Sintering Process 1655649230

Sintering Process
Ironmaking Course 2010

1
Contents
1. Introduction
1.1. The concept of sinter
1.2. Technological evolution on sintering process
2. Raw materials to the sintering process
2.1. Iron ores (sinter feed)
2.2. Solid fuels
2.3. Fluxes and additives
3. Stocking and preparation of raw materials
3.1. Raw materials stocking yard
3.2. Raw material blending
Sintering Process – Ironmaking Course 2010

2
Contents
4. Iron ore sintering process

4.1. Raw materials storage
4.2. Mixing and granulation step
4.3. Blend loading on the strand
4.4. Ignition step
4.5. Sintering step
4.6. Sinter cake breaking and cooling
4.7. Sinter size preparation step

3
Contents
5. Sinter quality
5.1. Typical chemical specification – Brazilian sinter
5.2. Physical quality
5.3. Metallurgical quality
5.4. Overview of sinter quality
6. Model of iron ore classification
7. Sinter pot test

4
1. Introduction

5
1. Introduction
1.1. The concept of sinter
9 Iron ore agglomerate produced on the sintering process which it uses

heat to fuse separate iron ores fines into larger particles, that are
suitable for charging to the blast furnace.
9 In the past, the sintering technology was created to reuse the
ironmaking residues and fine ores in the blast furnace.
9 Currently, the focus was changed. Now, the sintering aims to
elaborate a high quality burden to the blast furnace.
9 Sinter is the main metallic burden of the large blast furnaces.
10 mm 10 mm
(1) Ordinary sinter (2) HPS sinter

6
1. Introduction
1.1.1. Self-fluxing sinter
9 The sintering feed also contains fluxes, sinter return fines and solid
fuels.
9 From a chemical point of view it is important to note that the lime
added to the sinter is important as a flux for the blast furnace.
9 Main advantages of adding fluxes to the sinter:
1. to generate slag with the impurities present in the iron ores and solid
fuels producing a suitable matrix for cohesion of the particles;
2. to improve the physical and metallurgical properties of sinter;
3. to reduce the melting temperature of the iron ore blend;
4. to promote the decarburization reaction of the limestone (CaCO3 ->
CaO + CO2, cost 117 kJ/mole) outside of the blast furnace. The required
heat is not taken from the blast furnace gas flow.
9 Sinter may be categorized into acid sinter, self-fluxing sinter and
super fluxed sinter.
9 Self-fluxing sinter brings the lime required to flux its acid components
(SiO2, Al2O3). Super-fluxed sinter brings extra CaO to the blast
furnace.
9 For self-fluxing and super-fluxed sinter, the lime reduces the melting
temperature of the blend and at relatively low temperatures (1100oC
to 1300oC) strong bonds are formed in the presence of FeO.

7
1. Introduction
1.1.2. Homogeneous and heterogeneous sinters
9 The homogeneous sinter (type A) is produced based on high thermal
level (>1300oC) for a long time.
9 The heterogeneous sinter (type B) is produced based on low thermal
level (<1300oC), or if the raw mix is submitted to high thermal level
for a very short time.
9 The heterogeneous sinter has superior performance into the blast
furnace, due to the higher reduction capacity when in contact with the
reduction gas.
9 The heterogeneous sinter needs less solid fuel to be produced.
(1) Columnar calcium ferrite

(2) Magnetite
(3) Skeletal rhombohedral hematite
(4) Glassy silicate
(5) Pore
(6) Acicular calcium ferrite
(7) Grown hematite grain
(8) Glassy silicate
(9) Unmelted ore

8
1. Introduction
1.2. Technological evolution on sintering process
9 Currently, the iron ore sinter has been the main metallic burden to the
blast furnaces. The most of blast furnace in the world operates with
more than 60% of sinter on the burden.
Technological Evolution of Sintering Process
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9 This is due to the great technological evolution of the production

process and sinter quality improvement.

9
1. Introduction
1.2.1. Typical layout of Greenwalt sintering plant
9 The first Greenwalt sinter plant was constructed in 1890 to
agglomerate non-ferrous fines.
9 Greenwalt plant is a batch-type process.
Silos Carregamento
Chaminé
Forno ignição móvel Grelha basculante
Exaustor
- Small strand area = 20 to 30m2

- Fixed strand
- Mobile ignition furnace
- Discharge by batch
- Higher production cost

10
1. Introduction
1.2.2. Typical layout of Dwight-Lloyd sintering plant
9 Dwight and Lloyd constructed the first continuous sinter plant in 1906.
9 Today, modern and large sinter strands are 5 meters wide and an effective
sinter area larger than 400m2. Productivity is typically 30 to 46t/m2/day.
STORAGE BINS A RETURN FINES

B IRON ORES
A B C D E F C IRON ORES
D COKE
E LIMESTONE
DRUM MIXER F WASTES
STACK
SURGE HOPPER
DRUM FEEDER IGNITION

FURNACE
BREAKER
SINTER
- Big strand area = 100 to 600m2 MAIN COOLING

DEDUSTING BOX HOT SCREENING
- Mobile strand BLOWER
- Fixed ignition furnace
- Continuous discharge RETURN FINES COLD
SCREENING
- Lower production cost

11
1. Introduction
1.2.2. Typical layout of Dwight-Lloyd sintering plant
9 Sinter machine
Sinter Machine No3 – USIMINAS

12
2. Raw materials to the

sintering process

13
2. Raw materials
2.1. Sintering raw materials
IRON ORE: iron source suitable to the sintering process
Base Ore: it is used in higher proportion
Addition Ore: it is used in smaller proportion
FUEL: energy supplier to the sintering process

Gaseous: COG, BFG, LPG
Liquid: fuel oil Used on the ignition step

Solid: coke breeze (from coal or petroleum), charcoal, anthracite
FLUX: used to decrease the blend melting temperature

Basic: limestone, lime, dolomite, dunite / serpentine
Acid: quartz (sand)
ADDITIONS: it is used to adjust some sinter characteristics or

to recycle industrial waste
Iron bearing: Millscale, BF dust, industrial waste
Others: BF slag, Mn ore

14
2. Raw materials
2.2. Iron ores
9 The iron ore mine products can be divided on lump ore, sinter feed and pellet
feed. Lump ore is an appropriated size range to be used as direct charge for the
reduction furnaces (Blast Furnace and Direct Reduction).
PRIMARY
Size Range PRODUCTS
10 to 50mm
< 9,35mm
< 0,15mm
10 to 50mm
9 Sinter feeds and pellet feeds need to be agglomerated before of using in blast
furnace. Sintering and pelletizing processes were developed for that.

15
2. Raw materials
2.2. Iron ores
IRON ORE: iron source suitable to the sintering process (sinter
feed)
Base ore: iron ores that are used in higher proportion in the
mix due to its good chemical and physical characteristics
Addition ore: iron ores that are used in lower proportion in

the mix aiming to adjust some sinter characteristics or to
reduce sinter cost
Iron ore blend: the current concept is based on the

definition of an iron ore blend that meets the interest
characteristics of the several iron ores, taking into account
also availability, logistics and cost aspects

16
2. Raw materials
2.2. Iron ores
9 The chemical composition of the sinter feed blend is defined to attend the
necessities of the downstream processes on steelmaking chain:
Sintering process
- physical and metallurgical properties of sinter (mechanical strength, RDI,
reducibility, softening and melting properties etc)
Blast furnace
- gas and liquid flow into blast furnace (dependent of the sinter quality)
- volume and quality of the BF slag (viscosity, desulphurization capacity etc)
Steel plant
- chemical quality of the hot metal (low P, low S)
9 Chemical composition of some commercial sinter feeds.
Iron Ores FeT SiO2 Al2O3 Mn P S LOI
Yandi - BHP 57,03 5,61 1,07 0,030 0,008 0,010 10,20
MAC - BHP 61,56 3,21 1,89 0,080 0,013 0,035 6,20
Mt Newman - RTZ 63,78 3,26 1,96 0,080 0,015 0,010 2,92
Pilbara - RTZ 62,48 3,83 1,99 0,140 0,016 0,030 4,70
Hamersley Yandi - RTZ 57,77 4,79 1,44 0,030 0,010 0,010 10,03
SFCJ 66,90 1,10 1,00 0,500 0,033 0,000 1,60
SSFT 65,00 3,80 1,00 0,170 0,049 0,000 1,90
SSFG 65,00 3,20 1,20 0,250 0,049 0,000 1,70

17
2. Raw materials
2.2. Iron ores
AUSTRALIAN IRON ORES BRAZILIAN IRON ORES

18
2. Raw materials
2.2. Iron ores
9 The size distribution of the sinter feed blend is one of the most important
aspects to the sintering performance. In the past, the Astier Curve was used to
define an ideal size distribution for the individual sinter feeds.
A= Ideal Blend
B= Astier Curve
% Passing (cumulative)
% Retained (cumulative)
9 But, currently, the concept adopted is of an iron ore blend with a suitable size
distribution.

19
2. Raw materials
2.3. Solid fuel
9 The main functions of the solid fuels in the sintering process are: (i) to supply energy to the
process, and (ii) to increase the bed permeability during the process.
9 Coke breeze is the most usual fuel on integrated steelworks due to its good chemical and
physical characteristics. The coke fines can not be used in blast furnaces.
9 The chemical quality of fuels is an essential aspect on the choice of fuels for sintering process.
In general, the anthracite has higher ash and volatile material contents than coke breeze. The
ash of the anthracite has high deleterious compounds as Al2O3 and P.
Combustíveis
Solid Fuels
Sólidos Ash
Cinzas
(%)(%) Volatile
Mat. Volátil
Mat.(%)
(%) Fix
Cfixo
C (%)
(%)
Peerles Eagle (Coal) 7.25 34.61 58.14
Blue Creek (Coal) 9.15 25.22 65.63
Coppabella (Anthracite) 8.71 19.71 71.58
Buchanan (Coal) 4.90 18.37 76.73
Invercoal (Anthracite) 7.26 11.39 81.35
África do Sul (Anthracite) 16.04 10.92 73.04
Yongcheng (Anthracite) 10.29 8.43 81.28
Thong Hai (Anthracite) 16.92 6.51 76.57
Beijing (Anthracite) 15.81 5.14 79.05
Kussbass (Anthracite) 11.43 4.04 84.53
Donbass (Anthracite) 16.42 2.98 80.60
Coke
CoqueBreeze
Breeze 13.48 2.18 84.34
Coke
CoquePetrobrás
Petrobrás 0.02 11.08 88.90
Coke
CoqueEUA
EUA 0.02 12.24 87.74

20
2. Raw materials
2.3. Solid fuel
9 To be used in sintering process the fuel shall be high heating capacity, suitable
reactivity (combustion rate) and size distribution.
0,2
Amostra A - MA - BEIJIN G
0,18 Amostra B - HVB A - P.EAGLE
Amostra C - HVB A - B.CREEK
9Reactivity is the 0,16

Amostra D - AN - YONGCHENG
Amostra E - MA - DONBASS
combustion rate of Amostra F - SA - S.AFRiCA
the fuel at presence
(min-1)
0,14 Amostra G - COQUE PETRO
of oxygen. Amostra H - Mist LVB - COPPABELLA

Amostra I - MVB/LVB - BUCHANAN
0,12
Reatividade ao ar (min-1)
Amostra J - MOIN HA COQUE
Amostra K - COQUE VERDE
Reactivity
0,1 Amostra L - SA - COLOMBIANO
Amostra M - AN - TH
Amostra N - AN - SK
0,08
0,06
0,04
0,02
0
0 100 200 300 400 500 600 700 800 900 1000
-0,02
Temperature
Temperatura (oC)
(oC)
9 When more than one type of solid fuel is used in sintering process it is very
important to consider the reactivity of each one. The use of two solid fuel with
very different reactivity can increase the flame front thickness and to decrease
the permeability of the sintering bed. (more details will be commented ahead)

21
2. Raw materials
2.3. Solid fuel
9 Finer solid fuel burns more fast and accelerates the process, but the heat
liberation is very fast too decreasing the sinter yield. Coarser solid fuel burns
slowly and decreases the velocity of the flame front. Thus, it is essential to
adjust the size distribution of each type of fuels to the its reactivity pattern.
PARTICLE
PARTICLE SIZE
SIZE (mm)
(mm)
OPERATIONAL ASPECTS SCALE
OPERATIONALASPECTS
7 3 1 0.5 0.25 <0.25
SINTERABILITY
SINTERABILITY PILOT
PILOT
BURNT
BURNTEFFICIENCY
EFFICIENCY INDUSTRIAL
INDUSTRIAL
BED
BEDPERMEABILITY
PERMABILITY INDUSTRIAL
INDUSTRIAL
MIXING
MIXING INDUSTRIAL
INDUSTRIAL
MINIMIZE
MINIMIZESKULL
SKULL INDUSTRIAL
INDUSTRIAL
IDEAL
IDEALRANGE
RANGE INDUSTRIAL
INDUSTRIAL
9 In terms of the aspects linked to the sintering process performance, the ideal
size range of coke breeze is from 0.25mm up to 3.0mm. But, this ideal range
may change based on iron ores characteristics, types of fuels and process
particularities. So, it is very important to define the fuel specification based on
sinter pot tests.

22
2. Raw materials
9 The fluxes have as base function to generate slag with the impurities
present in the iron ores and solid fuels producing a suitable matrix for
cohesion of the particles. The physical strength depends on the quality
of that final matrix.
9 The fluxes can be divided on 02 (two) categories:
Basic fluxes: sources of CaO and/or MgO
Acid fluxes: sources of SiO2 and/or Al2O3
9 Main basic fluxes:
- Limestone – CaCO3; Burnt lime – CaO
- Dolomite – (Ca,Mg)CO3; Dunite/serpentine - Mg3.SiO5.(OH)4
- Olivine – (Mg, Fe)2 SiO4
9 Main acid fluxes:
- Quartzite or sand – SiO2; Bauxite – Al2O3
9 MgO has the function to adjust the slag viscosity and desulphurization
capacity.
9 It is essential to the sintering process and sinter quality to identify the
ideal size distribution of the fluxes.

23
2. Raw materials
9 The burnt lime is used as binder in the sintering mixture aiming to improve the
fine particles agglomeration and, consequently, to increase the sintering plant
productivity.
Mean size of granules (quasi-particles) (mm)
Productivity (t/h/m²)
Ref: KSC Ref:Kobe Steel
Burnt lime (%) Burnt lime (%)
9 The additives are used to add some chemical elements in attendance the needs
of the blast furnaces. Sources of Mn and Ti are usually utilized in sintering
mixture. Recycled materials are also considered as additives.

24
3. Stocking and preparation

of raw materials

25

3.1. Raw materials stocking yard
9 After delivery to the steel works the raw materials are individually
piled on primary stockyards.
9 And during its receiving the raw materials are sampled for chemical
and size distribution evaluations.

26

9 The iron ores are stored and blended in pre-determined ratios. The
blending can be done by mixing appropriate quantities on a conveyor
belt before arrival at the sinter plant or with a blending pile.
9 In general, there is a blending pile on formation (filling stage) and

another one on consumption (reclaiming stage).

27

9 These piles are constructed by depositing the different iron ores and
fluxes in layers in a longitudinal direction and then perpendicularly
reclaimed them. This method of layering and reclaiming is to ensure a
homogeneous mix.
Chevron Pile
9 Normally, the blending piles are carried out with the iron ores and part
of fluxes needed for the sintering process.

28

29

4.1. Sintering plant typical layout
9 Dwight and Lloyd constructed the first continuous sinter plant in 1906.
9 Today, modern and large sinter strands are 5 meters wide and an
effective sinter area larger than 400m2. Productivity is typically 30 to
45t/m2/day.
Mixing step
Sintering step
Storage step
Cooling step
Size
preparation
step
Baosteel sinter plant

30

Storage step

31

- Raw material storage -

32

4.2. Raw material storage
9 Previously to the sintering machine every raw materials (iron ore
blend, fluxes, fuels and return fines) are individually stored in a set of
bins coupled with weighting systems.
Fixation
Fix structure
Wheels
Wheels
Vibrator
Mobile structure
Vibrator CST
Conveyor belt
with balance
9 The sintering feed is carried out by blending appropriate quantities of

each material on a conveyor belt which conducts the total blend to the
mixing system.

33

4.2. Raw material storage – Project of bins
9 To calculate the capacities of raw materials bins is done a materials

balance (see example below).
Hearth layer
Raw materials
Unit
Coke Waste of process
Return fines
9 Total mixture = sinter + return fines + waste of process

34

9 To calculate the capacities of raw materials bins is done a materials

balance
Specific
consump- Nominal production Project production
tion (x 1.30)
Si = Sinter total production (t/h)

Return Fines (RF) = 350 to 500 kg/t sinter(1)
Waste of process (WP) = coke fines, dust,
moisture, CO2
(1) RF is obtained based on pilot plant tests with the sintering mixture. In this test is evaluated the
coke consumption to balance the return fines.

35

9 Flow sheet of a basic project of the sintering plant
(a)
Exaustor / EP
Exaustor /
EP

36

9 In this example have been considered 16 hours of storage capacity

and have not been considered bins for anthracite and dolomite.

37

4.2. Raw material storage – Control system
9 Below is shown an example of a typical control system of raw

materials feeding.
Control system of the raw materials and return fines

Controle da razão de F.R
To Surge Total
Hopper. Total raw
Mat.
mix flow
primas
Return Limestone Dunite Lime Blend Others Coke
fines (t/h) (t/h) (t/h) (t/h) (t/h) (t/h) (t/h)
Ratio Found demand

Setpoint Set
Setpoint
pointpara
paraMateria
total de
Setpoint for
Primas
materias primas
Total raw mix
Água
Water

38

Mixing step

39

- Mixing and granulation steps -

40

4.3. Mixing and granulation steps
9 The total blend is mixed in a rotating drum to ensure an homogeneous
mix (mixing step). After that, water is added up to reach the optimum
moisture for primary bonding between ore particles (granulation step).
Drum mixer
9 Both the mixing and granulation steps may be done in the same drum
mixer or on two serial mixers.

41

9 The sintering performance depends on the efficiency of mixing and

granulation of the blend.
Feeding
Water
Drum mixer
Discharging
Raw material Mixing step Granulation step
9 J.P.U. = Japanese Permeability Unit

42

9 The sintering bed needs a good permeability for the air to be sucked
through the blend, to guarantee a high strand productivity and a
proper efficiency of solid fuel burnt.
Homogeneous flow Heterogeneous flow

43

9 Liquid bridges between particles are responsible to begin the

granulation process.
A B C
Solid
2r
a Liquid
R 2
D E F
1
Granulation
R
θ stages
2r
Effect of the moisture on the granulation process
“Liquid bridge”
9 Capillary forces are responsible to decrease the distance between the

particles increasing the granule resistance. The excess of moisture has
a harmful effect on the granule resistance and on the bed stability.

44

9 Studies about of granulation process in drum mixer have shown that
higher efficiency is obtained for the cascade pattern (see below).
Occupation index = A’ / A
Cataract pattern
Occupation Index (% volume)
A
Cascade
pattern
A’
Fr. No = V2 / (g . D)
V = rpm (rotations per minute)
D = diameter of drum
Slip pattern
g = gravity acceleration
Froude number (x10-3)
9 The granulation efficiency depends on the amount of material,

residence time into the drum and rotation velocity.

45

9 The physical characteristics of the iron ore strongly affect the
granulation efficiency, such as size, shape, roughness etc.
Nucleus particles + 0,70 mm Coarse particles act as nucleus of the granule
Intermediate particles 0,20 to 0,70 mm Intermediate particles don’t participate of the granule
Adherent particles - 0,20 mm Fine particles adhere on the nucleus to form granule
9 These iron ores characteristics affect the amount of water necessary

to reach the maximum granulation efficiency (optimum moisture).

46

9 The mineralogical / microstructural aspects and the size distribution of
the commercial iron ores have a strong effect on the mixtures
granulation efficiency and on the bed permeability.
- Dense Hematite (DH)
- Coarse Microplaty Hematite (CMH)
- Fine Microplaty Hematite (FMH)
- Hematite / Marra Mamba (H/MM)
- Marra Mamba (MM)
- High Alumina Pisolite (HAP)
- Low Alumina Pisolite (LAP)
9 This is due to the differences of porosity and specific surface among

the iron ores.
47

9 Iron ores with high goethite content have a higher saturation moisture
than hematite ores. Saturation moisture is the maximum amount of
water that the ore can absorb.
- Coarse Microplaty Hematite (CMH)
- Hematite / Marra Mamba (H/MM)
- Marra Mamba (MM)
- High Alumina Pisolite (HAP)
Effect of the amount of

intermediate particles
9 A higher blend saturation moisture results on a higher specific fuel

consumption on the sintering process.

48

9 Increasing the intermediate particles in the mix decreases the
granulation efficiency and, consequently, decreases the bed
permeability and the strand productivity.

- Marra Mamba (MM)

49

9 Each sintering blend has a proper optimum moisture that assures the
maximum granulation efficiency and bed permeability.
Permeability (J.P.U)
Water Content (%)
do = harmonic mean size (mm)
9 The size distribution of the iron ore blend has strong relation with the
optimum moisture and bed permeability.

50

9 The increase of fines (-0,25mm) in the mix decreases the granulation

efficiency and, consequently, decreases the bed permeability and the
strand productivity.
B Plant
Productivity (t/m2.h)
Productivity (t/m2.h)
C Plant
A Plant
– 0,25mm (%) Burnt lime (%)
9 Burnt lime has a strong positive effect on the granulation efficiency

and bed permeability during the sintering process.

51

4.3. Mixing and granulation steps – Mixer Project
ø
L L
= X = 3 to 6
D
BASIC DATA
Nominal capacity QN 671 t/h
Project capacity QP 873 t/h
Inclination angle φ 1,5o to 3,0o
Rotation N 6 to 9 rpm
Occupation index O.I. 15%
Residence time t 4 to 7 min
Friction angle (iron ore) Β 40o
Material density d 2 t/m3
How can we evaluate the parameters L, D, N of mixer?

52

4.3. Mixing and granulation steps – Mixer Project
N = V critical * K
60 2g 42,3
k
V critical = * D
* =
2π d
Β
V critical = 1,77 * *L
s*t*d
Q (t/h) t π D2 * L
Volume = * =
O.I. * d 60 4
Ref.: Hitachi / Mitsubishi / Lurgi

53

Sintering step

54

- Blend loading on the strand -

55

9 The blend is deposited on layers of 400 to 900mm height on the sinter
strand.
Reciprocal belt
de Mistura conveyor
Comporta
Blend bin Bedding bin
(surge hopper)
Comporta
Drum feeder
Deflective plate
Carro setor
Cut plate
Bar car
Bedding
de
feeder
9 The strand bottom is always covered by a small layer of sinter (typical

15 to 25mm size range) to prevent the flame front from reaching the
sinter cars – bedding layer.

56

9 There are different types of systems to load the blend on the strand.
(1) No segregated blend loading
(2) Segregated blend loading
(1) Surge hopper

(2) Charging gate
(3) Drum feeder
(4) Deflective plate
(5) Deflective belt
(6) Cutting plate
(7) Deflective drum
9 The segregated blend loading systems aim to increase the bed

permeability. These systems are mainly used in Japan and Brazil.

57

9 The advantages of segregated mixture loading are commented below.

− it permit to improve the bed permeability, increasing the sinter plant
productivity;
− it permit to reduce the thermal heterogeneity along the bed, improving
the physical and metallurgical qualities of the sinter;
− it permit to reduce the coke consumption.
Conventional ISF
Conventional feeder Intensified sifting feeder (ISF)
40°~ 60°
65°

58

9 Comparison of the bed loading and thermal patterns between

conventional and ISF systems.
CONVENTIONAL ISF
Feeder
Conventional
TEMPERATURE (°C)
TEMPERATURE (°C)
Uniform bed
Pattern
of mix
5 10 15 5 10 15
TIME (min.) TIME (min.)
¾ The benefits of the segregating system

Pattern alone are obtained after adjust on size
of
sinter
distribution of fuels and fluxes
Strength (Shatter index)

59

4.4. Blend loading on the strand – ISF system
9 The ISF system is compounded by sets of steel bars spinning on different

directions (see below). The movement of bars avoids material build-up.
Top view
Front view
9 Each set of steel bars is 500mm width, thus for a sinter plant of 4,5 meters we
need 09 sets of steel bars.

60

4.4. Blend loading on the strand – ISF system view

61

4.4. Blend loading on the strand – ISF system view

62

- Ignition step -

63

4.5. Ignition step
9 The sintering process starts with ignition of the top layer.
9 The flame is produced by combustion of liquid or gaseous fuels. The

most common are the gaseous fuels, mainly COG and BFG.

64

4.5. Ignition step
9 There are different types of burners. The most efficient are the line
burners, due to the uniformity of the burnt.
Spherical valve
COG
Air
Butterfly
valve
Gas nipple
Air nipple Vortex

formation
Refractory
Conventional burner Line burner

65

4.5. Ignition step
9 The suitable choice of the time and temperature ignition is essential to

guarantee the progress of flame front and a proper sinter quality.
9 The excess of ignition also brings up

damages to the sintering process as:
- decreases the bed permeability
- decrease the metallurgical
properties of sinter

66

4.5. Ignition step
9 An ignition control system manages the fuel and air feeding based on set point.
If the control system identifies some problem with air or fuel feeding the sinter
machine is stopped.

67

4.5. Ignition step
9 Example of bad ignition affecting the uniformity of the burnt. In this case, the
sinter return fines generation will be very high, decreasing the sinter yield.

68

- Sintering step -

69

4.6. Sintering step – general view
9 The sintering process starts with ignition of the top layer with fans
sucking the heated air down through the sinter bed.
9 The fuels in the bed generate the heat to melt and fuse the ore
particles together.
Deflective
Surge hopper plate
Drum
feeder Ignition
furnace Plastic Sinter
Flame Front Final Sinter

Wet
Mixture Drying
Sinter
Breaker
Hearth
Screening
Layer
Return fines
9 At the end of the sinter strand the flame front has passed all the way
through the bed to the bottom.

70

4.6. Sintering step – general view
9 Thermocouples installed under the last wind box measures the gas
temperature permitting to determine the Burnt Terminal Point (BTP).
Wind box
Thermocouples
9 In general, the strand speed is controlled of way that the Burnt

Terminal Point (BTP) happen in the last but one wind box.

71

4.6. Sintering step - Fundaments
9 The iron ore sintering mechanism is determined by the development of two
different phenomena: Air
9 • physical phenomenon of heat transfer from the top

layer to the bottom layer due to the action of air forced Sinter
through of bed. A thermal front is formed and the
propagation speed is proportional to the air flow rate.
Several factors affect the propagation of this thermal
front: (i) bed height, (ii) moisture and size distribution Cooling stage
of the blend, (iii) loading density, (iv) ignition intensity
and others; Combustion front
9 • chemical phenomenon of fuel combustion generating Heat transfer front

heat and a chemical reactions front. The evolution of Dry and calcined mixture
this front is function of some factors: (i) amount and

reactivity of the solid fuels, (ii) moisture and chemical Wet mixture
composition of the mixture, (iii) self-characteristics of Hearth layer
the iron ores etc. Gas
9 The two phenomena above are interdependent and should present the same
propagation speed to guarantee the maximum flame temperature. The
equilibrium between the two phenomena is fundamental to the burnt quality
and, consequently, to the high process performance, low specific fuel
consumption and high sinter quality.

72

9 In the region above of combustion front the cold air changes heat with the hot
sinter, then it being pre-heated.
Air
(a) Drying
(b) Dehydration
Chemical
reactions
(c) coke ignition
Sinter (d) Carbonates decomposition
(e) Silicates formation
(f) Re-oxidation and re-crystallization
Bed height (cm)

Air
Cooling stage
Tair < Tsinter
Combustion front
Combustion front
Heat transfer front Gas

Dry and calcined mixture Tgas >> Tmixture
Mixture
Wet mixture
Hearth layer
Gas
Temperature (oC)
9 In the combustion zone almost every reactions of formation of the mineralogical

phases happened above 1200oC, and gas and solid change between them the
functions of heat receptor and supplier. Below of the combustion zone the hot
gases change heat with the cold mixture heating it.

73

9 The figures below show examples which the fuel reactivity and the oxygen
content affect the thermal pattern of bed.
Air
1 – coke and 4% oxygen
A – coke and air
B – charcoal and oxygen
Sinter 3 – coke and 21% oxygen
(1)
Depth bed (mm)

Depth bed (mm)
Cooling stage
(2)
Combustion front
Heat transfer front

Dry and calcined mixture (3)
Wet mixture
(4)
Hearth layer
Gas
Bed temperature (oC) Bed temperature (oC)
9 Solid fuels of very low reactivity or very high reactivity may promote differences
between the fronts of combustion and heat transfer. A suitable size distribution
of fuel is key point to optimize the sintering process.

74

9 Process Reactions: In the sintering process some reactions happen

on temperatures lower than melting point of the materials (reactions
in the solid state). Below are show some examples of reactions and its
respective zones where happen it.
Sintering Zones Process Reactions

Wet Zone Hydration of burnt lime CaO + H2O → Ca(OH) 2 + heat
Vaporization of water ( H2O ) liq. → ( H2O ) g - heat
Drying Zone Dehydration of goethite/ Ca(OH) 2 → CaO + H2O - heat
hydroxides 2 (FeOOH) → Fe2O3 + H2O - heat
2C + O2 → 2CO + heat
Combustion of carbon
C + O2 → CO2 + heat
CaCO3 → CaO + CO2 - heat
Decomposition of carbonates
(Ca,Mg)CO3 → CaO + MgO + CO2 - heat
Combustion Zone 3 Fe2O3 → 2 Fe3O4 + O2 - heat
2MnO2 → Mn2O3 + ½ O2 - heat
Iron oxides reduction/thermal
Mn2O3 → 2 MnO + O2 - heat
dissociation
3 Fe2O3 + CO → 2 Fe3O4 + CO2
2 Fe3O4 + CO → 3FeO + CO2
Cooling Zone Iron oxides re-oxidation (FeO) → (Fe304) → ( Fe203 )

75

9 Agglomeration Reactions: In sintering process some reactions happen on

temperatures higher than melting point of the materials (reactions between
solid-liquid and liquid-liquid). These reactions are responsible for the
agglomerate formation. Below are show some examples of reactions and its
respective zones where happen it.
Sintering Zones Agglomeration Reactions

Formation of slag
Formation of acicular calcium ferrites
Low temperature assimilation
Formation of granular hematite
Combustion Zone
Melting of calcium ferrites
Crystallization of magnetite
High temperature assimilation Formation of secondary hematite
Crystallization of calcium ferrites
Cooling zone
Vitrification and crystallization of silicates
9 Due to the null mobility of the materials, the contact among the particles of iron
ore, CaO, SiO2 and others it is a very important aspect to happen the reactions
in the solid state.
9 The agglomeration reactions more important of the sintering process are
commented as follow.

76

9 Agglomeration reactions happening during sintering process (reactions scheme)
(1) (2) (3)
(4)
< 1300°C
(4) (5)
> 1300°C

77

9 Step 1:
- Hematite (Fe2O3) and CaO react producing the first calcium ferrites, around
1100oC (solid-solid reaction).
- Around 1200oC these calcium ferrites start the formation of liquid phase.
- The liquid, rich in CaO and Fe2O3, begins to get iron oxides, SiO2, Al2O3,
MgO).
(1) (2) (3)
(4)
< 1300°C
(4) (5)
> 1300°C

78

9 Step 2:
- In these point can happen the superficial disintegration of hematite by the
action of the liquid phase forming the granular hematite.
(1) (2) (3)
(4)
< 1300°C
(4) (5)
> 1300°C

79

9 Step 3:
- After the liquid phase has assimilated CaO and Al2O3, the evolution of the
reaction between phase liquid and hematite forms acicular calcium ferrites in the
solid state (needle form), rich in Al2O3 and SiO2.
(1) (2) (3)
(4)
< 1300°C
(4) (5)
> 1300°C

80

9 Step 4:
- If the process temperature not reach more than 1300oC, or if the residence
time above of 1300oC is very short, the microstructure after cooling will be rich
on acicular calcium ferrites in a bulk of crystalline silicates and granular
hematite. That is the heterogeneous sinter.
(1) (2) (3)
(4)
< 1300°C
(4) (5)
> 1300°C

81

9 Step 5:
- If the process temperature exceeds 1300oC and the residence time above it is
long, the calcium ferrites and the coarser iron ore particles melt and react
forming hematite or magnetite and a vitreous slag. If the Al2O3 content in
calcium ferrite is very low the calcium ferrite dissolve on lower temperature,
around 1250oC.
(1) (2) (3) - During the cooling step,
skeletal rhombohedral
hematite precipitates from
liquid phase and the calcium
ferrites crystallize as long
flakes named columnar
form. That is the
homogeneous sinter.
(4)
< 1300°C
(4) (5)
> 1300°C

82

9 Physical and metallurgical properties of sinter
Description of the Properties

Type of sinter
Physical Metallurgical
Low tumbler strength (TI) Low reducibility index (RI)

High disintegration under
Homogeneous Low shatter strength (SI)
reduction (RDI)
Poor softening and melting
properties
High tumbler strength (TI) High reducibility
Low disintegration under
High shatter strength (SI)
Heterogeneous reduction (RDI)
Good softening and melting
properties

83


84

9 Beyond to affect the sinter microstructure

85

9 Melt with good fluidity and a low melting temperature is generally
desirable to obtain a favorable sinter pore structure.
Microstructure of agglomerates after assimilation test with individual iron ores

- Assimilated part -

86

9 The iron ore porosity has effect on the sinter porosity and its physical and
metallurgical properties.
- RD = 89%
- RD = 71%
- RD = 70%
- RD = 75%
- RD = 77%
- RD = 84%
- RD = 79%
- RD = 89%

87

9 By changing the physicochemical properties of the primary melt, alumina plays an
important role in the reshaping and coalescing process during sintering.
9 Alumina is very effective in increasing the viscosity of calcium ferrite slags, particularly
at temperatures below 1 573 K.
9 The observed effects of alumina on the physicochemical properties of the primary melts
are expected to have a great impact on the reshaping and coalescing process of primary
melt and bubbles during the sintering process, eventually leading to a unique sinter
pore structure.
9 In Figure is showed that the pore area increases drastically, and the pore shape
becomes more irregular as alumina increases from 1.6 to 2.4%.
88

9 The high temperature properties of iron ores may be represented by:
Assimilation intensity: Ability of forming low melting liquid phase through
reactions between CaO and iron ore. It’s represented by the lowest
assimilation temperature.
Liquid phase fluidity: Flowing capacity of liquid phase.
Bonding phase strength: Strength of bonding phase resulting of CaO and
iron ore reaction.
Connecting-crystal strength: Strength of bonding among iron ore crystals.
SFCA forming ability: Ability to form SFCA (silico-ferrite of calcium and
aluminium) in sinter from CaO and iron ore reactions.
9 It is believed that the strength, reducibility and size distribution of sinter particles
and the yield from a sinter strand are determined by the inherent strength of the
bonding phases present and the structure of the pores.
9 The blend design should have in account the complementarily of the iron ores in
terms of the high temperature properties, aiming to reach high sintering process
performance and high sinter quality.

89

9 The reactivity between iron ore and CaO is not good for sintering performance
and quality sinter when it is too high or too low. Therefore, arranging ores with
different assimilations in pairs or groups to get the complementary effect should
be paid attention, e.g., arrange the ores of high assimilation with the ores of low
assimilation.

90

Breaking and
Cooling step

91

- Sinter breaking and cooling -

92

4.7. Sinter breaking and cooling
9 The sinter cake drops off the end of the strand into a collecting bin. In
this occasion it is around 600oC to 800oC of average temperature.
Sinter drops off

93

9 The cake sinter is broken up into manageable chunks and cooled

before to be sent to screening system.
(a) Sinter breaker (b) Sinter coller
9 In general, the sinter temperature after cooling is 180oC maximum to

avoid burning the conveyor. Some sintering plants use steel conveyor
named pan conveyor permitting higher sinter temperatures.

94

9 There are two more common types of cooler projects: (i) annular table
cooler, and (ii) dip rail cooler.
Annular table cooler Dip rail cooler or Pressure cooler
9 On both cases the sinter cooling is by convection due to the forced air
passing through the sinter bed. Coolers fan are used to promote the
cooling air.

95

9 Pressure cooler project show the start and end points of the cooling
process.
Sinter a 650ºC
Qe = 220x106kcal/h
Sinter a 100ºC
Qs = 30x106kcal/h

96

9 Below are shown some parameters that are considered in the cooler
project.
Parameters Project values

Sinter density 1600 kg/m3
Air density 1,166 kg/m3
Specific heat of sinter 0,226 kcal/kg.oC at 650oC
0,201 kcal/kg.oC at 100oC
Specific heat of air 0,24 kcal/kg.oC
Sinter temperature 650oC (Entrance)
100oC (Exit)
Air temperature 20oC (Entrance)
300oC (Exit)
Convecção
Convection
Co
ão
nd
uç
Cold air uç
Hot air
nd
ã o
Co
Co
ão
nd
uç
uç
ã
nd
o
Co
Convecção
Convection

97

Size preparation
step

98

- Sinter size preparation step -

99

9 Below is shown a typical flow sheet of the system of sinter size

preparation.
Cooling
Crushing mill
Crushing mill
Screen 1
Screen 2
Bedding
Blast furnace
Cold return fines

100

9 Below is shown a typical crushing mill to adjust the sinter size

distribution.

101

9 Below is shown a typical screening system to adjust the sinter size

distribution.
Typical Screener
Example of blind screen

102
5. Sinter quality

103
How Iron Ores Characteristics Impact the Performance of

the Sintering Process?
KEY SINTERING Crystal

LOI Al2O3 + 1,0 mm - 0,15 mm
PERFORMANCE INDEXES Size
Bulk Density (d) Ç Ç È Ç

Productivity
Ç Sinter Yield (y) Ç È È
P = d *y * v
Velocity (v)
È Ç È
Ç
Fuel Consumption È È È È Ç È
Sinter Mechanical Strength* Ç ÈÇ È È
Sinter Reduction Degradation Index

È
È
Sinter Reducibility Ç È Ç
* Dependent of iron ore particles size

Ores with small crystal size, low LOI, low Alumina and coarse tend to exhibit
better performance in the sintering process.

104
Why Vale Ores Demand Less Fuel during the Sintering Process?
9 Effect of the Loss on ignition on the fuel consumption during sintering: one of the drivers
for superior Value In Use
72
Coke Breeze Consumption (kg/t sinter)
70
68
66 Australian Hydrated
Ores
64
62
60 LABORATORY RESULTS
Brazilian Ores FIXED % RETURN SINTER FINES
58
0 2 4 6 8 10 12
Loss on Ignition (%)
Vale ores have lower LOI, which lowers sinter

plant fuel consumption

105
How Iron Ores Characteristics Impact the Performance of

the Blast Furnace?
KEY BLAST FURNACE Crystal
SiO2 Al2O3 P S Alkaline
PERFORMANCE INDEXES Size
Permeability Ç È È È
Productivity
Slag Volume È È È È È È
Ç
Reducibility Ç È È È
Permeability Ç È È È
Coke
Slag Volume È È È È È È
Consumption È
Reducibility Ç È È È
Hot Metal Quality Ç È È
Ores with small crystal size, low gangue and low S tend to
perform better in the Blast Furnace.
Ores with low P have good performance in the BOF

106
Quality of Vale ores and others players of the market
Fines: Iron Contents (%) Fines: Levels of Impurities (%)
ORE 1 56.9 0.045 8.60

Others Players
ORE 2 61.2 0.093 5.60

ORE 3 58.7 0.051 6.60
ORE 4 62.8 0.095 6.40
ORE 5 61.7 0.082 5.70
CHINESE CONC. 62.0 0.043 6.15
ITABIRA 64.8 0.050 5.50

CARAJÁS 66.0 0.035 2.60
GUAIBA 64.8 0.060 5.20
Silica and Alumina

Fe Content Phosphorus Content
Content
The lower gangue and phosphorous contents of Vale Iron Ores

help in reducing fuel consumption and increasing productivity.

107
Sinter Feed Comparison

Alumina (Al2O3)
5
Vale
4 India
Al2O3 content (%)
Australia
Vale
3 South
IndiaAfrica
Australia
2 South Africa
0
A B C D E F G H I J
Iron Ores
Above a certain alumina content, it tends to increase the Reduction Degradation Index,
which measures the tendency of an ore to disintegrate inside the Blast Furnace,
decreasing permeability and thus, performance
The alumina content of Blast Furnace slags is generally limited at 15%, thereby limiting
the amount of alumina charged or requiring more flux addition, increasing slag volume
and decreasing performance.
The increase in Alumina content also results in higher slag viscosity, which tends do
difficult pulverized coal injection, thus decreasing performance.

108

Phosphorous (P)
0,20
Vale
India
P content (%)
Australia
South Africa
0,10
0,00
A B C D E F G H I J
Iron Ores
Nearly all phosphorous charged into the Blast Furnace is transferred to the hot metal.
Therefore, low phosphorous ores will result in low P hot metal.
Cleaner steels, such as Interstitial Free, used for exposed auto bodies, white lines and
complex deep drawn shapes demand ultra low P steel.
The higher the phosphorous level in the hot metal, the higher will be the refining costs to
remove this phosphorous, with increase in the consumption of fluxes, slag volume and
oxygen as well as reduction in the productivity of the steelmaking shop.

109

Loss On Ignition (LOI)
12
Vale
10
India
8 Australia
LOI (%)
South Africa
6
0
A B C D E F G H I J
Iron Ores
Ores with high loss on ignition lend negative effects to the sintering process: (a) reduction
in productivity; (b) increase in fuel consumption; (c) reduction in the sinter mechanical
strength.
Japanese steelmakers developed techniques that minimize the deleterious effects of
hydrated ores. However, there still is a limit to the usage of these ores in the sinter mix.

110

Silica (SIO2)
10
Vale
8 India
SiO2 content (%)
Australia
6 South Africa
0
A B C D E F G H I J
Iron Ores
The highest the silica charged into the furnace, the higher will be the volume of slag
generated (also known as slag-rate).
Besides, more flux will have to be added to correct for the slag chemical composition, key
to the process stability and removal of sulfur.
The increase in the slag rate results in the decrease of the Blast Furnace permeability in
the lower regions of the furnace, fuel consumption increase and loss of productivity,

111

Size Distribution
100%
- 0,25mm
80% 1,0 - 0,25mm
+1,0mm
60%
(%)
40%
A-C Vale
20% D–E India

F-I Australia
0% J South Africa
A B C D E F G H I J
Iron Ores
Adequate size distribution (low dispersion, high average particle size) allow for higher
permeability of the sinter cake, and consequently, higher productivity in the sintering
process. Coarser sinter feeds usually allow for higher permeability of the sinter bed.
Steelmaking mills always use several ores in the sintering process, which allows for
adjustments in the sinter bed characteristics.
Australian Ores are coarser than Brazilian Ores.

112
Comparison between Vale and Competitors Sinter Feeds

The Impact of Genesis
H2O WEATHERING
P, T,
Fe(32%)
“Brown Ore”
H2O
SiO2(50%) Hydration Degree (LOI), %
Hematite 2 4 6 8 Goethite10
Carajás Australian Ores
20
Average Crystal Size, µm
METAMORPHISM
Ferrous Quadrangle Ores

Vale is the only mining company with an assortment
“Blue Ore”
40
of metamorphic and weathered ores, with crystal
sizes ranging from small to medium.
Vale ores have lower impurities, i.e. gangue (SiO2
60 and Al2O3) and P than ores from Australia and
India.
Furthermore, Vale ores have lower loss on ignition
80 (LOI) than Australian Ores.
Australian ores are coarser than Vale ores.
100

113
Comparison between Vale and Competitors Sinter Feeds

The Impact of Genesis
H2O WEATHERING
P, T,
Fe(32%)
“Brown Ore”
H2O
SiO2(50%) Hydration Degree (LOI), %
Hematite 2 4 6 8 Goethite10
Carajás Australian Ores
20 MECHANICAL
Average Crystal Size, µm
STRENGTH
METAMORPHISM
Ferrous Quadrangle Ores

“Blue Ore”
RDI
40
REDUCIBILITY
60 COKE
CONSUMPTION
PRODUCTIVITY
80
100
Quantities arising in the
arrow direction

114
5. Sinter quality
5.2. Physical quality of sinter – Shatter Index
Shatter Index (%)

Shatter Index (%)
Al2O3 in mixture (%) CaO/SiO2

115
5. Sinter quality
5.3. Metallurgical quality of sinter – RDI

116
5. Sinter quality – Effect of bed height
Gás Consumption (104 Kcal)

+100mmHC
-2000Kcal/t-s
.Sinter Yield(%)
Entrada Resf (ºC)

Temp Sinter
Bed Height (mm) Bed Height (mm)

118
Concept of HPS process

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Sintering Process

Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

4. Iron ore sintering process

Sintering Process – Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

9 Iron ore agglomerate produced on the sintering process which it uses

(1) Ordinary sinter (2) HPS sinter

Sintering Process – Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

(1) Columnar calcium ferrite

Sintering Process – Ironmaking Course 2010

9 This is due to the great technological evolution of the production

Sintering Process – Ironmaking Course 2010

Forno ignição móvel Grelha basculante

- Small strand area = 20 to 30m2

Sintering Process – Ironmaking Course 2010

STORAGE BINS A RETURN FINES

DRUM FEEDER IGNITION

- Big strand area = 100 to 600m2 MAIN COOLING

Sintering Process – Ironmaking Course 2010

Sinter Machine No3 – USIMINAS

Sintering Process – Ironmaking Course 2010

2. Raw materials to the

Sintering Process – Ironmaking Course 2010

FUEL: energy supplier to the sintering process

FLUX: used to decrease the blend melting temperature

ADDITIONS: it is used to adjust some sinter characteristics or

Sintering Process – Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

 Addition ore: iron ores that are used in lower proportion in

 Iron ore blend: the current concept is based on the

Sintering Process – Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

AUSTRALIAN IRON ORES BRAZILIAN IRON ORES

Sintering Process – Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

9Reactivity is the 0,16

of oxygen. Amostra H - Mist LVB - COPPABELLA

Sintering Process – Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

Sintering Process – Ironmaking Course 2010

Burnt lime (%) Burnt lime (%)

Sintering Process – Ironmaking Course 2010

3. Stocking and preparation

Sintering Process – Ironmaking Course 2010

3. Stocking and preparation of raw materials

Sintering Process – Ironmaking Course 2010

3. Stocking and preparation of raw materials

9 In general, there is a blending pile on formation (filling stage) and

Sintering Process – Ironmaking Course 2010

3. Stocking and preparation of raw materials

Sintering Process – Ironmaking Course 2010

4. Iron ore sintering process

Sintering Process – Ironmaking Course 2010

4. Iron ore sintering process

Baosteel sinter plant

Sintering Process – Ironmaking Course 2010

4. Iron ore sintering process

Baosteel sinter plant

Sintering Process – Ironmaking Course 2010

Addition ore: iron ores that are used in lower proportion in

Iron ore blend: the current concept is based on the