SINTERING

TECHNOLOGY
By:
Shukdeo Prasad
Chapters

 Definition.
 History of Sinter technology.
 Process of Sintering.
 Advantages of sinter over other Ferocious
materials. Used in B.F
 Input Raw Materials to BF.
 Process inside BF.
 Performance assessment of BF.
Chapters
 Effect of Sinter on BF operation.
 Sinter quality requirement by BF.
 Average quality of Raw Materials to Sintering
plant at JBL Durgapur.
 Average Sinter quality at JBL Durgapur.
 Standard Raw Materials quality for good quality
sinter making.
 Average charge burden in Sintering Plant atJBL
Durgapur.
Chapters

 Sinter process control parameters.

 Method of burden calculationin sintering plant.
 Standard sinter quality parameters and
permissible deviations.
 Effect of sinter quality parameters on BF
operation.
 Methods to control Sinter quality parameters.
 Sinter quality testing procedures.
Chapters
 Thumb rulesTo assess process/quality
parameters.
 Techno Economics Parameters.
 Sinter cost.
 Definition of Sintering
 Sintering is the Agglomeration of Iron ore fines
(0 to8mm) along with Flux fines at high
temperature (1200 to 1300c) using coke fines as
solid fuel to raise the temperature. During
agglomeration at high temperature all
constituent materials fuse together and become
a porous heterogeneous solid mass (lump)
called SINTER.
 History of Sintering Technology
 Sintering process was developed mainly to utilize under
size of lump ore (0-- 8 mm size) called iron ore fines which
otherwise could not be charged directly in blast Furnace.
Based on sinter technology for Copper, Lead, Zinc ore, first
time Iron ore sintering technology was developed in the
middle of 19th century in Germany. Then first proto type
pot type Iron ore sintering machine with upward draught
was installed in 1892 in Germany. After ten years of trial
two no. pot type sinter machines of small capacity were
installed for commercial production in USA. The pot type
upward draught sinter machines were having many
constraints e.g. exhausting, charging and discharging was
from the same side, there was high Iron Ore loss and high
dust emission, high operational and maintenance cost ,and
Ignition was very difficult.
History of Sintering Technology
 The weak points of pot type upward draught sintering process was
solved in early 20th century by developing continuous sintering
machine with downward draught by Dwight and Lloyd of Germany.
The first sinter machine on design of Dwight and Lloyd was
successfully tested at Canania consolidated company in 1908. Since
then this types of machines are called Dwight-Lloyd type sinter
machines. There are two types of Dwight-Lloyd sinter machines; one
is Horizontal tray machine and the other is Straight line sinter
machine. In Horizontal tray sinter machine there is a circular rotary
table, a fixed ignition furnace and charging equipments. After sintering
is completed sinter is scrapped off from rotary table by a scraper fixed
over the machine. As such machines are of low capacity so they are
not popular in iron ore sintering. They are mainly used for Copper
/Lead/ Zinc ore sintering.These machinesareof25sq,m/30sq.m/40sq.m
/50sq.m capacity only. Recently some private steel companies in India
have installed horizontal tray machines (Called Annular sinter
machine).These machines are mainly supplied by CHINA.
History of Sintering Technology
 The straight line sinter machines may be built in bigger sizes. In this type of
sinter machines also Ignition furnace and charging equipments are fixed. After
sintering is completed it is dropped from connected pallets at discharge end. This
type of sinter machines are coming in various sizes varying from 50sq.m
sintering area to 600sq.m sintering area. Majority of the steel plants have
Dwight-Lloyd type straight line sinter machines in sizes matching to their sinter
requirement.
 When first sinter was made it was without flux. This type of sinter is called Acidic
sinter this type of sinter when used in BF just replaces lump ore only. Coke rate
and Flux additions in BF remains as usual and only advantage was that Iron ore
fines was utilized. Later on flux was also added in mix charge for sinter making.
This type of sinter is called basic sinter. Use of basic sinter brought much affect
in BF operation. After using basic sinter in BF raw flux addition was reduced
coke rate has gone down and BF productivity increased. Basic sinters are of two
types i) self flux sinter and ii) super flux sinter. When flux addition in sinter is just
enough to take care of flux required for sinter percentage in BF burden it is called
self flux sinter. When flux addition in sinter is extra enough to take care of total
flux requirement in BF it is called super flux sinter.
Histry of Sintering Technology
 In India sintering technology came late. As India is rich in good
quality Iron ores so necessity of sinter was not felt previously. Old
Blast furnaces installed in TISCO and IISCO were designed for
100% iron ore lump only. First sinter machine of 75sq.m .sintering
area was commissioned in TISCO in 1958.Second sinter plant came
at Bhilai in1959. Subsequently many sinter plants were installed in
India but till 1990 BF operators were not enthusiastic in using sinter
(very reluctantly were using sinter in BF burden). Only after several
trials at Bokaro; sinter quality was established suiting to Blast
Furnace operation Bokaro Blast Furnaces started producing clean
hot metal at lowest per unit cost ;other steel makers started looking
for the reasons of low cost , high productivity and clean hot metal at
Bokaro steel plant. Then it was established that good quality high
percentage of sinter in BF burden is the main cause behind BF good
performance.
Histry of Sinter Technology
 Since then sinter which was regarded as source of
problems in Blast Furnace became remedy of problems
in Blast Furnace. There after outlook of BF operators
towards sinter changed and they started demanding
more and more sinter. All steel plants started adding to
their sintering capacity and its use. They started
increasing sinter plant production capacity .New sinter
plants started coming up. As on today no steel plant can
imagine its existence without a sinter plant of its own.
Now a days we are making super fluxed sinter by Dwight
-Lloyd type Sinter Machine with downward draught.
Material Flow Chart
Sintering Process
Material Balance
 Sintering Process
 All prepared materials (blended and sized) are stocked in
proportioning bins bunkers(six bunkers for iron ore, mill scale and
BF return, two bunkers for Quick Lime, two bunkers for Coke, two
bunkers for Flux and two bunkers for cold sinter return total 14
bunkers) and are charged in predetermined proportion by weight on
a common belt. These raw materials put on conveyor layer by layer
come to primary mixing drum where they are thoroughly mixed with
only 25% of water addition. After primary mixing material goes to
secondary mixer where balance75% of water requirement is added.
From secondary Mixer material comes out in micro ball form and
delivered to mix bin bunker
 Above sinter machine .This material is called green mix.
 Now total charge on Sinter machine is put in two layers first layer of
30—40mm thick is laid with sintered material size 5-10mm called
hearth layer/bedding layer. Over bedding layer, green mix material is
laid making total bed height of charge 700mm.
.
 Sintering Process
 This charge enters into ignition hood where two rows of ignition burners
(2x8) are installed .B.F gas is used as ignition fuel. B.F gas flames maintain
about 900-1000degree centigrade temperature inside furnace .When
charge comes below ignition burners coke in top layer of charge is
ignited .Due to downward draught maintained below pallets, heat from
burning coke travels downward. Suction below grates -1500mm (in wind
boxes) is created by a big ID fan. Coke burning phenomenon called flame
front travels from top to bottom, fusion of materials called sintering follows
behind it. Generally fusion temperature is maintained between 1200-1400
degree centigrade. By the time material fuses and stick together coke
burning is over and flame front moves downward .Fused material starts
cooling down called sintered/sinter completed. This phenomenon moves
from top layer to bottom layer on horizontally moving pallets .By the time
pallet reaches over last wind box coke burning phenomenon reaches to the
bottom of the charge and there is nothing more to burn .This point is called
Burn Through Point(BTP) . Sintering process ends here .BTP is
determined by the highest temp. Of wind box. Flame front followed by
materials fusion called sintering process moves from top layer of charge to
the bottom most layer of charge. Generally sintering speed is
1200mmto1300mm per hour (20-- - 22mm/min)
Sintering Process
 Sintering Process
 During sintering of 700mm layer of charge following chemical reaction takes
place
 C+O2 =CO+CO2
 Fe2O3+CO =Fe3O4 +CO2
 Fe3O4 +CO =FeO +CO2
 Partial reduction process takes place e.g. from above when Fe2O3 converts
to Fe3O4, O2% in iron ore goes down from 48/ (112+48) =30%to 64/
(168+64) =27.58%. Similarly when Fe3O4 is converted to FeO ,O2% goes
down from27.58% to16/128=12.5%.From here it is clear that when Fe2O3
Changes to Fe3O4 to FeO , O2% is going down from 30% to27,58 to12.5%
that is why it is called reduction process.
 At high temperature when sintering is taking place some more chemical
reactions also take place e.g. CaO+Fe2O3 react and form
CaOFe2O3(Calcium Ferrite),2CaOFe2O3 (Dicalcium Ferrite),
CaO2Fe2O3(Calcium Diferrite),CaOFeOSiO2 (Iron
Monticellite),Al2O32SiO2
2H2O(Cablinite),FeOAl2O3(Hercynite),2FeOSiO2(Fayalite),CaO
SiO2(Calcium Silicate),2CaO SiO2
Sintering Process
 (DiCalcium Silicate),3CaoSiO2 (Tricalcium Silicate),FeO (Wustite).
SiO2,FeO,CaO,Al2O3 together are called S F C A
 After sintering is over partial cooling takes place on balance portion
of machine and then sinter falls at m/c discharge end due to return
travel of pallets .The big chunk of baked materials (sinter) is broken
into pieces (below 150mm in size) by single roll horn crusher
(SRC).Broken sinter pieces fall on hot screen where -5mm size
sinter is screened out and recycled along with fresh materials.
 +5mm sinter pieces at about 700-800 d c are put on straight line
cooler, where air is blown from bottom by four blowers. This forced
air takes heat from sinter pieces and goes upwards to atmosphere
and sinter cools down. By the time sinter reaches to discharge end
of straight line cooler it is sufficiently cooled( below 100d.c ) this
cooled sinter is again screened on cold screen in three segments
 Sintering Process
1 -5mm under size called cold return goes to two bunkers in proportioning
bins where from it is recycled along with fresh raw materials.
2. 5-10mm size sinter is taken to bunker above sinter machine and used as
bedding layer/hearth layer
3. +10mm size sinter goes to two sinter storage bunkers (2x1000t) by
conveyor belt. Here from B F draws sinter as per their requirement . B F
also screens out -5mm before charging sinter into Blast Furnace . This
under size -5mm called B F return is taken to raw material yard, where
from it is consumed by sinter plant along with fresh iron ore.
 So to say sintering is a physical phenomenon. ,so input chemical share
of raw materials is passed on to Blast Furnace in sinter form .Some
percentage of FeO generation during sintering is the by product of the
process . So to say garbage input to sinter plant is garbage out put from
sinter plant .
 Sinter is the basic iron bearing material of Blast Furnace burden so sinter
quality both physical and chemical is dictated by Blast Furnace
operators ..Sinter quality requirement varies from plant to plant and
furnace to furnace .
Advantages of Using Sinter in B.F
 Gainful utilization of huge quantity of Iron ore fines (under size)
generated at mining stage
 Iron ore fines is easily available at much cheaper rate than lump
ore
 Other solid metallurgical wastes generated in integrated steel
plants are gainfully utilized in sinter making solving huge problem
of solid wastes pollution / dumping space.
 Use of Super flux sinter in Blast Furnace burden eliminates
charging of raw flux in Blast Furnace creating more space for iron
bearing materials i.e. sinter//Lump ore .It also helps in substantial
reduction in coke rate.
 As sinter is pre fluxed so reducibility of sinter is better than lump
ore.
 As sinter is stronger and harder than lump ore so crumbling of
sinter is less also, granular shape is maintained up to bottom of
furnace hence permeability for air/gas flow inside BF is better.
 Sinter size range is narrower so heat zone distribution inside
furnace is better and stable.
Advantages of Using Sinter in B.F

 Softening melting temperature of sinter is high and softening to

melting temperature range is very narrow (120degree cent.) so
cohesive zone is very thin hence pressure drop across cohesive
zone is very less so wind acceptability in furnace is better
 Iron Ore Ts=1175dcand Tm 1490dc, Sinter Ts=1380dc and Tm
=1580dc. Ts and Tm of sinter depends on FeO in sinter, more FeO
more Ts and more Tm.
 As sinter is porous than lump so ingress of reducing gas (CO) is
better than lump ore so reduction process is very fast.
 As sinter is made by agglomerating fines at high temperature many
constituent harmful elements like sulpher present in raw materials is
burnt in sinter plant itself so less sulpher input to blast furnace. Hot
metal is much cleaner from SMS point of view.
 Material handling in blast furnace stock house becomes easy and
least logistics are needed
 Blast furnace operation becomes more smooth and stable with
sinter
 Input Raw Materials to B.F

1.Iron bearing materials-CLO (lump Iron

ore) ,Pellets, DRI, Sponge Iron, Sinter.
2.Flux-LimeStone, Dolomite, Quartzite.
3.Fuel-Hard Coke, Coal Tar, Coal Dust, Natural Gas.
 Performance assessment
parameters of B.F
1.Production
2.Productivity
3.Wind Acceptability
4.Trouble Free Operation
5.Hot metal Quality
6.Coke Rate
7.Slag Rate
8.Coale Dust Consumption
9. CO/CO2 Ratio
10.Refractory Consumption
11.Water Consumption
12.O2 Consumption
13.Trouble Free Blast Furnace Campaign Life
14.Differencial Pressure
15.Dust Generation (Collected in Dust Catcher)
Effect of Sinter On B.F Performance
 The performance of Blast Furnace is adjudged with respect to its;
1) Productivity
2) Coke rate
3) Quality of Hot Metal along with higher temperature and lower slag rate 4) wind acceptability
of Blast Furnace. Accordingly Sinter quality to match with Blast Furnace requirement is
as:-
1) Granulometry of Sinter should be higher MPS (19-22mm)
2) Gangue materials (CaO+MgO+SiO2+Al2O3+TiO2) in sinter should be =18(+/-) 1%
3) FeO in sinter should be 8-9%
4) RDI of Sinter should be(22-30 %)
5) Strength of sinter (TI) should be = >70%
6) Reducibility of sinter (RI) should be = >65%
7) Softening melting characteristic should be favorable. (Higher temperature narrow
range)
a) More the percentage of sinter in BF burden less the Coke rate
b) More the RDI of sinter more the Coke rate.
c) Higher the RDI of sinter less the Productivity of Blast Furnace.
d) Bigger the MPS of sinter (20-22mm) less the fuel rate.
e) Bigger the MPS of sinter more the Productivity.
f) Higher the basicity of sinter less the Coke rate.
g) Higher the Basicty of sinter higher the Productivity of BF
h) More the strength of sinter (TI) lesser the Coke rate.
i) More the sinter strength more the BF Productivity.
Sinter Quality Requirement for B.F

 Chemical specification:-
 FeO 8—9 %
 Basicity (CaO/SiO2) 1 .8 –2.0
 CaO 10—11%
 Al2O3/SiO2 0.4—0.6
 MgO 2.5—3.0 %
 SiO2 4.5—5.5 %
 Al2O3 2.5%max
 Reducibility Index (R I) 65 %.min.
 Reduction Degradation Index (R D I) 20—30%
 Average Quality of Input Raw
Materials at JBL
I OF T Fe(57—59) % ,Al2O3(5—7)%,SiO2(4.5-7)%
 Flux (lime stone and dolomite mixed) CaO (38 –40)%,
MgO(10—11)% , SiO2(4—4.5)%, Al2O3 (1.1—1.3)%
 Coke FC- (60—84)%, Ash(18—35)%, VM (3—4)%
 Average charge burden in
sintering plant at JBL Durgapur
 IOF (including B F Return) ---- 80.5 T/H 55.9%
 Coke 6.6T/H
4.7%
 Flux 18 T/H 12.6%
 Internal Return 30T/H 21%
 (Hot and cold return)
 Water 6.5 T/H 4.5%
 Quick Lime 2T/H 1.3%
 Total charge rate 143.6 T/H
(So to say 144T/H)
100%
Average Sinter Quality at JBL
 TFe 50-52 %
 FeO 8-9%
 CaO 12-13%
 SiO2 6-7%
 Al2O3 3-6%
 MgO 3-3.3%
 Basicity 1.9-2.1%
 TI 70-71%
 RDI 24-28 %
 RI 69-71%
 Mean size (MPS) 20-23mm
 Standard Raw Material Quality for
Good Sinter Making

 Specification of good quality raw materials for optimum Productivity and quality of
sinter is given below. While procuring raw materials for sintering plant both
chemical and physical specifications must be given equal importance.
 1) Iron ore fines
 Chemical specification Physical specification
 T Fe 63% min. +10mm 5% max.
 Al2O3 2% max. – 3mm 60 +_2%
 SiO2 3% max. -0.15mm 15% max.
Ratio Al2O3 /SiO2 0.4 to 0.6 MPS 2.5to3.25 mm
 Moisture 5%max.
Standard Raw Material Quality for
Good Sinter Making
 2) Lime Stone
Chemical specification Physical specification
 CaO 50%min. +40mm 5% max.
 Al2O3 1.5%max -5mm 5%max.
 SiO2 2% max. Size 5—40mm
 MgO 2.5% Moisture 2.5% max
After crushing -3mm 90% min
 3) Dolomite
 Chemical specification Physical specification
 MgO 20%min. +40mm 5%max.
 CaO 30% -5mm 5%max.
 Al2O3 1.5% max. Size 0---40mm
.SiO2
2%max Moisture 2.5% max.
After crushing -3mm 90%min.
 Standard Raw Material Quality
for Good Sinter Making
 4 ) Coke Breeze
 Chemical Specification Physical Specification
 Fixed Carbon 80% min. Size 0-----10mm
 Ash 20% max. (-) 0.5mm 30% max.
 Volatile Matter 2% max. Moisture 10% max.
After crushing -3mm 90% min
And -0.5mm 30% max
 5) Quick Lime
 Chemical Specification Physical Specification
 CaO 90% min Size 0----3mm
 Al2O3 1.5%max +3% 5%max.
 MgO 2.5%max. L.O.I 5%max
 SiO2 2% max. Bulk Density 1.25—1.47 T/m3
 Reactivity 350min

 6)Mill Scale
 Chemical Specification
 T.Fe 70% min
 Al2O3 1.0% max
 FeO 50% min.
 SiO2 1% max.
 CaO 1.5% max.
Physical Specification
Size 0----5mm
( +) 5mm 5%max
Oil and grease 2%max.
more than 2% rejected
Moisture 2.5%max.
 Standard Raw Material Quality
for Good Sinter Making
 7)Flue Dust
 Physical Specification Chemical Specification
 TFe 30% 0---3mm 100%
 Sio2 6%
 C 45%
 MgO 0.8% LOI 48%
 Al2O3 4% CaO 3.5%
As this item is the metallurgical waste generated inside plant so chemical
Composition is not mandatory. Whatever has been shown here are only indicative.
 8) E A F Slag
 Chemical Specification Physical Specification
 TFe 30% size 0---5mm
 SiO2 15% (+)5mm 10% max.
 MgO 7%
 CaO 30%
 Al2O3 7%
Other metallurgical wastes like SIP sludge ,DRI dust/granules, Pig Iron dust, Ferric Oxide from CRM etc. also
may be used in sinter making.
 Standard Raw Material Quality
for Good Sinter Making
 Other metallurgical wastes like SIP sludge ,DRI dust/granules, Pig Iron dust, Ferric Oxide
from CRM etc. also may be used in sinter making.
 Iron Ore particles above 3mm and already sintered materials do not simulate and do not
take part in sintering ;they are trapped in molten (sintered) particles hence if +3mmparticles
are more in charge though physical appearance of sinter will look good but TI and FeO of
sinter will be less. +8mm particulates in charge work as heat sink . They are neither sintered
nor do they allow sinterable material to be sintered. Means they absorb more heat but do not
fuse and other useable materials around it starve for heat and do not fuse. So +8mm
particulate in charge should not be more than 5%. Closer the grain size range betters the
sinter properties. Therefore Mean Size of particulates should be within2.5 to 3.25mm only
(MPS should be 2.5 –3.25mm) as chemical and physical properties of sinter is dependent on
sintering temperature and proportioning (by weight) of constituent materials, therefore weigh
feeders and dosimeters in proportioning bins must be accurate and consistent. To monitor its
performance regular cleaning, zeroing and calibration after drop tests must be done. Sintering
property of ore fines varies from source to source (mine to mine).So source of better sintering
property should be earmarked and procurement to be maximized from that source only. Also
as far as possible no of sources to be minimized for better blending and consistency of
quality.
Sinter Process Control Parameters
 Some of the standard quality/operating parameters are to be monitored constantly for better sinter
quality and productivity.
1)Mean Particle Size of charge should be 2.5 –3.25mm
2) Crushing index of coke should be (-) 3mm 90%min.and
 (-) 0.5mm in crushed coke should be 30% max.
 MPS of crushed coke should be 1.5 mm
 Fixed carbon in coke should be 80%min.
 VM in coke should be 2% max.
3) Crushing Index of Flux should be 90% min..
 And (-1mm)in crushed flux should be 65%max.
4) Alumina to silica ratio in sinter (Al2O3/SiO2) between 0.4—0.6 gives better slag chemistry in BF
5)Good quality quick lime addition at the rate of 25to 40kg per ton of sinter gives better balling index and
pre heating of charge leading to better productivity.
6) 600---700 mm bed height gives better Sinter quality .Coke rate is less, TI is better ,FeO is Low ,RDI is
better
7) Flue gas flow in main flue duct @1500 –2000M3 per tone of charge gives optimum sintering
temperature/sintering speed.
8) Air filtration velocity through charge bed should be 0.3to 0.4m/sec. and air flow rate @100m3 per sq.m
sintering area per min.
9) Suction through charge ( Suction under grate, measured in flue duct) at 700mm bed height should be
1400—1550mm negative.
10) BTP temperature 300—325 degree centigrade at 13th. Wind box indicates good sin
 Sinter Process Control Parameters
11) Charge level in mix bin should be maintained at 30—50% and charge level concave .This gives better horizontal
segregation of particulates.
12) Segregation plate angle to be maintained between 55—60 degree with horizontal. This will give better vertical segregation.
13) Maintain Ignition temperature in ignition furnace at1100-1200 degree centigrade by mix gas of C.V 2000KC/m3this gives
quick ignition of coke in upper layer and gives better sintering speed.
14) Moisture in charge after SMD to be maintained at 6.5 –7% of charge.
15) Balling Index after SMD (+3mm after SMD//+3mm after PMD) should be 1.6 min.
16) Sintering at 1300—1400 d.c gives better TI, better FeO, and better RDI.
17) Standard sinter yield (sinter output/charge input) is 0.625 (62.5%)
18) Sinter cake yield (sinter at SRC/total charge input should be 0.897or 89.7%
19) Sinter made with charge of finer grain size (with narrow size range 2.5-3.0mm) gives better TI and RDI even at lower FeO
20)Standard sinter size to Blast Furnace is MPS 18—22mm, with +50mm 5%max,and
-5mm5% max
21) Flue gas to main ESP temp. To be maintained between 125 d .c and170d.c
22) Dust input to ESP is 2g/M3 and from chimney it is 50mg/m3 ESP efficiency is (1950/2000 )x100=97.5% .
23) Steam addition in SMD @3-4t/hr.at2.5-3kg pr. And300dc temp. Helps in better preheating of charge and better balling
index.
24) Improving permeability of bed by improving balling index gives better sinter properties than that of improving by increasing
particulate size of charge
25) High FC coke gives better sinter quality than low FC coke with more coke rate. Heat value of coke is directly proportional
to carbon content in coke and so the temperature rise.
26) Total gangue material in sinter (SiO2+CaO+Al2O3+MgO+TiO2) 18—19 % gives better TI and RDI
27) If (SiO2+Feo+CaO+Al2O3)/TFe is between 0.48 –0.55, TI will be better.
28) Sinter with 1.6—1.8% Basicity gives lower TI. This range of Basicity sinter is more fragile. More than this range or lower
than this range gives better TI.
29) Al2O3+MgO+TiO2 in sinter should not be more than 4%.
30) In last but one wind box temperature should be highest above 300d.c and in previous and next to this wind box
temperature should be about 25d.cless than this temperature.
 Charge Burden Calculation
method- 1
 Feed rate calculation in sintering plant is done when plant is starting a fresh or after
major shut down or whenever raw material quality is changed or BF changes its
quality demand.
 In view of BF quality demand and considering quality of available raw materials in
proportioning bins of sintering plant. Proportion of each ingredient is calculated before
hand, before feeding starts from proportioning bins . The proportion of each
constituent material (feed rate by weight) is done in proportioning bins.
 Roughly it is done first with basic raw materials e.g. Iron Ore Fines, Lime Stone,
Dolomite and Coke.
 Here sinter quality required by Blast Furnace and Raw materials quality are
hypothetical for learning purposes only. Actual may be different at Site:-
 Sinter quality is FeO 8.5%
CaO 10%
MgO 2.5%
SiO2 5%
Basicity of sinter ( CaO/SiO2) = 2 .00
 Charge burden Calculation
method -1
 Let us suppose available Raw materials quality on dry weight basis is as:-
 Iron Ore Fines TFe 64%
SiO2 2.5%
Al2O3 2%
 Lime Stone CaO 50%
MgO 2%
 Dolomite CaO 30%
MgO 20%
 Coke FC 82%
Ash 18%
Now let us suppose dry weight of lime stone in charge is x kg/t sinter and that of dolomite is y kg /t of sinter
Keeping above sinter quality in mind CaO in 1 T of sinter = 100kg and MgO = 25kg
Hence 0.5x+0.3y =100------------------CaO balancing------(1)
0.02x +0.2y =25--------------------MgO balancing (2)
Multiplying equation (1) by 2 and equation (2) by 3 we get
1x + 0.6y =200 -------------- (3)
And 0.06x+0.6y =75 ---------------(4)
Subtracting equation (4) from equation (3) we get
0.94x =125--------------------------(5)
Therefore x = 125/0.94 = 133kg dry weight of lime stone
And y = (200-133)/0.6 =112kg dry wt. of dolomite
 Charge Calculation (Method #1)
 In sinter, lime stone is in calcined form, so in one ton of sinter calcined lime stone
weight is133x (1-0.43) =133x0.57=76kg as LOI of lime stone is 43% and
 that of dolomite is 45%Calcined dolomite weight =
 112x(1-.45)=112x0.55=61.6=62kg
 Standard coke rate per ton of sinter at 82% FC is 60 kg
 So ash in one ton of sinter =60x(1-0.82) =60x0.18=10.8=11kg/t of sinter
 Now 1000kg sinter= Sintered iron ore +calcined lime stone+ calcined dolomite +coke
ash
=Sintered iron ore+76+62+11=Sintered iron ore+149kg
 Therefore Sintered iron ore =1000-149=851 kg
 Hence dry weight of iron ore in one ton of sinter =85/(1-LOI) =851/0.97 =877kg (as
LOI of iron ore =3%)
 Therefore in one ton of sinter, dry weight of--
 Iron Ore 877kg
 Lime stone 133kg
 Dolomite 122kg
 Coke 60kg
 Considering moisture in raw materials
 Iron Ore fines--- 5%
 Coke breeze 10%
 Lime stone 5%
 And Dolomite 5%
 Charge burden Calculation
method -1
 Natural weight of Raw materials, per ton of sinter comes--
 Iron Ore 877/0.95 =923kg
 Lime stone 133/0.95 =140kg
 Dolomite 112/0.95 =118kg
 Coke breeze =60/0.95=67kg
 So total charge from proportioning bins per ton of sinter
 = 923+140+118+67 =1248kg the constituent materials in percentage form =
 Iron Ore Fines =923x100/1248=73.95% =74%
 Lime stone =140x100/1248 =11.2% =12%
 Dolomite =118x100/1248 =9.4=10%
 Coke =67x100/1248 =5.3 %=5.5%
 Now suppose pallet width is 2.2m, Charge bed height is 500mm,Sinter machine speed =1m/min
 Total charge on sinter machine per hour =60x2.2x1x0.5x1.7 =112.2t/hour
 Reducing water content from total charge from proportioning bins=
 112-7=105t/hr
 Individual raw materials will be
 Iron ore = 105x0.739= 77.7t/hr
 Lime Stone will be = 105x0.12 =12.6t/hr
 Dolomite = 105x0.10 =10.5 t/hr
 Coke will be = 105x0.55 =5.77t/hr
 TOTAL = 106.5t/hr
 Add water = 6.5t/hr
 ------------
 Grand Total 113t/hr
 Charge burden Calculation
Method -1
 Here no sinter return ,no bedding layer has been considered;
but after a few hours of operation bedding layer and sinter
return (hot and cold) will also be generated, which are to be
consumed at the rate they are generated .As bedding layer is
not going in proportioning bins ; in burden calculation it is not
considered. Hot and cold sinter returns are already sintered
materials so no extra flux is added for sinter return extra coke
only at the rate of 5.5% of sinter return is added and extra water
at the rate of 6.5% of sinter return is also to be added .In that
case either we have to increase bed height to accommodate
extra quantity of coke, hot & cold sinter return and bedding
layer or keeping the total charge rate same we have to readjust
% of iron ore fines, coke and water. Standard bedding layer
consumption at 30—40mm thickness is 10to 12t/hr.for 2.2m
wide sinter machine. Hot and cold sinter return together at the
rate of 31% of sinter production.
 Charge burden Calculation
Method -1
 In sinter making, apart from basic raw materials
metallurgical wastes and quick lime are also used.
These materials depending on their chemical
composition may be categorized in three categories (1)
Iron bearing materials(2) Flux bearing material and (3)
carbon bearing materials. Seeing the maximum
percentage of an element present in the waste material it
is categorized as Iron bearing or flux bearing or carbon
bearing material.. For example Mill scale contains TFe
>70% FeO>50% CaO 4% MgO 1.5% SiO2 2.3% and
Al2O3 7%. As TFe is maximum in mill scale i.e. >70%
so it will be considered as Iron bearing material and will
replace Iron ore fines in the ratio of 70/60 where 60 is
average Fe in Iron ore fines.
 Charge burden Calculation
Method -1
 Similarly Quick Lime has CaO >90%,MgO
3.5%,Al2O3 0.5% and SiO2 1.5% .So it is a
fluxing material and will replace Lime Stone in
the ratio of 90/45.
 Another material is Flue Dust, it contains TFe
30% C 45% MgO0.8% SiO2 6% Al2O3 3% and
CaO 3.5% .As C is maximum so it will be
considered replacement of coke in the ratio
45/82 and will also replace Iron Ore in the ratio
30/60.
Charge burden Calculation Method No.2
 Charge calculation of raw materials feed is done from
proportioning bins of Sintering Plant to achieve the sinter
chemistry at BF end. Raw materials in proportioning bins
are in normal state & in separate bins with Moisture as
received from source and are not gone through any
processing ( drying / backing ) this material while making
sinter has a process route of
proportioning ,mixing ,loading on sinter M/C, drying ,
burning , sintering & finally coming out in the form of
Sinter. So when converted to sinter final weight of all
ingredients changes & proportion of each such material
in sinter form by weight changes to different value . In
computerized method of burden calculation (charge
calculation ) we go backward from sinter at the BF end
to raw materials at proportioning building.
 before going further, following points should be kept in
mind --
 Charge calculation method 2
 Dry All chemical analysis of raw materials given by lab, are on dry basis.
 weight of material =normal Wt.-Moisture
 Moisture={(normal wt.- Dry wt.)/Normal Wt.}X100
 To calculate dry weight 500gm material is heated at 500o C for 2 Hr.
 LOI =Loss on Ignition
 LOI={(Dry Wt. – Wt. after Ignition) / Dry Wt.} X 100
 To find out LOI 500 gm of dry material is heated at 900oc for 1 Hr. then loss
in Wt. is found out.
 Fe in sinter comes mainly from sintering iron ore fines & mill scale
 CaO in sinter mainly comes from sintering of lime stone & Q/lime a little
from Dolomite.
 MgO in sinter comes mainly from Dolomite & a little from Limestone
 SiO2 in sinter mainly comes from Iron ore fines & a little from flux & coke.
 Al2O3 in sinter mainly comes from Iron ore fines & a little from flux & coke .
Charge calculation method 2
 Then we again forward calculation & chive the value of each
parameters after sintering & do the necessary correction in basic In
chart below we put sinter wt 1000 kg & as per BF demand other
parameters are put on 1000 kg basis .Than we calculate the basic wt
of iron ore ,limestone ,dolomite& coke doing backward calculation
LOI chemical analysis & moisture in raw materials as given by lab.
 wt. to rich the final wt of each of parameters equal to or very near to
that given by BF
 After 8 Hr of running with the charge rate calculated above sinter
analysis is done & course correction is done in the feed rate for
deviation if any in sinter parameters. For example ,CaO in sinter has
come 11 % against plan of 12 %.As explained above CaO in sinter
has mainly comes from Limestone/Q/lime. So if we do feed rate
correction in Q/lime feeding than we have to increased by 10/0.81 kg
=12.3 kg /T of sinter (CaO in Q/lime is 81 %).
 Feo in sinter is achieve by sintering process & some extent by
increasing coke rate for which charge calculation not needed .It is
only by trail & error method
 Other wise if we go for increasing CaO in sinter by 1% by in creasing
lime stone feeding than we have to increase lime stone feed rate
10/(1-moisture)XCaO in limestone=25.3 kg /ton of sinter
Charge calculation method 2
 Other wise if we go for increasing CaO in
sinter by 1% by in creasing lime stone
feeding than we have to increase lime
stone feed rate 10/(1-moisture)XCaO in
limestone=25.3 kg /ton of sinter
 Feo in sinter is achieve by sintering
process & some extent by increasing coke
rate for which charge calculation not
needed .It is only by trail & error method
 Charge Calculation (Method #2)
Raw Material Chemistry% Sinter Chemistry
Sl No Mater Feed Moist Dry TFe CaO MgO SiO2 Al2O3 LOT( Sinte TFe Cao MgO SiO2 Al2O3 Basic
ial Rate ure( Wait %) red ity
(kg) %) (Kg) Wt(K
g)

1 I/O 908 8 836 64.0 3.00 2.80 5 795 535. 25.0 23.4
Fines 0 04 8 08

2 BF 50 2.5 48.7 52.0 11.6 3.30 5.50 3.50 48.7 25.3 5.65 1.61 2.68 1.70
Retur 5 0 0 5 5 5 1 6
n

3 L/S 76 1.5 75 0.60 45.0 3.00 7.00 1.25 40 45 0.45 33.7 2.25 5.25 0.93
0 5 7

4 Dolo 129 1.5 127 0.52 29.0 21.0 1.00 1.15 45 70 0.66 36.8 26.6 1.27 1.46
0 0 0 3 70 0

5 Q/ 25 25 81.0 3.30 4.00 1.50 9 22.7 20.2 0.82 1.0 0.37

Lime 0 5 5 5 5

6 Coke 87 15 74 55(o 30(A 75 18.5 10.1 5.55

f sh) 75 0
Ash)
7 Total 127 118 100 561. 96.4 31.3 45.4 33.4 2.12
5 5.75 0 50 85 55 56 26 2

8 Cal.C 100 56.1 9.64 3.13 4.54 3.34 2.12

he. 5 8 5

9 Des. 100 56.2 9.5 3.2 4.5 3.33 2.1

Che. 5
 Sinter Quality Analysis & permissible Deviations
Sl Parameters Best Quality Permissible limit Frequency of Acceptable
No Sample Deviation

1 TFe (+/-)0.5%W.R.T Set Target (+/-) 1% W.R.T Set Target Analysis of Each ------
Sample

2 Basicity (+/-)0..08%W.R.T Set Target (+/-)0.12%W.R.T Set Target Analysis of Each As Per BF
(CaO/SiO2) Sample

3 FEo (+/-)0.5%W.R.T Set Target (+/-) 1% W.R.T Set Target Analysis of Each 7-14%
Sample

4 SiO2 (+/-)0.05%W.R.T Set Target (+/-) 16% W.R.T Set Target Ave. of All Sample As per BF
in 24hrs

5 Al2O3 (+/-)0.05%W.R.T Set Target (+/-) 15% W.R.T Set Target Ave. of All Sample As per BF
in 24hrs

6 MgO As per BF As per BF As per BF As per BF

7 TI (+6.3 mm%) 73% 70% Ave. of All Sample 65% MIN

in 24hrs

8 Under Size(-5 3% 5% Analysis of Each 15 % Max.

mm) Sample

9 RDI(-3.15 mm%) 22-28% 35% Ave. of All Sample 40% Max.

in 24hrs

10 RI 70-75% 65% Ave. of All Sample 65% Min.

in 24hrs

11. S 3.03% 0.08% Ave. of All Sample .12% Max.

in 24hrs
Effect of Sinter Quality on BF Operation
 The biggest advantage of using sinter in BF is ,that we
may manipulate sinter quality parameters as and when
needed for better operation of BF.
 In BF and in Sintering Plant there is one similarity of
process- Coke burning rate to give optimum intensity of
heat is arsenical
For faster process. For optimum heat generation
optimum air flow per unit cross section of working area
must be uniform. This is possible only when
permeability through charge is good so that heat
distribution is uniform.
 Effect of sinter quality on BF
operation
 FeO – (8.5 to 9.00%)-It is the indicator of sinter
strength and sintering temperature. Good
strength of sinter less breakage in side BF and
better permeability through charge, better
reduction process.
 Better the FeO of sinter ,increases softening /
melting temperature, increases granular zone,
better permeability of charge ultimately better
BF operation.
 Effect of Sinter Quality on BF
Operation
 T.I ---(67-75%)Tumbler Index (Drum
Index) This is the indicator of Sinter
strength. Higher the T.I 71% and above
indelicate more strength of sinter ,less
breakage in side BF, Narrow size range of
sinter particles, better and uniform air
flow ,uniform heat distribution inside BF.
Effect of Sinter Quality on BF Operation
 T.Fe in sinter --- Hot Metal production from BF
comes from Iron Input in BF through Iron bearing
materials (Sinter)
Less gangue materials input, less coke rate,
less slag, clean Hot Metal.
 Basicity CaO/SiO (or CaO-SiO called
2 2
available lime) this is required for better
reducibility of sinter as well as good slag
chemistry and fluidity of slag in BF. Basicity of
slag in BF ( CaO+MgO)/(SiO2+Al2O3 )=0.98-1.1
 Effect of sinter quality on BF
operation
 R.D I-- Reduction Degradation Index (20-30 %).
In sinter Fe is mostly in the form of Fe 2O3
when reduction of Sinter starts at upper portion at 400-
600oc Fe2O3 reduces to Fe3O4 (Hematite to magnetite)
Sinter volume increases by about 25% so crack develops
on outer surface, which further widens and sinter breaks
into small pieces called disintegration these smaller pieces
choke the air passage (reduces permeability), causing less
and un-uniform air flow, leading to bad heat distribution .
Bad BF operation. Lower the RDI less disintegration, better
for BF.
 Effect of Sinter Quality on BF
Operation
 R.I –Reducibility Index – (66-75%) This is the
indicator of rate of reduction of sinter in lower
portion of BF, at higher tem. (900-1100oc)
means rate of removal of O2 from Fe2O3 to
Fe3O4to FeO at higher temperature.
 M.P.S (Mean Particulate Size) of Sinter ,Best
value is 16 to 23mm, Higher the mean size of
Sinter, Better permeability of charge in BF,
Better size range, good and uniform air flow,
better heat distribution, good BF operation.
 SINTER QUALITY AND METHODS TO ASSESS THE VALUE
 About 50gm of representative sinter sample powder is prepared this
sample is put in X .Ray m/c (XRF) this gives the reading of chemical
composition of sinter( TFe,CaO,Al2O3,MgO,SiO2 etc .only) .FeO is not
measured by XRF. This is done by wet method.
 Shatter Index (S.I) (good value is 1.4max or75%min.) This is the
indication of Sinter strength.
 Method to assess the shatter index -----10kg of sinter sample size 10mm
to 40mm is taken and dropped thrice from 2 m height on a 20mm thick
steel plate (-)10mm so generated is screened out then ratio of --
original total sinter wt. /Balance +10mm sinter wt. Is measured this ratio
is called shatter index Value should be 1.4 max
 The same thing may be expressed as ratio of +10mm balance sinter
wt./total sinter wt. x100 = SI ( good value in this method is 75%min.)
 Drum Index/Tumbler Index -- There is another method of assessing sinter
strength called tumbler index (T.I)/drum Index (D.I)
 In this method 15kg of sinter sample size +10-- -40mm is taken in a drum
of 1 m diameter. And drum is rotated @25 rpm for
8minutes(i.e200revolutions in 8 minutes) -6.3mm fraction so generated is
screened out then ratio of weight of balance +6.3 mm sinter/original total
weight(+10—40mm) multiplied by 100 is called tumbler index or drum
index ( norm is 70%min.).
 SINTER QUALITY AND METHODS TO ASSESS THE
VALUE
 Reduction Degradation Index (RDI)---This is a measurement to know sinters
behavior in blast furnace upper zone where temperature is 500dcto600dc and
sinter reduction has started. Actually when sinter starts reducing at 550-600dc its
molecular structure changes from Hematite to Magnetite (Fe2O3 +CO---Fe3O4
+CO2) In this phenomenon sinter volume increases about 10—25% (sinter
swells) so crack develops on sinter surface and on further heat this crack widens
further and sinter breaks into pieces ;this phenomenon of breaking sinter into
pieces is called disintegration of sinter .More such disintegration of sinter block air
passage (reduce permeability of charge inside Blast Furnace , hence wind
acceptability in furnace goes down and so the process. This phenomenon is
artificially created outside BF in laboratory by creating similar environment in lab..
 In this test 500gm of sinter sample size +16- 21mm is taken in a tube of
dia.75mm (called reactor) and heated up to 550dc and soaked for10minutes in N2
gas only. Then a reducing gas of composition CO 20%+CO2 20%+N2 60% is
passed through hot sinter. This phenomenon is continued for 30minutes.
 Then gas flow is stopped and sinter is cooled by N2gas. When sinter is cooled
to room temperature it is put in a mini drum of ID 130mmandlength200mm
given900revolutionsin 30minutes (it means drum is rotated at the speed of30rpm
for 30 minutes) then-3.15mm so generated is screened out and ratio of-3.15mm so
generated to original sample weight is multiplied by 100.the value in % term is
called RDI the norm for good RDI is (22to30%)
 SINTER QUALITY AND METHODS TO ASSESS
THE VALUE
 5) Reducibility Index (R.I)
 This is the final phase of reduction phenomenon of sinter in B.F .This process
occurs in lower portion of B.F where temperature is around900-1100d.c.
(Fe3O4+CO---FeO+CO2 andFeO+CO---Fe+CO2).
 To assess R.I, 500gm of sinter sample size 19-21mm is taken in a tube and
heated up to900d.c and a gas of composition CO 30%+N2 70% is passed for
3Hr.(180minutes) then heating and gas flow is stopped and sinter is cooled in
inert atmosphere by passingN2 over sinter till it is cooled to room temp. Then
sinter is weighed . Ratio of reduced sinter to original sinter weight is
taken .This value multiplied by 100 gives the R.I of sinter. More accurately it is
calculated as---
 Reduced weight of sinter
 R.I = ----------------------------------------------------------------- X100
 Original sample weight (0.43xFe-0.112FeO)
 Fe and FeO are the % of sinter sample before reduction (norm of good R.I
is > 65 %.)
 SINTER QUALITY AND METHODS TO ASSESS THE VALUE
L.O.I of a material (Loss on Ignition)
Dry weight weight-weight after Ignition
 LOI= -----------------------------------------------------x 100 = LOI in %
Dry weight

 Dry weight of material = Natural weight of material – moisture in material

Natural weight of material – Dry weight of material
 Moisture in a material = ----------------------------------------------------------------------X100.
Natural weight of material

 Moisture It is expressed in terms of %.

 SINTER QUALITY AND METHODS TO
ASSESS THE VALUE
 METHODE TO CACULATE PARTICULATE MEAN SIZE:-
 This method is called Arithmetic mean size:-
 Suppose sinter particulate are measured as +A, +B, +C, +D, +E, +F and –F mm. & values
are a, b, c, d, e, f, g% then P.M.S. of sinter will be calculated as

 a×[{A+(A+10)}/2] ×b{(B+A)/2}+ c×{(C+B)/2}+ d×{(D+C)/2}+ e×{(E+D)/2}+ f×{(F+E)/2}+g(F+0)/2 Z

---------------------------------------------------------------------------------------------------------------------------- = ------------ mm
100
100

 E.g. A= +60mm, a = 0%, B= +40mm, b= 2.75%, C= +10mm, c=93.92%, D= +5mm, d= 2.6%,

 E= -5mm, e=0.73% then in this case sinters PMS:-

0×[{60+(60+10)}/2]+ 2.75×{(40+60)/2}+ 93.93×{(10+40)/2}+ 2.6×{(5+10)/2}+ 0..73×{(0+5)/2}

P.M.S. = -----------------------------------------------------------------------------------------------------------------------------------
100

= 2934.245 mm. =29.342mm

100
Methods to Control Sinter Quality
TI (Tumbler Index Control) Best value >69%
 a) Increase FeO of sinter T.I improves
 b) Reduce Al2O3 in charge TI Improves
 c) Reduce +5mm particulate in charge T.I Improves
 d) Improve balling Index of charge T.I Improves
 e) Increase Basicity of Sinter T.I Improves
 f) Increase bed height of charge TI Improves
 After 250mmbed height every 100mm increase
 In bed height improves T.I by 1.5to 2%
 g) Improve coke and flux quality
 (Both chemical and physical) T.I Improves
 h) Improve sintering process T.I Improves
 I) Reduce sinter machine speed T.I Improves
 J) Reduce Al2O3 andTiO2 in charge T.I improves
 k) Reduce Sinter return in charge T.I Improves
 l) Improve Moisture in charge T.I Improves
 Method to control sinter quality
 Balling Index and control of balling index:—
 The ratio +3mm in charge after SMD /+3mm before SMD (after PMD) is called Balling Index
value It must be above 1.6 min.
 METHODS TO IMPROVE BALLING INDEX:-
 a) Increase addition of good quality quick lime in charge
 (40k.g/t of charge.) Balling Index Improves
 b) Increase of SMD diameter Balling Index Improves
 c) Increase of SMD length Balling Index Improves
 D) Addition of steam in SMD Balling Index Improves
 e)Reduce charge rate in SMD Balling Index Improves

 METHODS TO IMPROVE FeO IN SINTER:- FeO of Sinter (best value 8.0—9.5 %)

 a) Increase of coke feed rate in charge Improves FeO

 b) Increase of bed height Reduces FeO
 c) Increase in balling Index Improves FeO
 D) Increase Ignition temperature Improves FeO
 e) Reduce Sinter Machine speed Improves FeO
 f) More moisture in charge (optimum) Improves FeO
 g) Reduce +5mm particulates in charge Improves FeO
 h) Reduce bed height Improves FeO
 i) Close damper of cooling zone wind boxes Improves FeO
 R.D.I of sinter (best value 22—30 %)
 Method to control Sinter quality
 METHODS TO IMPROVE RDI:-
 a) Better sintering process Improves R.D.I
 B) Increase bed height Improves R.D.I
 c) Fine particulate in charge (2.5—3.0mm) Improves R.D.I
 D) Higher FeO (not fused) Improves R.D.I
 e) More moisture in charge (optimum) Improves R.D.I
 f) Better balling index in SMD (1.6 min.) Improves R.D.I
 g) Increase MgO in sinter Improves R.D.I
 H )Reduce SiO2 in sinter Improves R.D.I
 I) Reduce Al2O3 and TiO2 in sinter Improves R.D.I
 j) Increase Basicity of sinter Improves R.D.I
 K) Increase Ignition Intensity Improves R.D.I
 l) Reduce Sinter Machine speed Improves R.D.I

Method to control Sinter quality
Sinter Return generation (good value is 25-35 % of sinter production)

 CONTROL OF SINTER RETURN GENERATION:-


 a) Increase FeO of sinter Reduces Sinter Return
 b) Increase bed height Reduces Sinter Return
 c) Improve sintering process Reduces Sinter Return
 d) Increase Moisture in charge (up to optimum) Reduces Sinter Return
 f) Improve coke and flux crushing
 and better granulometry of charge
 (2.5—3.0mm) Reduces Sinter Return
 g) Reduce +5mm particulate in charge Reduces Sinter Return
 h) Improve balling index of charge Reduces Sinter Return
 I) Improve Ignition Temperature Reduces Sinter Return
 j) Reduce sinter machine speed Reduces Sinter Return
 Method to control Sinter quality
 B.T.P ( good value -on last but one wind box temp. should be 300dc min. and in
wind boxes prior to it and next to it temperature should be 25 dc less than it
 a) Reduce sinter machine speed BTP Improves
 b) Increase coke feed rate in charge BTP Improves
 c) Improve balling Index BTP Improves
 d) Increase +5 mm particulate in charge BTP Improves
 e) Increase main fan gate opening
 (Increase air volume through charge) BTP Improves
 f) Increase suction below grate BTP Improves
 G) Increase Ignition temperature BTP improves
 h) Reduce bed height BTP Improves
 I) Increase moisture in charge (up to optimum) BTP Improves
 THUMB RULES / IMPERICAL FORMULESE .
 CORRECTNESS OF MOISTURE IN CHARGE-----
 Take a fistful of charge from charge from m/c after drum feeder, press
it fully in fist, see, if lump is formed, shake the palm, if lump breaks
into pieces and palm is not wet ,It indicates, moisture is correct. If ball
is not formed after pressing, moisture is less, if ball is formed but not
breaking after shaking the palm also palm is wet, moisture is
more .Take suitable action accordingly.
 See at discharge end of sinter m/c the falling sinter cake .if two third
upper portion of sinter cross section is dark and bottom one third is
red hot and no un-sintered material at bottom of cake –means
sintering processes is good. If more than half of cross section is red
hot sintering is not completed sinter m/c speed is more reduce sinter
m/c speed accordingly. If less than one third cross section is red hot
means sinter is completed before set point sinter m/c speed is less
increase it.
 If upper section of falling sinter cake is fused/bright red hot and
bottom material is unsintered, means coke is more reduce coke
accordingly and see the effect after one hour. And take further action
accordingly.
 If spark is coming from top surface of sinter bed when it is coming out
from ignition hood means coke is excessive reduce coke in charge
 Thumb Rules/Empirical Formulae
 If cracking sound is coming from sinter bed as soon as it is coming
out from ignition hood .it means +5mm iron ore pieces are more in
charge. Change the material.
 See behind charge leveler if material accumulation is more charge
is getting too much pressed .reduce feed from drum feeder.
 Take a palm full of coke from coke crusher outlet and pickup
coarser particles (more than +3mm size) if only 3-4 pieces are
found coke crushing is above 90% it is good. If coarser particles are
more than 6 pieces crushing is poor less than 90% adjust coke
crusher gap.
 Ignition temperature in ignition hood is directly proportional to CV of
ignition gas. More the CV of gas more will be the temperature.
 Thumb rules/Empirical Formulae
 If total gangue material in sinter (SiO2+CaO+MgOAl2O3) is
around18-19% TI and RDI will be better.
 If SiO2+FeO+CaO+Al2O3, in sinter divided by TFe of sinter is
between 0.45 to0.55 TI will be more than 70%
 If sinter falls on SRC with loud sound FeO in sinter is good (above
8%)
 If loud sound is coming from ignition furnace and materials are flying
out of ignition furnace ignition air pres Sintering temperature in bed
is directly proportional to CV of coke. More the CV of coke, better
the sintering process.
 sure is more reduce it. If moisture in charge is too less then also
similar phenomenon will be observed, take suitable action.
Techno Economics parameters
 Available Hours– Calendar hours in a month
minus Planned shut down hours in the month.
 Availability of Sinter M/C -Calendar Hours in a
month minus Planned shut down hours in the
month deviated by calendar hours in the month
multiplied by 100,It is expressed in terms of %
 Utilization -Available hours in the month minus
Unplanned stoppage hours deviated by
available hours multiplied by 100. It is expressed
in terms of %
 Techno Economics Parameters
 Production of Sinter --Sinter sent to BF bunkers in a month
is declared as Sinter production of Sintering Plant.
 Productivity of Sinter Machine - Sinter production in a day
divided by running hours in a day divided by Sintering area of
Sinter M/C it is expressed in term of T/m2/hr.
 Sintering Area of Sinter M/C--- The sinter m/c area sealed
from all side and connected to main exhauster through wind
boxes below sinter m/c is called Sintering Area.
Techno Economics Parameters
 Capacity Utilization of Sinter M/C or Sinter m/c
performance or Efficiency of Sinter m/c –Sinter
production in a day divided by Rated capacity of
sinter m/c multiplied by 100. it is expressed in
terms of %
 Quality performance of Sinter Plant --- actual
Sinter return from BF divided by rated sinter
return from BF multiplied by 100.It is expressed
in terms of %.
Techno Economics Parameters
 Consistency of Sinter Quality - total no. Of test results
within the prescribed range of quality parameters
prescribed by BF divided by Total nos. of samples
tested, multiplied by 100. It is expressed in terms of %.
 Overall Plant Effectiveness - Plant Utilization multiplied
by capacity utilization multiplied by quality performance.
 Sinter Yield - Sinter Production divided by Total charge
put on sinter m/c multiplied by 100. it is expressed in
terms of %
 Specific consumption of Raw Materials --- Raw material
consumed divided by Sinter production .It is expressed
in terms of kg/t of sinter.
Techno Economics Parameters
 Sinter Return Generation--- Total Sinter return
generated from hot and cold screens in 24 hrs.
divided by Sinter production in 24 hrs multiplied
by 100. It is expressed in terms of %of sinter
produced.
 Skip Sinter --- Sinter charged in BF after
screening in BF.
 Yield of Skip Sinter --- Skip Sinter divided by
Skip Sinter plus BF return multiplied by 100. It is
expressed in terms of % sinter production.
Techno Economics Parameters
 Specific Ele. Power consumption --- Total Electricity
consumed by Sintering Plant in 24 hours divided by total
sinter production in 24 hours. It is expressed as KWH/T
of sinter
 Specific Gas consumption --- Total gas consumed in 24
hours divided by sinter production in 24 hours. It is
expressed in terms of M3/T of sinter.
 Coke Rate -- Total coke consumed in 24 hours divided
by sinter production in 24 hours. It is expressed in terms
of Kg/T of sinter.
 Techno Economics Parameters
 Quick Lime consumption rate = Total quick lime consumed in a day/ sinter production in a day It is
expressed in kg/t sinter.
 Electric power consumption - Total Electrical power consumed in a day/ total sinter produced in a day
-- it is expressed in KWH/T sinter
Sinter delivered to B.F
 Sinter yield =---------------------------------------- x 100 =62.5%
Gross charge consumed
 Skip Sinter --sinter charged in B.F after screening at BF end (Sinter from sintering plant – B.F Return)
Sinter falling on SRC
 Sinter cake yield = -------------------------------- x100 =89.7%
Gross charge
Dry weight-weight after Ignition
 L.O.I of a material (Loss on Ignition) = ----------------------------------------x100 =LOI in %
Dry weight

 Dry weight of material = Natural weight of material – moisture in material

Natural weight of material – Dry weight of material
 Moisture in a material = -------------------------------------------------------------------- x 100 =Moisture.
Natural weight of material
 It is expressed in terms of %.

 Coke Rate = total coke consumed in a day/ Sinter produced in a day----expressed in

kg/t sinter
 Sinter cost
 Total Raw Materials consumed in 24 hours plus handling
loss whole multiplied by unit cost of raw materials plus
Handling cost plus cost of electric power consumed
plus cost of gas consumed plus cost of water consumed
plus spares consumed plus consumables consumed
plus repair and maintenance cost plus Man power cost
plus administrative and overhead cost.
 Per Ton Sinter cost --- Total cost as above in 24 hours
divided by Sinter produced in 24hours . It is expressed in
terms of Rs./sinter.