Development of a 3-D Sinter Process Mathematical Simulation Model

Abstract

A 3 dimensional sinter process mathematical simulation model has been developed for the purpose to make it possible the designs of sinter process from the stereoscopic viewpoint. This sinter process model can calculate not only the progress of sintering reactions and the resultant changes in the bed structures such as pore ratio and minerals composition but also the qualities of produced sinter. Through a pot sintering test, this sinter process model was confirmed authentic and able to calculate also the distributions of sinters property such as minerals composition inside sinter cake. This sinter process model was used for the analysis of the effects of gas flow plate on the sintering performance.

Modeling Sintering Process of Iron Ore

“…Each of these components has its own particle diameter, porosity, shape factor and density. The overall heat transfer coefficient between the gas and solid phases is given by the Ranz-Marshall equation modified by Akiyama et al for moving beds and incorporated together with the interfacial area to give the overall heat transfer of solid to gas phase and vice-versa (Akiyama et al 1993, Castro et al 2000, Austin et al 1997, Castro et al 2002, Yamaoka et al 2005 ( ) ( ) ( ) ( ) …”

“…6 are calculated by solving eq. (7) for each phase, with the temperatures of each phase as incognita (Yamaoka et al 2005, Castro et al 2005, Nakano et al, 2010, Kamijo et al 2009 ( )…”

“…In the present work, a comprehensive mathematical model to describe the phenomena within the sinter strand is presented. The present model differs significantly from the former ones due to the concept of multiple and coupled phenomena treatment, three -dimensional treatment of the sinter strand and detailed mechanism of chemical reactions involved in the process (Castro et al 2005, Yamaoka et al 2005. The interphase interactions are considered via semi empirical sub-models for the momentum transfer, energy exchange due to chemical reactions, heat conduction, convection and radiation.…”

“…The mechanism of the oxidation and bonding phase formation in the sintering process conditions were studied by Yang et al (Yang et al 1997). Yamaoka and Kawaguchi (Yamaoka & Kawaguchi, 2005) discussed 3D variations on sinter properties produced on a pot apparatus experimental facility and presented a mathematical model based on transport phenomena to simulate the experimental conditions and draw some correlations to predict sinter properties based on model variables and measurements. However, there are few comprehensive mathematical models describing the sintering process in an industrial machine such as the usual Dwight-Lloyd process.…”

Summarized Achievements of the Porous Meso-mosaic Texture Sinter Research Project

“…16) Simulation designs and analytical studies based on mathematical models of this sort are important techniques not only for promoting the scientific clarification of sintering processes, but also for determining which design factors should be optimized, such as packing density, melting assimilation ratio, melt viscosity, and sinter cake structure. 17) We therefore prepared a liquid phase diagram of the Fe 2 O 3 -FeO-CaO-SiO 2 -MgO-Al 2 O 3 system which is essential for performing quantitative design studies, and we prepared parameters relating to the formation of pores and voids and to the melting assimilation behavior of limonitebased ores under low slag conditions. Furthermore, as the most important parameter for controlling the sintering reaction, we focused on the grain size and apparent density (porosity) of the granulated material, and with regard to the related granulation phenomena we performed a quantitative study of the physical properties of limonite and the specifications of granulation equipment.…”