The influence of H_2O(g) content in circulating flue gas on sintering was studied by simulating the flue gas circulating sintering.The results show that the burning speed of solid fuel and the heat transfer rate during sintering process are improved when the H_2O(g) content increases from 0 to 6%,which accelerates the sintering speed.However,when the H_2O(g) content exceeds 6%,the over-wet zone in sinter bed is thickened,which deteriorates the permeability of sintering bed.In addition,the magnetite content in sinter increases,while the acicular calcium ferrite content decreases.Accordingly,the sinter yield and tumble index decrease with excessive H_2O(g) content.To guarantee the yield and quality of sinter,the favourable H_2O(g) content in circulating flue gas should be controlled to be less than 6%.
Structure model of granules,boundary value of nucleus and powder,and the relationship between granulation efficiency and boundary value were investigated.Granules of sintering mixtures are composed of adhesive powder and nucleus.In the mixtures,particles larger than 1.00 mm act as nucleus and particles smaller than 0.25 mm act as adhesive powder.Particles with size between 0.25-1.00 mm can be adhesive powder as well as nucleus depending on the granulation conditions.When the boundary value is close to 0.25 mm,the granulation efficiency is lower than 50%.When the boundary value is close to 1.00 mm,the granulation efficiency is above 90%.The boundary value is influenced by the iron ore type,granulation moisture,fineness of raw materials and burnt-lime activity.Good adhesive capability,suitable moisture content,appropriate particle size distribution and high burnt-lime activity make the boundary value move towards 1.00 mm and improve the granulation efficiency.
Li-shun YUANXiao-hui FANMin GANGui-ming YANGYi WANG
Circulating flue gas can reduce the emission of flue gas , and furthermore , it can reuse the waste heat effectively in the sintering process.Compared with conventional sintering , O2 that gets through the sintering bed decreases because of substituting circulating gas for air.The influences of O2 content on sintering process are studied through simulating the flue gas circulation sintering with artificial gas.It shows that , with the reducing of O2 content in circulating gas , the combustion speed of fuel decreases and incomplete combustion degree increases , which makes the flame front fall behind the heat front and reduces the heat utilization efficiency of fuel.The ultimate result is that the temperature of sintering bed decreases and the liquid phase reduces.In addition , the reducing atmosphere is strengthened because of flue gas circulation , which makes the magnetite increase yet calcium ferrite reduce gradually. Because the content of calcium ferrite with good strength reduces , the sinter yield and tumble strength decrease.To ensure the sinter index , the favorable O2 content of circulating flue gas is no less than 15%.
Grate-kiln-cooler has become a major process of producing iron ore pellets in China. Due to the diversity of the raw materials used and the multi-device multi-variable characteristics,this process still encounters with control problem. An attempt was proposed to deal with this issue. The three-device-integrated feature of the process was firstly analyzed to obtain control strategy,and then an intelligent control system using a combination of expert system approach and Takagi-Sugeno( T-S) fuzzy model was developed. Expert system approach was used to diagnose and remedy the abnormal conditions,while T-S fuzzy model was used to stabilize the thermal state. In the construction of T-S fuzzy rules,antecedents were identified by fuzzy c-mean clustering algorithm incorporated with subtractive clustering algorithm,and consequent parameters were identified by recursive least square algorithm. The control system was applied in a Chinese pelletizing plant and the application results demonstrated its effectiveness of stabilizing the thermal states within three devices.
Gui-ming YANGXiao-hui FANXu-ling CHENXiao-xian HUANGZong-ping LI
It is of great significance for cleaner production to substitute bio-energy for fossil fuels in iron ore sintering. However, with the replacement ratio increasing, the consistency of heat front and flame front is broken, and the thermal utilizing efficiency of fuel is reduced, which results in the decrease of yield and tumble index of sinter. Circulating flue gas to sintering bed as biochar replacing 40% coke, CO in flue gas can be reused so as to increase the thermal utilizing efficiency of fuels, and the consistency of two fronts is recovered for the circulating flue gas containing certain CO2, H2 O and lower O2, which contributes to increasing the maximum temperature, extending the high temperature duration time of sintering bed, and results in improving the output and quality of sinter. In the condition of circulating 40% flue gas, the sintering with biomass fuels is strengthened, and the sintering indexes with biomass fuel replacing 40% coke breeze are comparative to those of using coke breeze completely.
Cooling process of iron ore pellets in a circular cooler has great impacts on the pellet quality and systematic energy exploitation. However, multi-variables and non-visualization of this gray system is unfavorable to efficient production. Thus, the cooling process of iron ore pellets was optimized using mathematical model and data mining techniques. A mathematical model was established and validated by steady-state production data, and the results show that the calculated values coincide very well with the measured values. Based on the proposed model, effects of important process parameters on gas-pellet temperature profiles within the circular cooler were analyzed to better understand the entire cooling process. Two data mining techniques—Association Rules Induction and Clustering were also applied on the steady-state production data to obtain expertise operating rules and optimized targets. Finally, an optimized control strategy for the circular cooler was proposed and an operation guidance system was developed. The system could realize the visualization of thermal process at steady state and provide operation guidance to optimize the circular cooler.
Gui-ming YANGXiao-hui FANXu-ling CHENXiao-xian HUANGXi LI
The properties of circulating gas have a significant effect on sintering with flue gas recirculation,and the influence of CO in sintering process was investigated.The results show that the post-combustion of CO conducts in sinter zone when flue gas passes through the sintering bed,which releases much heat and reduces the consumption of solid fuel.The ratio of coke breeze can be reduced from 5% to 4.7% with 2% CO in circulating flue gas.In addition,with the increase of CO content in circulating flue gas,the combustion efficiency of fuel is improved,and the flame front is increased slightly while still matches with the heat transfer front.These are beneficial to increasing the maximum temperature and prolonging the high temperature duration,especially in the upper layer of sintering bed.As a consequence,the productivity,vertical sintering velocity and quality of sinter are improved.
The effect of biochar substituted for anthracite as reductant on magnetizing-roasting pyrite cinder was investigated.The key of magnetizing-roasting is the gasification reaction between reductants and CO2.Since biochar could react with CO2 more rapidly at lower temperature,the reactivity of biochar is better than that of anthracite.The gasification of biochar could produce reducing condition ofφCO/(φCO+φCO2)about 10%-20% between 700-800 ℃,which is in accord with the atmosphere and temperature of Fe2O3 reduction.So it is beneficial to the reduction of iron mineral of pyrite cinder.Compared with anthracite,biochar could decrease the roasting temperature from825 to 750 ℃ and roasting time from 20 to 15min,which shows that a better effect of magnetization could be obtained in the condition of lower temperature and shorter time.Using biochar as reductant,iron concentrate extracted from pyrite cinder as about 64%iron grade could be produced,and the recovery is over 90% under the condition of above 90% grinding particle less than 0.045 mm and magnetic intensity of 0.124-0.194 T.
