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Rate-Limiting Mechanism in Iron Ore Sintering Process with Waste Gas Recycling

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Abstract

Recycling waste gas through the sinter bed has an advantage of saving solid fuel. Depending upon the amount of waste gas recycled and its CO content, an equivalent quantity of solid fuel is saved. FeO is one of the key indicators of fuel needed for sintering; its optimization is critical to the consistency in sinter quality. Sinter pot tests were conducted to identify the effect of varying amounts of waste gas recycled. FeO and Tumbler Index increased with increasing waste gas up to 30%. Beyond 40% waste gas recycled, Tumbler Index decreased and the disintegration of the sinter was noticed. Incidental variation in the rate of solid fuel in an industrial scale Sinter Plant with waste gas recycling arrangement has resulted in a large variation in FeO than expected. Above 20%, productivity got adversely affected and Tumbler Index dropped as oxygen in the recycled gas started dropping below 19%. The rate-limiting mechanism has been identified as the underlying reason for low FeO. The deficiency of oxygen has affected the combustion efficiency of solid fuel, and hence, fresh airflow has been optimized to maintain the productivity and quality parameters. The variation in the carbon rate was restricted to 0.77 ± 0.5 kg/t, and oxygen was maintained above 19% to achieve consistent performance.

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Abbreviations

a :

Activity

BTP:

Burn through point

BTT:

Burn through temperature

CO:

Carbon monoxide

dCr:

Difference in carbon rate

dFeO:

Difference in FeO

ΔG :

Free energy change

ΔH :

Enthalpy change

ΔS :

Entropy change

ESP:

Electrostatic precipitator

FA Fan:

Fresh air fan

FC:

Fixed carbon

FeO:

Wüstite

Fe2O3 :

Hematite

Fe3O4 :

Magnetite

LOI:

Loss on ignition

NTP:

Normal temperature and pressure

p :

Partial pressure

ppm:

Parts per million

RDI:

Reduction degradation index

SFCA:

Silico ferrite of calcium and aluminum

SWGR:

Selective waste gas recycling

t :

Temperature in Celsius

T :

Temperature in Kelvin

TI:

Tumbler Index

VM:

Volatile matter

WGR:

Waste gas recycling

WGR Fan:

Waste gas recycling fan

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Acknowledgments

The authors express their gratitude to the Sinter Plant collective for their support in installing a waste gas recycling system in the pot sinter facility, during the pot tests and optimization of WGR.

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Authors and Affiliations

  1. JSW Steel Ltd, Vijayanagar Works, Toranagallu, Karnataka, 583275, India

    Veera Brahmacharyulu Angalakuditi, Sudhakar Karre & Lokendra Raj Singh

  2. Department of Chemical Engineering, BITS Pilani KK Birla Goa Campus, Zuarinagar, Goa, 403726, India

    Saroj Sundar Baral

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  1. Veera Brahmacharyulu Angalakuditi
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  2. Sudhakar Karre
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  3. Lokendra Raj Singh
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Correspondence to Veera Brahmacharyulu Angalakuditi.

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Angalakuditi, V.B., Karre, S., Singh, L.R. et al. Rate-Limiting Mechanism in Iron Ore Sintering Process with Waste Gas Recycling. Trans Indian Inst Met 74, 713–723 (2021). https://doi.org/10.1007/s12666-020-02162-w

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