual dust
emission limits of 200 – 800 tons per year. In Linz, a mid-size industrial town in Upper
Austria, the sinter plant of the integrated steel mill accounted in 2001 for 14% of the overall
PM 10 emissions [5]. Reduction of PM10 / 2,5 emissions is therefore a major challenge for
steel mills [6].

Sinter Plant Off-Gas Cleaning

The operation of a sinter machine requires an under pressure generated by the ID- fan in
the range of 15-20 kPa. For wear protection of the impeller, a dust separator has to be
installed upstream of the ID-fan. For this purpose, ESPs or cyclones are usually applied
(Figure 1). Additional off-gas cleaning systems are installed downstream of the ID-fan,
where they are not exposed to the high under pressure generated by the ID-fan.

-2-
Figure 1: Typical process flow sheet for sinter machines

In the IPPC document “Best Available Techniques Reference Document on the Production
of Iron and Steel” [7], fabric filters installed downstream of electrostatic precipitators (ESP)
are considered as one possible BAT technique for off-gas cleaning of sinter plants. Over
the last years, a trend to install additional fabric filters in sinter plants for improved
reduction of dust emissions is obvious [8]. In combination with flow injection systems
upstream of the filter, simultaneous reduction of acid gases (SO2, HCl, HF), volatile heavy
metals (Hg) and toxic organic compounds (PCDD/F, PAH) can be achieved [9, 10, 11].

With fabric filters clean gas dust emissions of sinter plants can be reduced to values below
5 mg/m³ (STP) [10]. However, even few damaged filter bags can cause a substantial
increase in clean gas dust concentration [10, 12]. Therefore, careful selection of fabric filter
material is important for assured operation in compliance with low dust emission limits
together with minimization of the expense for exchange of filter bags.

PM 10 / 2.5 in Sinter Plant Off-Gas

In figure 2, the cumulative mass distribution of dust emitted from various sinter plants is
shown. Most particle size measurements have been done by impactors. Therefore, the
particle size is based on the aerodynamic diameter (dae). Assuming an average density of
the particles (ρP) of 2500 kg/m³, the calculated Stokes diameters (dSt) will be about 1/3
smaller than the aerodynamic diameters (ρ0 = 1000 kg/m³).
ρ0
d St = d ae .
ρP

At sinter plant 6, the particle size determination was performed using electron microscope

-3-
images of short time exposed filters, thus the particle diameters are equivalent to Stokes
diameters.

Figure 2: Cumulative mass distribution of dust emitted from sinter plants

(sinter plant 1-5, 7,8: particle size measurement by impactor – aerodynamic diameter of
particles; sinter plant 6: particle size determination by scanning electron microscope –
Stokes diameter of particles)

Fabric Filters for Sinter Plant Off-Gas Cleaning

The properties of dust from sinter plants require careful attention with regard to the design
of the filter and selection of fabric filter material. Regarding the filter material, two types of
malfunctions have to be considered: first: clogging due to continuous infiltration of the filter
material by dust particles or condensing material, which results in an ongoing increase of
the pressure drop and second: loss of break strength of the filter material, which results in
damage of the filter bags and consequently increases the clean gas dust concentration.
For one filter installed at a sinter plant for off-gas cleaning, an expected life time of the filter
bags of 3.5 years has been reported [10].

For optimization of filter design and fabric filter material selection, a pilot plant with a
capacity of 90.000 m³/h was built and operated at a sinter plant for nearly 2 years. The

-4-
pilot plant comprised of a pulse-jet filter and a flow injection system is described in detail
elsewhere [9]. The pulse-jet filter is designed for vertical filter bags (length: 7 m, diameter
160 mm). For pre-selection of fabric filter material, a smaller test unit has been operated
for several months. In this pre-test, the behaviour of three different filter materials
regarding dust infiltration has been investigated. In figure 3, sections of two of the tested
filters are shown. The filter material in the left picture is a membrane type filter. This type of
filter material is covered with a thin membrane to improve surface filtration characteristics.
No noticeable dust deposition inside filter material could be detected with the microscope
whereas the section of a similar filter material without a membrane (Figure 3, right) shows
substantial dust infiltration.

Figure 3: Image of used filter material photographed with a light microscope;

Left side: Section of filter material with membrane on top; Right side: similar filter material,
but without a membrane

As a result of this pre-test, only membrane type fabric filter materials have been
considered for the pilot plant. The use of membrane type filter material for de-dusting in
cases where the dust contains a high fraction of very fine particles is also suggested in the
literature [13]. The pilot plant was equipped with filter bags made of two different
membrane type fabric filter materials, both with the same specific costs.

Samples of used filter material have been taken periodically for testing regarding the
following parameters: air permeability, infiltration of dust and tensile strength. Air
permeability was measured according ISO 9273. Infiltration of dust was investigated using
different methods. Images of cut sections of the filter material were photographed using a
light microscope (type: Motic SMZ-168 (stereomicroscope) and Olympus BX51) and a
scanning electron microscope (type: Zeiss SUPRA 35). For quantification of the amount of

-5-
infiltrated dust, filter samples were leached after vacuum cleaning of the high dust side of
the filter. The dissolved dust was analysed by ion chromatography (type: Dionex ISC-
1000) for calcium, sodium, potassium, ammonium, chloride and sulphate. These ions
account together with the hydroxide ion of unreacted sorbent for more than 90% of the
dust discharged from the filter [14]. Tensile strength was tested according ISO 9073-3.

Results and Discussion

As expected, the measured dust concentration after the fabric filter was always below
5 mg/m³ (STP) [9]. Because the two different types of filter bags were installed in one filter
unit, there was no possibility for separate measurements of the clean gas dust
concentration after the different fabric filter materials.

For filter material A, a distinct descent in air permeability was observed in the first six
months of operation (Figure 4) whereas afterwards the measured values were nearly
constant. In contrast, the air permeability of filter material B did not show the expected
downward trend. The measured values are scattered over the range of air permeability of
new filter materials.

140%
[% of average permeability of new material]

120%
new filter material A

new filter material B

100%
Air Permeability

80%

60%

40%

Filter material A
20% Filter material B

0%
0 5000 10000 15000

Time of Operation [h]

Figure 4: Air permeability of used filter material (average air permeability of new filter
material equivalent to 100%)

-6-
With the microscope, no noticeable dust deposition inside filter material A could be
detected (Figure 5). Also, filter material B showed little signs of dust infiltration (Figure 6).
Only some dust infiltration could be detected along the seams.

Figure 5: Image of filter material A; Left side: after 1550 hours of operation;
Right side: after 12300 hours of operation

Figure 6: Images of filter material B after 1550 hours of operation; Left side: section of
filter with membrane on top; Right side: section of filter across lengthwise seam

The outcome from the microscopic inspection was confirmed by scanning electron
microscope images (Figure 7).

Furthermore, only small amounts of infiltrated dust were found in the leaching tests.
Figure 8 shows the mass of infiltrated dust (sum of the analysed ions) related to the mass
of the new filter material. The initial rate of net dust infiltration diminished after the first six
months of operation and is almost zero. For both filter materials, the mass of the infiltrated
dust stays below 1% of the filter mass.

-7-
Figure 7: Images of filter material after 1550 hours of operation photographed wit a
scanning electron microscope; Left side: filter material A; Right side: filter material B

1,0%
Infiltrated Dust [% of mass of clean filter]

0,8%

0,6%

0,4%

0,2% Filter material A

Filter material B

0,0%
0 5000 10000 15000
Time of Operation [h]

Figure 8: Relative amount of infiltrated dust in used filter material

However, dust infiltration still occurs but is nearly in equilibrium with dust discharge from
the filter material. In the time before the second plant stop where samples have been
taken (at about 3300 h), the pilot plant was operated for several days using different
sorbent containing sodium instead of hydrated lime. After this stop, hydrated lime was in
use again. The amount of sodium in filter material A was extreme high in the second
sample compared with the first sample (Figure 9). In the next sample, the amount of
sodium was back at the usual value. This can be attributed to the effect of discharge of
infiltrated dust from the filter material.

-8-
 0,05%

0,04%
Sodium in Infiltrated Dust
[% of mass of clean filter]

0,03%

Filter material A

0,02%

0,01%

0,00%
0 5000 10000 15000
Time of Operation [h]

Figure 9: Relative amount of sodium in used filter material A

The Tensile strength of filter material A shows a substantial decline in both direction of the
fabric material (warp and weft). Extrapolation of the available results predicts that the
tensile strength will be down at the suggested limit after an operation time of 2.5 to 3 years
(Figure 10).

For filter material B, the decrease of tensile strength was much less (Figure 11). Provided
that the measured trend can be extrapolated for such long time, tensile strength of filter
material B will be above the suggested limits for more than ten years.

Conclusion
Significant reduction of PM 10 / 2.5 emissions of sinter plants can be achieved by fabric
filters on a continuing basis. The high fraction of PM 10 /2.5 in the dust from sinter plants
could cause clogging of filter material due to dust infiltration. That would essentially
increase the expense for exchange of filter bags for long-term plant operation.

The investigated membrane type fabric filter materials showed only very little clogging
effects. After an increase in the first six months of operation, both air permeability and
amount of infiltrated dust stayed at almost constant values.

-9-
 120%
Tensile Strengtg [% of break strength at first test]

100%

80%

60%

40%
Filter material A - Weft
Limit for Tensile Strength - Weft
20%
Filter material A - Warp
Limit for Tensile Strehgth - Warp
0%
0 5000 10000 15000 20000 25000
Time of Operation [h]

Figure 10: Tensile Strength of used filter material A (break strength of filter material at first
test equivalent to 100%)

120%
Tensile Strengtg [% of break strength at first test]

100%

80%

60%

40%

Filter material B - Weft

20% Limit for Tensile Strength - Weft

Filter material B - Warp
Limit for Tensile Strehgth - Warp
0%
0 5000 10000 15000 20000 25000
Time of Operation [h]

Figure 11: Tensile Strength of used filter material B (break strength of filter material at first
test equivalent to 100%)

- 10 -
Substantial differences were identified regarding the tensile strength of the material.
Tensile strengths of filter material A showed a tremendous decline whereas the decrease
of the values for filter material B was only minor.

Considering the equal specific cost of both fabric filter materials, minimization of the
expense for exchange of filter bags is possible by selection of filter material B. Therefore,
the new full-scale off-gas cleaning system of the sinter plant in Linz will be equipped with
filter material B. Start-up of the system is scheduled for July 2007.

Acknowledgements
The research program of the industrial competence network for "Metallurgical and
Environmental Process Development" (KnetMET) has been financially supported within
the framework of the industrial center of competence and competence network program
(Kind/Knet) of the Federal Ministry of Economic Affairs and Employment, by the provinces
of Upper Austria and Styria and by the Styrian Business Promotion Agency.

References
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[2] Gebert, W.: Abgasreinigungssysteme für Sinteranlagen. Dissertation. Univ.

Kaiserslautern (1996) 24-26.

[3] Siemens VAI Metals Technologies, Internal Reports.

[4] Erste Allgemeine Verwaltungsvorschrift zum Bundes-Immissionsschutzgesetz

(Technische Anleitung zur Reinhaltung der Luft - TA Luft) vom 24. Juli 2002.
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[7] IPPC document: Best Available Techniques Reference Document on the Production
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[8] Hartig, W. and Lin, R.: Comparison of Waste Gas Cleaning Systems for sinter plants
of VDEh member works. Korean-German New Steel Technology Symposium, July 4-
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- 11 -
 [9] Fleischanderl, A., Neuhold, R., Meierhofer, G. and Lanzerstorfer, C.: MEROS® -
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[10] Schuster, E., Zirngast, J., and Zahn, M.: Experiences with flue-gas cleaning by bag
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[11] Erich, E. and Hillmann, C.: Weniger Dioxine aus Sinteranlagen. Umweltmagazin 33
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[12] Bach, B. and Schmidt, E.: Einfluss von Fehlstellen in Oberflächenfiltern auf die
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[13] Bank, M.: Basiswissen Umwelttechnik. Vogel Buchverlag, Würzburg (1995) 512.

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