Development and Application of an Integrated Simulation Model for Iron Ore Sintering

Abstract

An integrated simulation model for sintering of iron ore was developed to evaluate the effect of various controlling factors on sinter quality and was applied to commercial sintering process. The model consists of 6 submodels, which are permeability, heat pattern, melting, pore, mineral and quality models. By using the informations on ore qualities, characteristics of sintering machine and operating conditions as input data, the model can predict sinter quality, energy consumption, productivity and other operation performance in sintering process. The predicted values were in good agreement with the observed ones obtained by both pot tests and actual tests in commercial plants. The model was introduced into sinter plants in Kashima Steel Works as operation guidance system. The fluctuation of sinter qualities was decreased by about 20% through the application of the model. The total energy cost on sintering operation was decreased by 5.5%. The economical feasibility studies were performed prior to the construction of a new sintering plant under the condition of the planned production capacity and sinter qualities. In accordance with the specification of productivity and sinter qualities required from blast furnace, new sinter feeds of iron ores were evaluated to obtain optimum operating conditions by the model.