DEM-Based Optimization of Horizontal Segregation in Sintering Charging and proposal of a Novel Spreading Strategy

Abstract

Horizontal segregation of sinter mixture caused by charging is one of the factors limiting the development of Super-high bed sintering. To improve charging process and reduce the horizontal segregation of mixture, the shuttle feeder and bin charging system of a 360 m² sintering machine was simulated using the discrete element method. The operational parameters of the shuttle feeder, including limit positions, dwell time, and conveying speed, were systematically optimized. The results show that after parameter optimization, the mixture flatness index decreased from 526.88 to 481.85, and the horizontal segregation index decreased from 4.08 to 3.69, representing reductions of 8.55% and 9.56%, respectively. However, significant horizontal segregation still remained. A subsequent theoretical analysis indicated that the effectiveness of shuttle charging in mitigating horizontal segregation is subject to an inherent limitation. In light of this limitation, a novel charging method, referred to as spreader plate charging, was proposed. According to the simulation results, the spreader plate charging achieved a mixture flatness index of 54.01 and a horizontal segregation index of 0.89, which were reduced by 88.79% and 75.9%, respectively, in comparison with the parameter-optimized shuttle charging. These results demonstrate a substantially enhanced horizontal uniformity of the sintering feed.