US3849115A - Sintering process - Google Patents

Sintering process Download PDF

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Publication number
US3849115A
US3849115A US00237660A US23766072A US3849115A US 3849115 A US3849115 A US 3849115A US 00237660 A US00237660 A US 00237660A US 23766072 A US23766072 A US 23766072A US 3849115 A US3849115 A US 3849115A
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Prior art keywords
burden
sintering
sinter
zone
draft
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Expired - Lifetime
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US00237660A
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English (en)
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T Ban
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Davy McKee Corp
Mcdowell Wellman Engineering Co
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Mcdowell Wellman Engineering Co
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Priority to US00237660A priority Critical patent/US3849115A/en
Priority to AU43948/72A priority patent/AU464289B2/en
Priority to FR7225111A priority patent/FR2176642B1/fr
Priority to JP47106715A priority patent/JPS517602B2/ja
Priority to CA157,020A priority patent/CA980125A/en
Application granted granted Critical
Publication of US3849115A publication Critical patent/US3849115A/en
Priority to BE189052A priority patent/BE868712Q/xx
Assigned to DRAVO CORPORATION, A CORP. OF PA reassignment DRAVO CORPORATION, A CORP. OF PA ASSIGNS THE ENTIRE INTEREST AS OF MAY 15, 1980 Assignors: MCDOWELL-WELLMAN COMPANY
Assigned to DRAVO ENGINEERING COMPANIES, INC., A CORP. OF DE reassignment DRAVO ENGINEERING COMPANIES, INC., A CORP. OF DE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: DRAVO CORPORATION
Assigned to DAVY MCKEE CORPORATION, A DE CORP. reassignment DAVY MCKEE CORPORATION, A DE CORP. MERGER (SEE DOCUMENT FOR DETAILS). OCTOBER 04, 1988 - DELEWARE Assignors: DRAVO ENGINEERING COMPANIES, INC.
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/16—Sintering; Agglomerating
    • C22B1/20—Sintering; Agglomerating in sintering machines with movable grates
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling

Definitions

  • Ban 1 1 SINTERING PROCESS [75] Inventor: Thomas Eugene Ban, South Euclid,
  • the present invention provides an improved process for sintering particles composed of iron oxide, e.g., iron ore, combustible carbonaceous material, and water with a flux such as limestone optionally present and combining the principles of recyclng gases exiting from the burden adjacent the feed end back through the burden in a region toward the delivery end of a traveling grate as well as taking gases exiting from the burden adjacent the delivery end and passing them again through the burden near the feed end.
  • a flux such as limestone
  • Recycling of gases in this manner achieves desirable results such as reduction of the volume of gases handled, conditioning of the gases for removal of entrained particulate material by dust removing apparatus, and removal of entrained or volatilized organic as well as inorganic pollutants from the exhaust gas stream before discharge to the atmosphere.
  • the process combines the advantages of both hot recycle and cold recycle.
  • Sized self-fluxing or highly fluxed sinter has become recognized as a premium blast furnace charge and has enabled, for example, the blast furnaces of Japan to produce upwards of 10,000 tons of metal per day with coke rates of less than 1,000 pounds per ton of metal. This coke requirement is practically 50 percent of the ordinary rates of coke consumption achieved during the early l950s when peak blast furnace production was less than one-third of the current records of Japan.
  • Sintering has long been recognized and utilized as a means for reclaiming and upgrading materials such as blast furnace flue dusts, sludges, mill scales, and BOF fume.
  • Small sintering plants have been built for the sole purpose of sintering these reclaimable iron values, and larger plants have accepted these recycle materials as a component of a burden along with various grades of iron ore.
  • Sinter burden is comprised mainly of ore screenings, a combustible carbonaceous material, e.g., coke, water, and optionally a fluxing material, e.g., limestone.
  • a portion of the composition usually comprises one or more ofthe foregoing sources of reclaimed iron oxide-containing material.
  • Sintering involves high temperature processing of relatively finely divided material in high temperature gas-solid reactions. Through the processing cycle and ultimate materials handling, portions of the materials become entrained and enfumed within very high gas volumes required for sustaining the operations.
  • the present invention deals with a new concept for meeting these problems with an improved sintering system.
  • the improved process reduces air pollution and provides a high quality product at lower capital and operating costs.
  • the apparatus which is used is a traveling grate machine of either the linear or circular type, and preferably a liquid sealed circular traveling grate machine such as that described in US. Pat. No. 3,302,936.
  • the process is characterized by using recycle draft proceeding in a direction from adjacent the feed end toward the delivery end of the machine as well as from near the delivery end toward the feed end of the machine and utilizing in situ or strand cooling.
  • the present invention is in a process for sintering on a traveling grate which traverses both a sintering zone and a cooling zone on the same strand, the burden comprising iron oxide, combustible carbonaceous material, and water, the process comprising the stages of igniting the burden, such as with a gas torch; passing recycle oxygen-rich exhaust gas from a terminal cooling zone through the burden to effect sintering of the ignited burden as it moves along in the sintering zone and to produce relatively cold sinter exhaust gas; moving the burden from the sintering zone into the Cooling zone; recycling at least a portion of the relatively colder sinter exhaust gas through the burden to partially cool the sintered burden; and passing oxygenrich gas through the burden to further cool said burden in the cooling zone, to increase the temperature of the gas, and to yield an oxygen-rich recycle gas for recycling to the sintering zone.
  • oxygen-rich means above 12 percent by volume 0 Percentages in reference to gas composition are by volume. Those referring to solid compositions are by weight.
  • FIG. 1 is a simplified diagram of a conventional sintering process.
  • FIG. 2 is a simplified diagram of the improved sintering process of the present invention.
  • FIG. 1 is a simplified diagram of a conventional sintering process illustrating the sequence of sintering, hot crushing, hot screening, and cooling on a separate traveling grate.
  • the relatively large exhaust draft requirements are illustrated by the comparative sizes of fan, dust collector (electrostatic precipitator) and stack.
  • the two boxes identified as afterburner and electrostatic precipitator are shown in the sinter exhaust gas system to denote a series of draft or exhaust gas treatments such as absorption or incineration for removal of combustibles followed by dust removal as in an electrostatic precipitator. Draft emitted from such a sintering process is very high in volume and amounts to an exhaust draft to sinter product weight ratio of about 7.6.
  • FIG. 2 is a simplified diagram of the improved sintering process which illustrates the combination of sintering and cooling operations in a single rotation of the sealed circular traveling grate machine of the type shown in the above-mentioned U.S. Pat. No. 3,302,936.
  • the burden is generally continuously cast upon the traveling grate as a substantially uniform layer from 5 to inches thick and may desirably be deposited on a hearth layer of sized return material from 1 to 4 inches thick. Relatively cold draft from the initial windboxes of the sintering zone is recycled to the terminal hood or hoods of the sintering zone.
  • a two-stage sintering operation is shown.
  • the recycle draft from the first phase of sintering to the second phase is warm (200 to 300F.), slightly humid, and slightly depleted of oxygen.
  • the burden traveling from left to right as shown in the development of the circular traveling grate in FIG. 2 moves from the sintering zone encompassed by the first two hoods into the cooling zone encompassed by the succeeding two hoods.
  • the primary stage of cooling is carried outwith recycled draft from the terminal sintering stage.
  • the sinter exhaust draft is high in humidity, somewhat preheated, and provides for annealing during the terminal sintering and primary cooling stages.
  • Final cooling is carried out on the same strand with cool draft from the discharge end and crushing operation wherein the dust-laden draft exhausting from the final cooling stage is recycled to the initial stage of sintering in the sintering zone.
  • This recycling operation is known as hot recycle. It will be observed that relatively ambient air is picked up by the fan above the discharge extremity from beneath the hood over the discharge and crushing operations. Considerable entrained dust exists, and the dust-laden material is pumped downwardly through the burden into the final windbox of the system where the gas temperature is elevated considerably and the gases then recycled through a dust collector, a recycle fan, and into the primary sintering hood.
  • the oxygen content of the hot recycle gases is essentially the same as the ambient air and contains, therefore, from 26 percent by volume of oxygen. Dust which is collected in the final hood is arrested to a considerable extent by the hot semi-fused sintering bed and the lower more moist layers of the nodular sinter burden. Exhaust from the final sintering-primary cooling zone is directed to the stack through an electrostatic dust precipitator. This may be of either the wet or the dry type. From the diagram it will be observed that the exhaust draft has been sequentially directed through high temperature firing and cooling zones of the operations and thereby relieved of entrained combustibles and condensible matters. Supplemental heat for the operation, if necessary, may be provided by a torch within the cooling zone, and appropriate water injection may be used within the draft lines for tempering the thermal content thereof.
  • FIGS. 1. and 2 A most marked comparison between FIGS. 1. and 2 is the relative sizes of emitted exhaust draft volumes as represented by the relative sizes of the stacks.
  • the improved sintering process of the present invention emits a draft exhaust-to-product ratio of about 1.9 or practically one-fouth of that from the conventional sintering process. Adjustment for actual cubic feet per minute of draft flow indicates a draft volume ultimately submitted to treatment for removal of entrained particles which is only 31 percent of that for the conventional process. This significantly lowers capital and operating costs for the sintering process.
  • the hot crushing and screening operations of conventional practices as shown in FIG. 1 are recognized as one of the highest maintenance and poorly attended areas of the sinter plant.
  • the hot dusty environment thereof contributes to excessive machinery wear and inadequate conditions from a health standpoint for favorable attention.
  • Sinter cake as discharged from the sintering machine ranges from cold brittle surface portions to hot plastic semifused portions.
  • the discharge characteristic contains unreacted dry and wet portions of the burden which further contribute to maintenance and operating problems on the discharge end. These involve high temperature crush and distortion of materials, caking and blinding of the burden as caused by wet burden and dust fouling of the atmosphere as well as fouling of lubricated portions of the machinery.
  • the normal forced or induced air draft convection cooling of hot sinter as shown in FIG. 1 presents specific problems inherent with gas/solid segregation brought about by treatment of solid materials having a wide range of particle sizes. lnvariably, granular solids segregate through movement by piling, charging, and transferring wherein the larger sized particles orient in locations remote from those occupied by fines. Crushed and screened cooler charge material generally ranges from about 6-inch pieces to residual granular and unaffected micron-sized particles which when bedded on a traveling grate cooler tend to segregate and develop channels or paths for preferential cooling draft flow. Hot finer particles segregated from coarser lump sinter particles are relatively unaffected by the forced cooling draft which takes the path of least resistance and results in nonuniform cooling.
  • the'sinter exhaust is slightly humid and of relatively low temperature (200 300F.) containing suspended liquid and gaseous hydrocarbons together with solid particulate material which for the most part are normal sinter burden constituents, and new compounds as fumed materials such as volatilized salts, alkalies, and light metal oxides.
  • the discharge end exhaust gases are dry and of moderate temperature (300 40()F.). They contain high percentagcs of fine entrained particles of dry sinter burden.
  • the exhaust from the cooler is dry and relatively moderate in temperature (300 400F.) and contains largely coarser particles of sinter burden and small amounts of unsintered burden.
  • the cooler discharge exhaust (the final hood on the traveling grate in the cooling operation) is dry and of relatively low temperature (100 200F.) and contains small percentages of entrained coarser particles of sinter.
  • pollutants such as fine liquid and solid particulates and gaseous hydrocarbons
  • High efficiency removal of solid particulates may be accomplished with dry electrostatic precipitation apparatus which is useful in dropping out dry materials for recycle or disposal without attendant water pollution problems from soluble particulates.
  • Combustibles in the gaseous or liquid state, and condensibles such as hydrocarbons and volatilized fatty acids, can be removed by combustion in an afterburner by a gaseous incineration operation.
  • the improved sintering process of the present invention is preferably carried out on apparatus which is totally sealed for performing strand sintering and cooling with multipass recycled draft.
  • a liquid sealed circular sintering machine such as described in US. Pat. No. 3,302,936 eliminates leakage and draft in filtration between sinter bed, hood, and windboxes. This enables better control and minimization of exhaust draft volumes.
  • This apparatus minimizes the capital in-- vestment in operating costs for sintering.
  • Utilization of recycled draft for both sintering and cooling reduces the quantity of exhaust draft for treatment prior to discharge to the atmosphere.
  • the quality of the draft is also conditioned for optimum utilization by electrostatic precipitation apparatus in that it has increased temperature and increased moisture.
  • Entrained organics by reason of being re-introduced through a hot bed undergo oxidation in the body of the bed rather than in any external equipment such as an afterburner.
  • the bed itself may also act as a filter medium to recapture dusts.
  • the use of strand or in situ two-stage cooling eliminates hot crushing, hot recycling, and a separate cooler circuit.
  • sinter quality by the annealing sintering cooling operation with preheated draft and cold crushing operations.
  • There is an improvement in the sintering capacity by enabling forced firing capacity within the cooling zone.
  • FIG. 2 illustrates the recycling of the draft which results in an improved quality and a diminished quantity of exhaust draft.
  • the draft from the initial windboxes in the sintering zone is warm and humid at a temperature of about 250F. and contains about 9 percent moisture and 15 percent oxygen.
  • the composition will vary somewhat from case to case, depending upon the amounts of carbonates and hydrates decomposed during the sintering operation.
  • Continuous sintering test data shows that the recycle draft from the terminal portions of the sintering zone does not interfere with sintering practice and has been found to be beneficial.
  • preheated draft for sintering and cooling enables the production of more desirable sinter than that performed by conventional procedures utilizing ambient air. Individual tests have shown that preheated draft assists in the production of higher oxidation rates and a stronger sinter product. It has also been determined that the direction of passage of the draft through the burden, particularly in the cooling zone, may be either updraft or downdraft or a combination of updraft and downdraft.
  • the sinter bed as it enters this zone is highly permeable when sintering is complete because of consolidation of fine particulate matter, solidification of the plastic semifluid firing zone, and reduction of the high temperatures which cause draft expansion.
  • In situ strand cooling with warm recycle drafts though beneficial to sinter quality brings about lower cooling rates than that attained with ambient air.
  • the close interrelation between sinter draft requirements and cooling draft requirements could result in hotter than normal sinter product.
  • Heat balances indicate sinter product at a temperature of 250 to 350F. instead of the normal 300F.
  • the hotter sinter product in these cases can be brought to normal temperatures if desired by direct water quenching.
  • Such practices have shown sinter to be capable of quenching from about 400F. without noticeable degradation or weakening. Steam from such quenching operations if employed may be gathered within the discharge end draft stream or treated by separatedraft scrubbing operation.
  • Table 111 The two different types of operation for the improved process of FIG. 2 are presented in Table 111, each of which has a specific feature.
  • Introduction of water to the draft system of the second blower from the left in Draft Rates for Sintcring FIG. 2 lowers the temperature from about 500F. to about 200F. and enables extensive cooling to be performed at the expense of diminished hydrocarbon combustion in the cooling zone.
  • the omission of water from this draft stream enables the 500F. draft to be admitted to the third zone or first cooling zone, resulting in extensive hydrocarbon combustion at the expense, however, of cooling rates.
  • a burner or torch diagrammatically illustrated in the first part of the cooling zone can further assist the afterburning of the hydrocarbon emissions. in these cases of using hot draft for primary cooling, water quenching of the sinter product is made necessary.
  • a process in accordance with claim 1 wherein the burden comprises nodules of a sinter composition which comprises iron ore, combustible carbonaceous material and water.
  • a process in accordance with claim 1 which additionally includes the step of depositing the burden onto the traveling grate as a continuous bed having a substantially uniform depth of from 5 15 inches.
  • a process in accordance with claim 1 which additionally includes the step of depositing a hearth layer onto the traveling grate as a continuous layer having a substantially uniform depth of from 1 to 4 inches prior to deposition of said burden.
  • step (b) is passed downwardly through the burden.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Geology (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
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US00237660A 1972-03-24 1972-03-24 Sintering process Expired - Lifetime US3849115A (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US00237660A US3849115A (en) 1972-03-24 1972-03-24 Sintering process
AU43948/72A AU464289B2 (en) 1972-03-24 1972-06-27 Improved sintering process
FR7225111A FR2176642B1 (ja) 1972-03-24 1972-07-11
JP47106715A JPS517602B2 (ja) 1972-03-24 1972-10-26
CA157,020A CA980125A (en) 1972-03-24 1972-11-20 Sintering process
BE189052A BE868712Q (fr) 1972-03-24 1978-07-04 Procede de frittage de minerais

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JP (1) JPS517602B2 (ja)
AU (1) AU464289B2 (ja)
BE (1) BE868712Q (ja)
CA (1) CA980125A (ja)
FR (1) FR2176642B1 (ja)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4023960A (en) * 1972-10-25 1977-05-17 Metallgesellschaft Aktiengesellschaft Process for cleaning waste gases from sintering plants
US4191586A (en) * 1975-10-23 1980-03-04 Fives-Cail Babcock Method and apparatus for reducing the calorific consumption of a cement producing plant
US5786296A (en) * 1994-11-09 1998-07-28 American Scientific Materials Technologies L.P. Thin-walled, monolithic iron oxide structures made from steels
GB2347940A (en) * 1999-03-19 2000-09-20 British Steel Plc Iron ore sintering process with reduced emissions of toxic gases
US6461562B1 (en) 1999-02-17 2002-10-08 American Scientific Materials Technologies, Lp Methods of making sintered metal oxide articles
WO2003102252A1 (de) * 2002-05-29 2003-12-11 Mannesmannröhren-Werke Ag Verfahren zum sintern von eisenoxidhaltigen stoffen auf einer sintermaschine
US20130130185A1 (en) * 2010-09-24 2013-05-23 Outotec Oyj Method for starting a sintering furnace, and sintering equipment
US20130130186A1 (en) * 2010-09-24 2013-05-23 Outotec Oyj Method for the continuous sintering of mineral material and sintering equipment

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5123246B2 (ja) * 1972-06-26 1976-07-15
JPS51120905A (en) * 1975-04-15 1976-10-22 Hitachi Zosen Corp Waste gas circulation type sintering method
JPS51126903A (en) * 1975-04-30 1976-11-05 Sumitomo Heavy Ind Ltd A sintering facility
JPS5660098U (ja) * 1980-07-30 1981-05-22
JPS5967229U (ja) * 1982-10-25 1984-05-07 有限会社ト−ワ シ−ト状成形材料
JPS59104719U (ja) * 1982-12-29 1984-07-14 池田物産株式会社 合成樹脂含浸紙紐編織物
US10399193B2 (en) * 2017-01-25 2019-09-03 The Boeing Company Methods and apparatus to align threaded fasteners

Citations (7)

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Publication number Priority date Publication date Assignee Title
US2750272A (en) * 1950-06-05 1956-06-12 Allis Chalmers Mfg Co Process for production of hard burned agglomerates of fine magnetite ore
US2862807A (en) * 1957-05-02 1958-12-02 Cleveland Cliffs Iron Updraft pelletizing method
DE1136675B (de) * 1961-03-28 1962-09-20 Metallgesellschaft Ag Verfahren und Vorrichtung zur Durchfuehrung endothermer Prozesse auf dem Sinterband
US3244507A (en) * 1964-06-10 1966-04-05 Reserve Mining Co Method of indurating ore particles
US3332770A (en) * 1965-04-01 1967-07-25 Dravo Corp Apparatus for reduction firing of iron ore pellets
US3333951A (en) * 1965-06-14 1967-08-01 Mcdowell Wellman Eng Co Metallized pellets
US3732062A (en) * 1972-01-20 1973-05-08 J Porteus Method of and apparatus for reducing air pollution in the thermal processing of ores and other materials

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2750272A (en) * 1950-06-05 1956-06-12 Allis Chalmers Mfg Co Process for production of hard burned agglomerates of fine magnetite ore
US2862807A (en) * 1957-05-02 1958-12-02 Cleveland Cliffs Iron Updraft pelletizing method
DE1136675B (de) * 1961-03-28 1962-09-20 Metallgesellschaft Ag Verfahren und Vorrichtung zur Durchfuehrung endothermer Prozesse auf dem Sinterband
US3244507A (en) * 1964-06-10 1966-04-05 Reserve Mining Co Method of indurating ore particles
US3332770A (en) * 1965-04-01 1967-07-25 Dravo Corp Apparatus for reduction firing of iron ore pellets
US3333951A (en) * 1965-06-14 1967-08-01 Mcdowell Wellman Eng Co Metallized pellets
US3732062A (en) * 1972-01-20 1973-05-08 J Porteus Method of and apparatus for reducing air pollution in the thermal processing of ores and other materials

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4023960A (en) * 1972-10-25 1977-05-17 Metallgesellschaft Aktiengesellschaft Process for cleaning waste gases from sintering plants
US4191586A (en) * 1975-10-23 1980-03-04 Fives-Cail Babcock Method and apparatus for reducing the calorific consumption of a cement producing plant
US5786296A (en) * 1994-11-09 1998-07-28 American Scientific Materials Technologies L.P. Thin-walled, monolithic iron oxide structures made from steels
US5814164A (en) * 1994-11-09 1998-09-29 American Scientific Materials Technologies L.P. Thin-walled, monolithic iron oxide structures made from steels, and methods for manufacturing such structures
US6461562B1 (en) 1999-02-17 2002-10-08 American Scientific Materials Technologies, Lp Methods of making sintered metal oxide articles
GB2347940A (en) * 1999-03-19 2000-09-20 British Steel Plc Iron ore sintering process with reduced emissions of toxic gases
WO2003102252A1 (de) * 2002-05-29 2003-12-11 Mannesmannröhren-Werke Ag Verfahren zum sintern von eisenoxidhaltigen stoffen auf einer sintermaschine
US20130130185A1 (en) * 2010-09-24 2013-05-23 Outotec Oyj Method for starting a sintering furnace, and sintering equipment
US20130130186A1 (en) * 2010-09-24 2013-05-23 Outotec Oyj Method for the continuous sintering of mineral material and sintering equipment
US9534844B2 (en) * 2010-09-24 2017-01-03 Outotec Oy Method for the continuous sintering of mineral material and sintering equipment

Also Published As

Publication number Publication date
FR2176642B1 (ja) 1976-05-14
CA980125A (en) 1975-12-23
BE868712Q (fr) 1978-11-03
JPS517602B2 (ja) 1976-03-09
JPS4924823A (ja) 1974-03-05
FR2176642A1 (ja) 1973-11-02
AU464289B2 (en) 1975-08-21
AU4394872A (en) 1974-01-03

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