Mathematical Simulation of Iron Ore Fines Sintering Process with Solid Fuel Segregation Distribution and Corresponding Heat Pattern Study

The fuel segregation distribution sintering process, with a high fuel dosage in upper layer and a low fuel dosage in bottom layer of the sintering bed, was studied to handle uneven heat distribution problems in the conventional iron ore sintering process. A mathematical simulation method was adopted to contrastively study the fuel segregation distribution sintering process and the conventional iron ore sintering process. The accuracy of the model was verified through the sintering experiments. In addition, different heights of the upper and bottom sintering beds were discussed to assess the fuel segregation distribution sintering technology. In contrast to the conventional iron ore sintering process, the temperature evolution in the sintering bed using the fuel segregation distribution sintering technology tended to be more reasonable and the heat accumulation in the upper bed increased, which meant that the melt quantity index increased from 2178 to 2387 K·min, and cooling rate decreased from 360 to 199 K·min−1. The drawbacks of the conventional iron ore sintering process, such as the heat shortage in upper bed and excess heat in lower bed, were therefore improved, which was also proven to promote the sinter quality.