The science of sintering sarted to mature in the 1940s and became an important process for any integrated steel plant, out of the necessicty for avoiding iron ore fines(less than 14 mm sized lumps) in the blast furnace that may or may not contain high quality Ferrous containing iron ores.
It is referred to as a recycling process where all the rejected iron ore material, that may not fit the grade or size are brought together and baked into a coarse amalgam containing coke breeze, uniformly spread over the sintering bed, with a layer of return fines lying in between the coke layer and the belt, with 40% to 70% of the rejected iron ore on the top. This bed is then heated using the principle of surface lighting using a counter current smelting furnace that heats a complete segment of the layer from top to bottom using conduction.
The amalgamation process generates lumps that need crushing to fall in the material size of range 40 mm to 80 mm. These lumps are screened out and then fed to the blast furnace to increase the quality of the pig iron obtained as a product, and reduce waste by using all of the rejected iron ore fines. The undersize after the crushing is then sent back as return fines and the process starts all over again.
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