Detection of the assimilation characteristics of iron ores: Dynamic resistance measurements

Resistance in iron ore undergoes a sharp change of up to several orders of magnitude when the sintered solid phase changes to liquid phase.In view of the insufficiency of existing assimilation detection methods,a timing-of-assimilation reaction is proposed,which was judged by continuously detecting the changes in resistance at the reaction interface.Effects of pole position and additional amounts of iron ore on assimilation reaction timing were investigated.The results showed that the suitable depth of pole groove was about 2 mm,and there was no obvious impact when the distance of the poles changed from 4 to 6 mm,or the amount of iron ore changed from 0.4 to 0.6 g.The temperature of sudden change of resistance in the temperature-resistant image was considered to be the lowest assimilation temperature of iron ore.The accuracy of this resistance method was clarified by X-ray diffraction,optical microscope,and scanning electron microscope/energy dispersive spectrometer(SEM/EDS)analyses.

A pilot-scale study of selective desulfurization via urea addition in iron ore sintering

The iron ore sintering process is the main source of SO_2 emissions in the iron and steel industry. In our previous research, we proposed a novel technology for reducing SO_2 emissions in the flue gas in the iron ore sintering process by adding urea at a given distance from the sintering grate bar. In this paper, a pilot-scale experiment was carried out in a commercial sintering plant. The results showed that, compared to the SO_2 concentration in flue gas without urea addition, the SO_2 concentration decreased substantially from 694.2 to 108.0 mg/m^3 when 0.10wt% urea was added. NH_3 decomposed by urea reacted with SO_2 to produce（NH_4）_2SO_4, decreasing the SO_2 concentration in the flue gas.

Fundamental study on iron ore sintering new process of flue gas recirculation together with using biochar as fuel

It is of great significance for cleaner production to substitute bio-energy for fossil fuels in iron ore sintering. However, with the replacement ratio increasing, the consistency of heat front and flame front is broken, and the thermal utilizing efficiency of fuel is reduced, which results in the decrease of yield and tumble index of sinter. Circulating flue gas to sintering bed as biochar replacing 40% coke, CO in flue gas can be reused so as to increase the thermal utilizing efficiency of fuels, and the consistency of two fronts is recovered for the circulating flue gas containing certain CO2, H2 O and lower O2, which contributes to increasing the maximum temperature, extending the high temperature duration time of sintering bed, and results in improving the output and quality of sinter. In the condition of circulating 40% flue gas, the sintering with biomass fuels is strengthened, and the sintering indexes with biomass fuel replacing 40% coke breeze are comparative to those of using coke breeze completely.

Influencing factor of sinter body strength and its effects on iron ore sintering indexes

Sinter body strength, which reflects the strength of sinter, plays an important role in the improvement of sinter. In this study, the sinter body strengths of iron ores were measured using a microsintering method. The relationship between the chemical composition and sinter body strength was discussed. Moreover, sinter-pot tests were performed. The effects of sinter body strength on the sintering indexes were then elucidated, and the bottom limit of sinter body strength of blending ores was confirmed. In the results, the compressive strengths（CSs） of iron ores are observed to decrease with the increasing of the contents of loss on ignition（LOI）, SiO 2, and Al2O3; however, LOI of less than 3wt% does not substantially influence the CSs of fine ores. In the case of similar mineral composition, the porosity, in particular, the ratio between the number of large pores and the total number of pores, strongly influences the sinter body strength. With an increase of the blending-ore CSs used in sinter-pot tests, the yield, productivity, and tumbler strength increase, and the solid fuel consumption decreases. The CSs of the blending ores only slightly affect the sintering time. The CS bottom limit of the blending ores is 310 N. When the CSs of the blending ores increase by 10%, the yield, productivity, and tumbler index increase by 1.9%, 2.8%, and 2.0%, respectively, and the solid fuel consumption decreases by 1.9%.

Influence of coke rate on thermal treatment of waste selective catalytic reduction(SCR)catalyst during iron ore sintering

Waste selective catalytic reduction(SCR)catalyst as a hazardous waste has a significant impact on the environment and human health.In present study,a novel technology for thermal treatment of waste SCR catalyst was proposed by adding it to sinter mix for iron ore sintering.The influences of coke rate on the flame front propagation,sinter microstructure,and sinter quality during sintering co-processing the waste SCR catalyst process were studied.In situ tests results indicated the maximum sintering bed temperature increased at higher coke rate,indicating more liquid phase generated and higher airflow resistance.The sintering time was longer and the calculated flame front speed dropped at higher coke rate.Sinter microstructure results found the coalescence and reshaping of bubbles were more fully with increasing coke rate.The porosity dropped from 35.28%to 25.66%,the pore average diameter of large pores decreased from 383.76μm to 311.43μm.With increasing coke rate,the sinter indexes of tumbler index,productivity,and yield,increased from 33.2%,9.2 t·m^(-2)·d^(-1),28.9%to 58.0%,36.0 t·m^(-2)·d^(-1),68.9%,respectively.Finally,a comprehensive index was introduced to systematically assess the influence of coke rate on sinter quality,which rose from 100 to 200 when coke rate was increased from 3.5%(mass)to 5.5%(mass).

Present situation and development of saving energy and reducing emission technology in iron ore sintering process

The energy consumption of iron ore sintering process is about 10%- 15%of the total of iron and steel industry.Therefore,it is of great significance to take effective measures to reduce the energy consumption in the iron ore sintering process to reduce the costs of sintering product and cut down the emissions of harmful gases,such as CO_2 and SO_2.In this study,the technology development of saving energy and reducing emission in iron ore sintering process was reviewed and discussed;some new directions and measures of saving energy were presented for the sintering process in the future.

Disposal of zinc extraction residues via iron ore sintering process:an innovative resource utilization

Zinc extraction residue,a solid waste generated from the treatment of zinc-containing dust in rotary kilns,is commonly stockpiled in steel companies for extended periods.It poses significant disposal challenges and environmental pollution risks.So far,research on the treatment of zinc extraction residues has been slow,inadequate,and sporadic.For this gap,a novel approach was proposed to effectively treat the zinc extraction residue via the iron ore sintering process.It was feasible to add 1 wt.%of zinc extraction residues to the sintering raw materials.The more adequate mineralization reaction resulted in higher yield and tumbler indexes,despite a slight decrease in sintering speed.Although this may result in a slight decrease in sintering speed,the more complete mineralization reaction leads to improved sintering yield and tumbler index.Interestingly,the addition of zinc extraction residues reduced the CO and NO_(x) concentrations in the sintering flue gas.Thus,the iron ore sintering process provided a viable solution for resource utilization and environmentally friendly treatment of zinc extraction residues.

Combustion mechanism of benzene in iron ore sintering process:experimental and simulation

Benzene is a typical component of volatile organic compounds(VOCs)in the iron ore sintering flue gas.The combustion behavior of benzene directly affects the emission of VOCs in iron ore sintering process.The effects of temperature,benzene,and oxygen concentrations on the conversion ratio of benzene were investigated by experiments and numerical simulation.The experiments were carried out in a tube reactor at temperatures of 773-1098 K,benzene concentrations of 0.01-0.03 vol.%,and oxygen concentrations of 10-21 vol.%.The numerical simulation was performed with the plug flow model in the CHEMKIN program based on a kinetic model that consists of 132 chemical species and 772 elementary step-like reactions.The experimental results reveal that increasing the temperature and benzene concentration could signifi-cantly promote benzene combustion.It is attributed to the increase in the reaction rates of all steps in the pathway for forming CO_(2)and H_(2)O.In addition,due to the large equivalent ratio of oxygen to benzene,the conversion ratio of benzene remained constant at different oxygen concentrations.The simulation results were in good agreement with the experimental results and indicated that six elementary reactions dominated the formations of CO_(2)and H_(2)O.The oxidations of C_(6)H_(5)O,CO,and C_(5)H_(4)O intermediates to CO_(2)were the limiting steps in the reaction pathways.

Identification of working conditions and prediction of FeO content in sintering process of iron ore fines

The iron oxide(FeO)content had a significant impact on both the metallurgical properties of sintered ores and the economic indicators of the sintering process.Precisely predicting FeO content possessed substantial potential for enhancing the quality of sintered ore and optimizing the sintering process.A multi-model integrated prediction framework for FeO content during the iron ore sintering process was presented.By applying the affinity propagation clustering algorithm,different working conditions were efficiently classified and the support vector machine algorithm was utilized to identify these conditions.Comparison of several models under different working conditions was carried out.The regression prediction model characterized by high precision and robust stability was selected.The model was integrated into the comprehensive multi-model framework.The precision,reliability and credibility of the model were validated through actual production data,yielding an impressive accuracy of 94.57%and a minimal absolute error of 0.13 in FeO content prediction.The real-time prediction of FeO content provided excellent guidance for on-site sinter production.

Process control technology of low NO_x sintering based on coke pretreatment

Process control is an effective approach to reduce the NOx emission from sintering flue gas.The effects of different materials adhered on coke breeze on NOx emission characteristics and sintering performance were studied.Results showed that the coke breeze adhered with the mixture of CaO and Fe2O3 or calcium ferrite significantly lowers the NOx emission concentration and conversion ratio of fuel-N to NOx.Pretreating the coke with the mixture of lime slurry and iron ore fines helped to improve the granulation effect,and optimize the carbon distribution in granules.When the mass ratio of coke breeze,quick lime,water and iron ore fines was 2:1:1:1,the average NOx emission concentration was decreased from 220 mg/m3 to 166 mg/m3,and the conversion ratio of fuel-N was reduced from 54.2%to 40.9%.

Mechanism research on arsenic removal from arsenopyrite ore during a sintering process

The mechanism of arsenic removal during a sintering process was investigated through experiments with a sintering pot and arsenic-bearing iron ore containing arsenopyrite; the corresponding chemical properties of the sinter were determined by inductively coupled plasma atomic emission spectrometry (ICP-AES), X-ray diffraction (XRD), and scanning electron microscopy (SEM) coupled with energy-dispersive X-ray spectroscopy (EDS). The experimental results revealed that the reaction of arsenic removal is mainly related to the oxygen atmosphere and temperature. During the sintering process, arsenic could be removed in the ignition layer, the sinter layer, and the combustion zone. A portion of FeAsS reacted with excess oxygen to generate FeAsO4, and the rest of the FeAsS reacted with oxygen to generate As2O3(g) and SO2(g). A portion of As2O3(g) mixed with Al2O3or CaO, which resulted in the formation of arsenates such as AlAsO4and Ca3(AsO4)2, leading to arsenic residues in sintering products. The FeAsS component in the blending ore was difficult to decompose in the preliminary heating zone, the dry zone, or the bottom layer because of the relatively low temperatures; however, As2O3(g) that originated from the high-temperature zone could react with metal oxides, resulting in the formation of arsenate residues. © 2017, University of Science and Technology Beijing and Springer-Verlag Berlin Heidelberg.

Reduction of NO_(x)emission based on optimized proportions of mill scale and coke breeze in sintering process

Reducing NO_(x) emission of iron ore sintering process in a cost effective manner is a challenge for the iron and steel industry at present.Effects of the proportion of mill scale and coke breeze on the NO_(x) emission,strength of sinter,and sinter indexes were studied by com-bustion and sinter pot tests.Results showed that the peak value of NO concentration,total of NO emission,and fuel-N conversion rate gradu-ally decreased as the proportions of the mill scale increased because NO was reduced to N_(2) by Fe_(3)O_(4),FeO,and Fe in the mill scale.The strength of sinter reached the highest value at 8.0wt%mill scale due to the formation of minerals with low melting point.The fuel-N conver-sion rate slightly fluctuated and total NO_(x) emission significantly decreased with the decreased proportions of coke breeze because CO forma-tion and content of N element in the sintered mixture decreased.However,the sinter strength also decreased due to the decrease in the amount of the melting minerals.Furthermore,results of the sinter pot tests indicated that NO_(x) emission decreased.The sinter indexes performed well when the proportions of mill scale and coke breeze were 8.0wt%and 3.70wt%respectively in the sintered mixture.

Investigation on the evolution characteristics of bed porous structure during iron ore sintering

To better understand the evolution characteristics of bed porous structure during iron ore sintering,X-ray computed tomography scanning technology was used to analyze the pore parameters in different areas of the sintering bed.A pore skeleton structure model was established to study the characteristics of the airflow channels in different zones.The absolute permeability of different areas was calculated through simulation,and the corresponding streamline and pressure drop distribution were analyzed.The results show that the porosity of raw material zone,high-temperature zone,and sintered zone increases gradually,which are 37.69%,46.41%,and 55.57%,respectively.The absolute permeability calculation results of the raw material zone and sintered zones are 792.49μm^(2) and 20560.80μm^(2),while the tortuosity is 1.77 and 1.45,respectively.Compared with the raw material zone,the flow streamline in the sintered zone is thicker and denser,the airflow resistance and the pressure drop are minor.

Influence of oxygen-rich hot air composite gas medium on sintering performance and function mechanism

Hot air sintering technology is used to improve the quality and production efficiency of sintered ore.However,the current thick layer condition highlights the disadvantage of the low oxygen potential of the hot air sintering layer.Therefore,it is considered to use oxygen enrichment sintering to improve the environment of hot air sintering.Traditional sintering,hot air sintering,and oxygen-rich hot air sintering were compared through sintering cup experiments,and the influence of hot air and oxygen-rich hot air on sintering indexes was clarified.Hot air reduced the vertical sintering velocity,while improved the yield and tumbler index.Oxygen-rich hot air sintering contributed to improving the vertical sintering velocity while ensuring the quality of sintered ore,thus comprehensively improving production efficiency.Under the action of hot air,the highest temperature of the sintering layer increased and the high-temperature holding time was prolonged.After oxygen enrichment,the combustion efficiency of fuels in the upper layer of materials was promoted,which optimized heat distribution in the middle and lower layers of materials and increased the content of calcium ferrite in the sintered ore,thus strengthening the sintering process.

Sintering Properties and Optimal Blending Schemes of Iron Ores

In order to obtain good sintering performance, it is important to understand sintering properties of iron ores. Sintering properties including chemical composition, granulation and high-temperature behaviors of ores from China, Brazil and Australia. Furthermore, several indices were defined to evaluate sintering properties of iron ores. The results show that： for chemical composition, Brazilian ores present high TFe, low SiOz, and low Alz03 con- tent. For granulation, particle diameter ratio of Brazilian ores are high; particle intermediate fraction of Chinese con- centrates are low; and average particle size and clay type index of Australian ores are high. For high-temperature properties, ores from China, Brazil and Australia present different characteristics. Ores from different origins should be mixed together to obtain good high-temperature properties. According to the analysis of each ore＇s sintering prop- erties, an ore blending scheme （Chinese concentrates 20 ^-1- Brazilian ores 400//oo -k Australian ores 40 ~） was sugges- ted. Moreover, sinter pot test using blending mix was performed, and the results indicated that the ore blending scheme led to good sintering performance and sinter quality.

Effects of Temperature and Atmosphere on Sintering Process of Iron Ores

The relationship of time to minerals composition in sinters is investigated by mineragraphy are claritied observation and component analysis, and the effects of temperature and atmosphere on mineralization process. Results are obtained as follows. The initial melt forms below the eutectic temperature of CaO·Fe2O3 and CaO·2Fe2O3, which is complex substance containing Ca, Fe, Si and Al, rather than the binary calcium ferrite melt. Minerals composition of binding phase is related to local content of silica in melt, which is influenced by temperature. Appearance of the melt promotes the transition from hematite to magnetite, which then alters the mechanism of calcium ferrite formation. Before the formation of magnetite, the contents of Fe and Ca within the multiple calcium ferrite decrease with temperature, but in the case of magnetite presence, the content of Fe increases solely with increase of temperature and decrease of oxygen potential. Temperature and atmosphere determine minerals composition together, and bring influence on sintering process in different ways. It can be deduced that temperature affects kinetics of the mineralization process, but atmosphere just plays a role in thermodynamics.

Effect of Ca-Fe oxides additives on NOx reduction in iron ore sintering

As the emission control regulations get stricter,the NO;reduction in the sintering process becomes an important environmental concern owing to its role in the formation of photochemical smog and acid rain.The NOxemissions from the sintering machine account for 48% of total amount from the iron and steel industry.Thus,it is essential to reduce NO;emissions from the sintering machine,for the achievement of clean production of sinter.Ca-Fe oxides,serving as the main binding phase in the sinter,are therefore used as additives into the sintering mixture to reduce NOxemissions.The results show that the NO;reduction ratio achieves 27.76% with 8% Ca-Fe oxides additives since the Ca-Fe oxides can advance the ignition and inhibit the nitrogen oxidation compared with the conventional condition.Meanwhile,the existence of Ca-Fe oxides was beneficial to the sinter quality since they were typical low melting point compounds.The optimal mass fraction of Ca-Fe oxides additives should be less than 8%since the permeability of sintering bed was significantly decreased with a further increase of the Ca-Fe oxides fines,inhibiting the mineralization reaction of sintering mixture.Additionally,the appropriate particle size can be obtained when mixing an equal amount of Ca-Fe oxides additives of-0.5 mm and 0.5-3.0 mm in size.

Application status and comparison of dioxin removal technologies for iron ore sintering process

The emission of dioxins from the iron ore sintering process is the largest emission source of dioxins, and the reduction in dioxin emission from the iron ore sintering process to the environment is increasingly important. Three approaches to control the emission of dioxins were reviewed： source control, process control, and terminal control. Among them, two terminal control technologies, activated carbon adsorption and selective reduction technology, were discussed in detail. Following a comparison of the reduction technologies, the terminal control method was indicated as the key technology to achieve good control of dioxins during the sintering process. For the technical characteristics of the sintering process and flue gas, multiple methods should be collectively considered, and the most suitable method may be addition of inhibitors ＋ ultra-clean dust collection （electrostatic precipitation/bag filter） ＋ desulphurization ＋ selective catalytic reduction to sufficiently remove multiple pollutants, which provides a direction for the cooperative disposal of flue gas pollutants in future.

An efficient method for iron ore sintering with high-bed layer:double-layer sintering

Poor permeability and low sintering productivity restrict the development of high-bed sintering.An efficient method of the double-layer sintering process(DLSP)was proposed to achieve high-bed sintering and solve the aforementioned problems.Theoretical calculation and sintering pot experiments were implemented to investigate the double-layer sintering process.Traditional sintering process and DLSP were compared in terms of sintering indices,metallurgical properties and morphology characterization.Under the condition of traditional sintering process,DLSP successfully realized fast velocity and highly productive sintering of 1000-mm high bed.After the sintering bed is charged and ignited twice,the air permeability of the bed has been greatly improved.Sintering time is shortened significantly by simultaneous sintering of the upper and lower feed layers.Under the condition of bed height proportion of 350/650 mm and pre-sintering time of 20 min,the yield,tumbler strength,productivity and solid fuel consumption are 69.96%,65.87%,1.71 t(m^(2)h)^(-1)and 56.71 kg/t,respectively.Magnetite,hematite,calcium ferrite and complex calcium ferrite are the main phases of DLSP products.The metallurgical properties of DSLP products meet the requirement of ironmaking.It indicates that DLSP is an effective method to solve the disadvantages of bad permeability and low sintering productivity in high-bed sintering.

Research progress on multiscale structural characteristics and characterization methods of iron ore sinter

At present,blast furnace ironmaking is still the main process for producing molten iron,and sinters are the main raw material for blast furnace ironmaking.A sinter with good metallurgical performance can not only ensure smooth operation of the blast furnace but also reduce the blast furnace fuel ratio and increase the molten iron production.Structure is the most important factor affecting the metallurgical properties of the sinter.Thus,the research progress of sinter pore and mineral phase structures was reviewed and the mechanism by which they influence sinter properties was expounded.Multiscale characterization methods for the sinter and their advantages and disadvantages were introduced,and the future research direction of sinter was discussed.