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Latest Developments by Siemens VAI in Sintering Technology Anton Sebanz, Oskar Pammer, Hans Stiasny - Siemens VAI, Austria INTRODUCTION This paper presents Siemens VA's latest design fea- tures and solutions for a high-performing and eco- nomic sinter plants. Topics addressed include effi- cient sinter raw material mix preparation systems, a new sinter raw mix charging system, sinter cooling and selective recycling of sinter waste gas. In addition, advantages of modernization solutions are outlined, In recent years, a number of important develop- ments have been made in the field of iron-ore sin- tering technology, which have substantially con- tributed to increased productivity, improved and uniform product quality, reduced energy consump- tion, lower operational costs and particularly, deci- sive environmental advantages. Furthermore, the production capacity of sinter plants has been in- creased by up to 50% without increasing the waste gas volume, These benefits were primarily achieved through the application of the following technological developments: ‘+ Improved raw mix preparation through the implementation of the Intensive Mixing and Granulation System (IMGS) ‘+ Pallet width extension technology ‘+ Application of a new sinter cooling system ‘Selective waste gas recirculation Sinter Raw Mix Preparation System with the Intensive Mixing & Granulation System The IMGS is characterized by the combination of a specially-designed intensive mixer (Figure 1) and a granulation drum, installed downstream of the intensive mixer, preferably just in front of the sinter machine feeding system. Figure 1: Intensive mixer With the application of the IMGS, mainly the following benefits can be achieved: * No pre-blending (blending yards) required (only bunker blending system) * Completely homogeneous sinter raw mix with high and even permeability + High sinter plant productivity (>40 tim? x 24 h) even when ores and additives with high ultra fine grain sizes are to be sintered ‘© High and stable sinter quality, resulting in high performance of the blast furnaces ‘© Low electric energy consumption even when the sinter machine is operated with a high bed height ‘+ Low solid fuel consumption due to even fuel distribution With the IMGS, 100% of the sinter raw materials are treated and it is already available for a sinter production of up to approximately 20,000 tiday. 1S°06 Unuvver, october 2006 ‘Agglomeration Session ~ Paper No. 2.1 Page 1 of 6 Sinter Raw Mix Charged to the Sinter Machine by the Newly Developed Twin- Layer Charging System ‘As modern sinter machines are operated with bed heights of up to 800 mm, the raw mix charging system is of utmost importance. To achieve the re- quired uniform segregation under consideration of the material grain size and coke content in the sinter machine bed, as well as to maintain a high degree of permeability, the new twin-layer charg- ing system is applied. With the twin-layer charging system the coarser sinter raw mix is first charged on top of the hearth layer as the “lower layer’, fol- lowed by the charging of the finer sinter raw mix granules as the “upper layer” (Figure 2). The coke Portion is automatically increased in the upper layer by segregation. The sinter raw mix in the lower layer is pre-dried with hot off-air from the sinter cooler. f, Uy : Twin-layer charging system Figure With the twin-layer charging system, the following benefits are achieved: igh plant productivities even when the sinter machine is operated with a bed height of up to 800 mm © Lows fuel consumption + High, uniform and stable sinter quality Wide-body Sinter Machine Pallet Cars (’Grate-Wings Pallet Cars") The new sinter machine pallet design featuring grate wings pallet cars was developed as a highly economical solution for application in new sinter plants as well as for increasing the capacity of existing sinter plants. The pallet car body forms the Upper extension of the wind boxes, allowing a very economical sizing and arrangement of the suction area (Figure 3). Furthermore, between the suction area and the pallet car side walls, gas-tight rim- zone covers with a width of up to approx. 300 mm, depending on the bed height of the sinter machine, are installed. Figure 3: Grate wings pallet car With the new generation of sinter machine pallet cars, mainly the following operating benefits can be achieved: + Decreased waste gas volumes, as the false air sucked in along the side walls of conventional sinter machines is extensively reduced = Increased yield ‘+ Improved productivity ‘+ Lower energy consumption + Improved sinter quality When applied to new sinter machines, the new de- sign has the advantage that the width of the sinter building and of the sinter-machine supporting structure can be kept comparatively narrower. For example, the sinter building width as well as the sinter-machine supporting structure for a new 80 @[S'0S UnwAustria, october 2006 ‘Agglomeration Session ~ Paper No, 2.1 /Page 2 of 6 sinter machine with a pallet width of 5 m can be the same as required for a conventionally designed sinter machine with a pallet width of 4 m. With the application of this new design, the investment costs can therefore be kept lower than in the conventional design. When existing sinter machines are upgraded with the new pallet car design, the width can be in- creased up to approximately 1 m. Therefore, a con- ventional sinter machine with a width of e.g. 4m can now be extended to approximately 5 m, re- sulting in a capacity increase of approximately 25% (Figure 4), Tew Pallet Wi i [Sriginat Panet wiath = 4 7 Distance of supporting structure remains unchanged! jinter machines Figure 4: Extension of existing New Sinter Cooler Design Combined With Cooler Off-air Recirculation and Energy Recovery The main features of the new sinter cooler design are: + For sinter cooling, a circular sinter cooler with a specially designed cooler trough is applied (Figure 5). The trough shape minimizes the false air by-passing the sinter cooling process along the side walls. + A specially designed sealing system which re- duces the loss of cooling air * Aspecial direct charging system that assures vertically segregated layers (coarse material po- sitioned in the lower section within the cooler trough), results in an additional improvement of the cooling efficiency. Figure 5: Grate wings cooler troughs For further reduction of the dust emissions, the hot cooler off-air is re-circulated to the sinter machine. Itis used for: ‘+ Pre-drying of the sinter raw mix charged as lower layer to the sinter machine '* Hot ignition air in the ignition system to reduce ignition gas consumption ‘+ Annealing air after ignition ‘A main part of the warm cooler off-air is re- Circulated to the sinter machine where it is mixed in the selective sinter waste gas recirculation system with the sinter waste gas re-circulated to the sinter machine. With the newly designed sinter cooler system, the following main advantages are achieved: * Higher cooling efficiency resulting in decreased specific cooling air volume and decreased electric energy consumption © Substantially decreased off-air volume resulting in minimized environmental loads + Lower investment and operation costs * The new design can also be applied to increase the capacity of existing sinter coolers. This means that the capacity of a conventional cir- cular sinter cooler with a trough width of e.g. 4 m can be increased by approximately 20%, without the need to increase the cooling air volume. © @1S ‘06 Linwihustria, ocober 2006 ‘Agglomeration Session ~ Paper No. 2.1 / Page 3 of 6