This paper specifies the mathematical and physical modelling of the iron sintering process in laboratory conditions. The aim is to get the simplest approach (using thermodynamic software “HSC Chemistry”, version 9, Outokumpu Research Oy, Pori, Finland) that allows one to predict the output parameters based on the initial composition analysis. As a part of the application of mathematical modelling, a mass and thermal balance of combustion of carbonaceous fuels (including biomass) and a mass and thermal balance of high-temperature sintering of an agglomeration charge were determined. The objective of the paper was to point out the advantages of modelling using thermodynamic software and apply the results into a simulation of the sintering process. The outcome of mathematical modelling correlates to the outcome of physical modelling for fuel combustion and the agglomerate production in a laboratory sintering pan. The energy required to reach the desired sintering temperatures and acquire the standard quality of agglomerate was calculated using 4.97% of coke breeze. In a real experiment with the laboratory sintering pan, 4.35% of coke was used. When a biomass fuel with a lower calorific value (lignin) is used in the agglomeration charge, the amount of fuel has to be increased to 5.52% (with 20% substitution of coke). This paper also aimed at predicting methodological tools and defining thermodynamic conditions for creating an interactive simulation. In addition, kinetics should be considered to improve the predicting capabilities of the current model and therefore in further research it will be required to optimise the computational program pursuant to the results of the kinetics experiments.

The work is focused on studying the influence of the ratio of concentrate to iron ore on the phase composition of the iron ore agglomerate. The concentrate has significantly higher iron content than used iron ore, and is a determining factor, which influences the richness of the batch and consequently, the richness of the agglomerate. The increased iron content in the agglomerate can be achieved by adjusting the raw material ratio in which iron ore materials are added to the agglomeration mixture. If the ratio is in favor of iron ore this reflects in lower iron content in the resulting agglomeration mixture. If the ratio is in favor of a concentrate, which is finer, the fraction share of less than 0.5 mm will be increased, the permeability of the batch will be reduced, the performance of the sintering belt will decrease and the presence of solid pollutants will increase. The possibility of concentrate replacement by iron-rich iron ore with granulometry similar to that of concentrate was experimentally verified. The effect of the concentrate replacement by the finer iron-rich ore was tested in a laboratory sintering pan. There were performed six sinterings, with gradually changing ratio concentrate/iron ore (C/O). The change in the ratio of concentrate to iron ore, does not cause the occurrence of new phases, only the change in their prevalence, which does not bring a significant change of the qualitative indicators of the compared agglomerates. Concentrate replacement by iron ore up to 50% was optimal from technological, quality, and environmental aspects.

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Coke breeze is a special type of fossil fuel that significantly contributes to environmental pollution. Therefore, ways and opportunities to reduce its negative impact on climate change are being sought. Alternative fuels constitute one of the opportunities where biomass can play an important role. Biomass represents a new fuel for the sintering process and an attractive way to decrease CO2 emissions. Today, biomass is not considered for complete substitution of coke. Opportunities for its partial substitution are instead being sought. Each type of fuel is characterized by different properties and thus also by an appropriate scope of its substitution in an agglomeration mixture. This study covers the available options and the potential impact of this substitution on the structural and mineralogical composition of the agglomerate. These experiments were carried out by substituting coke breeze with biomass (hydrolyzed lignin). To perform the experimental sintering, a sintering apparatus—laboratory sintering pan (LSP)—was used, which was fully equipped with measuring devices and analyzers. The samples of agglomerates prepared by substituting 0%, 20%, 50% and 86% of coke breeze with biomass (hydrolyzed lignin) in dried form were analyzed by chemical and microscopic analysis-The representation of individual minerals in agglomerates was determined by powder X-ray diffraction analysis. Based on the results of the study regarding the impact of partial coke substitution with biomass on the mineralogical composition of the agglomerate, it can be stated that it is possible to substitute about 50% of coke with lignin in the sintering process. When lignin was used to substitute up to 50% of coke, agglomerates with minimal variations in the chemical and mineralogical composition were produced.

The use of lignin can be one of the methods of coke powder substitution in the agglomeration process. This article specifies the material research of lignin and the technological and ecological parameters of the agglomeration process in laboratory conditions using biomass lignin. The methodology of the Raman and infrared spectroscopy, representing a new approach in the analysis and assessment for the purposes of material characteristics for the agglomeration process, was applied to study the structure of carbonaceous matter. The material research of lignin has determined that its calorific value corresponds to ca. 80% of the calorific value of coke powder, while its reactivity is higher than that of the coke. Although the substitution of coke powder using different types of waste biomass (e.g., wood sawdust) in the production of the agglomerate is limited to the maximum of 8–15%, in case of lignin, more than 20% can be substituted, while the standard properties of the produced agglomerate are maintained. The lower emissions of sulfur and nitrogen oxides as well as the reduction of carbon footprint in the agglomeration process as a result of the so-called zero CO2 balance in the formation and processing of the biomass represent its positive aspects. Based on the laboratory research of lignin, up to a 50% substitution of coke powder with this type of biomass can be predicted for the technology of agglomerate production in real operation.