Optimisation of Sinter Quality using the Sinter Pot Pilot Facility
Authors:   , Butt Sallayman 
Published: January 2025

This investigation studies the complex area of sinter production, conducting an analysis of factors influencing thermodynamics, metallurgical testing, bed permeability, mineralogy formation, and blast furnace efficiency. Employing extensive experimentation and advanced data analysis, including leveraging computational tools such as thermodynamic prediction software FactSage and deploying a computer vision application named Intellesis, a novel aspect of this research emerges in iron ore sintering. The quality indicators for the sinter were examined through assessments of cold strength, degradation properties, chemical composition, microscopy, and mineralogy. Additionally, meticulous monitoring of process parameters, encompassing sintering time, temperature, flow rates, and flame front characteristics, ensured precision and accuracy in drawing conclusions.This investigation delves into the influential domain of particle size of flux, unravelling their intricate roles in shaping sintering thermal profiles and enhancing quality. Operating within the 1mm to 3.15mm particle size fraction demonstrates improved stability and homogeneity in iron ore sinter. The influence of particle size on oxygen accessibility to coke particles unfolds profound effects on combustion rates and temperature profiles.Exploring basicity levels provides a pivotal perspective on sinter quality. Operating within the optimal range of basicity 1.4 to 2.0, indicated by lower reductiondegradation index (RDI) values and superior mineralogical features, emerges as a significant finding. Analysis of Intellesis data reveals a uniform distribution of renown favoured Silico Ferrite of Calcium and Aluminium (SFCA) among iron oxide phases and a correlation corroborated by X-ray fluorescence (XRF) analysis indicating that higher basicity values correlate with stronger sinter and optimal FeO content. Thefindings here suggest that they agree with the current industry practice which is at a basicity of 1.7.The study dissects sinter properties related to silica and magnesium oxide (MgO) levels, shedding light on their intricate roles in sinter yield, SFCA formation, and productivity. A 7.0% silica level yields substantial sinter, coupled with remarkable SFCA formation. Furthermore, an optimal 2.5% MgO level was found, supported by optimal RDI values and superior SFCA production, which emphasises the critical role of compositional changes.Incorporating these insights, this thesis explains the pivotal role of key factors influencing sinter production, aiding the advancement of knowledge for iron and steel manufacturing. By optimising basicity value, particle size of flux, and other compositional changes, this study propels knowledge enhancement for an efficient and productive sintering process. This research marks substantial progress toward an efficient and productive sintering process through the optimisation of basicity levels, particle size of flux, and chemistry. The innovative use of Intellesis to analyse basicity, flux, and various chemistry levels further validates the findings, aligning with other quality indicators.