Detailed Sintering Process Report
Bengal Energy Limited
Prepared by: Mital Prasad
B.P. Mandal College of Engineering, Madhepura
Training Duration: 02/06/2025 to 28/06/2025
1. Introduction to Sintering
Sintering is a thermal agglomeration process in which iron ore fines, along with fluxes and
coke breeze, are fused to form a porous mass called sinter. This is used in blast furnaces for
efficient and uniform charging.
Sintering is a thermal agglomeration process in which iron ore fines, along with fluxes and
coke breeze, are fused to form a porous mass called sinter. This is used in blast furnaces for
efficient and uniform charging.
Sintering is a thermal agglomeration process in which iron ore fines, along with fluxes and
coke breeze, are fused to form a porous mass called sinter. This is used in blast furnaces for
efficient and uniform charging.
2. Importance of Sintering in Steel Plants
Sintering enhances the metallurgical performance of the blast furnace by improving bed
permeability and ensuring a uniform chemical composition of feed materials. It also helps
recycle fines and reduce waste.
Sintering enhances the metallurgical performance of the blast furnace by improving bed
permeability and ensuring a uniform chemical composition of feed materials. It also helps
recycle fines and reduce waste.
Sintering enhances the metallurgical performance of the blast furnace by improving bed
permeability and ensuring a uniform chemical composition of feed materials. It also helps
recycle fines and reduce waste.
3. Raw Materials Used in Sintering
The key raw materials include iron ore fines, limestone, dolomite, coke breeze, and return
fines. Each plays a specific role in ensuring proper fusion and strength of the sintered mass.
The key raw materials include iron ore fines, limestone, dolomite, coke breeze, and return
fines. Each plays a specific role in ensuring proper fusion and strength of the sintered mass.
The key raw materials include iron ore fines, limestone, dolomite, coke breeze, and return
fines. Each plays a specific role in ensuring proper fusion and strength of the sintered mass.
4. Mixing and Granulation
Raw materials are mixed thoroughly with moisture and granulated to form coarse particles
for uniform sintering. This step significantly affects bed permeability and final sinter
quality.
Raw materials are mixed thoroughly with moisture and granulated to form coarse particles
for uniform sintering. This step significantly affects bed permeability and final sinter
quality.
Raw materials are mixed thoroughly with moisture and granulated to form coarse particles
for uniform sintering. This step significantly affects bed permeability and final sinter
quality.
5. Charging on the Sinter Strand
The granulated mix is charged onto a moving grate known as the sinter strand. The
thickness and distribution of the bed are critical for successful sintering.
The granulated mix is charged onto a moving grate known as the sinter strand. The
thickness and distribution of the bed are critical for successful sintering.
The granulated mix is charged onto a moving grate known as the sinter strand. The
thickness and distribution of the bed are critical for successful sintering.
6. Ignition and Air Suction
An ignition hood heats the surface of the charge using gas burners. Simultaneously,
powerful suction from below the strand draws air through the bed, supporting combustion
and heat transfer.
An ignition hood heats the surface of the charge using gas burners. Simultaneously,
powerful suction from below the strand draws air through the bed, supporting combustion
and heat transfer.
An ignition hood heats the surface of the charge using gas burners. Simultaneously,
powerful suction from below the strand draws air through the bed, supporting combustion
and heat transfer.
7. Combustion Zone and Sintering
The combustion front moves downward through the bed, where fusion of ore particles
occurs. A sintering zone temperature of 1200–1300°C is maintained.
The combustion front moves downward through the bed, where fusion of ore particles
occurs. A sintering zone temperature of 1200–1300°C is maintained.
The combustion front moves downward through the bed, where fusion of ore particles
occurs. A sintering zone temperature of 1200–1300°C is maintained.
8. Cooling of Sinter
The sintered cake is discharged from the end of the strand into a rotary or belt cooler. Rapid
cooling preserves the mechanical strength of sinter.
The sintered cake is discharged from the end of the strand into a rotary or belt cooler. Rapid
cooling preserves the mechanical strength of sinter.
The sintered cake is discharged from the end of the strand into a rotary or belt cooler. Rapid
cooling preserves the mechanical strength of sinter.
9. Crushing and Screening
After cooling, sinter is crushed and screened into required size fractions (usually 10-50
mm). Oversized or undersized particles are recycled back to the process.
After cooling, sinter is crushed and screened into required size fractions (usually 10-50
mm). Oversized or undersized particles are recycled back to the process.
After cooling, sinter is crushed and screened into required size fractions (usually 10-50
mm). Oversized or undersized particles are recycled back to the process.
10. Product Storage and Transportation
Sized sinter is stored in bunkers and then transported via conveyors or vehicles to the blast
furnace for ironmaking.
Sized sinter is stored in bunkers and then transported via conveyors or vehicles to the blast
furnace for ironmaking.
Sized sinter is stored in bunkers and then transported via conveyors or vehicles to the blast
furnace for ironmaking.
11. Process Control and Automation
Modern sinter plants use DCS/PLC-based automation systems to control parameters like
bed height, ignition temperature, suction pressure, and sinter return rate.
Modern sinter plants use DCS/PLC-based automation systems to control parameters like
bed height, ignition temperature, suction pressure, and sinter return rate.
Modern sinter plants use DCS/PLC-based automation systems to control parameters like
bed height, ignition temperature, suction pressure, and sinter return rate.
12. Environmental Management
Dust extraction systems, electrostatic precipitators, and scrubbers are used to minimize
emissions. Water treatment and solid waste recycling are practiced to ensure sustainability.
Dust extraction systems, electrostatic precipitators, and scrubbers are used to minimize
emissions. Water treatment and solid waste recycling are practiced to ensure sustainability.
Dust extraction systems, electrostatic precipitators, and scrubbers are used to minimize
emissions. Water treatment and solid waste recycling are practiced to ensure sustainability.
13. Energy Efficiency in Sintering
Optimized fuel usage, waste heat recovery, and use of alternative fuels contribute to
reducing energy consumption in the sintering process.
Optimized fuel usage, waste heat recovery, and use of alternative fuels contribute to
reducing energy consumption in the sintering process.
Optimized fuel usage, waste heat recovery, and use of alternative fuels contribute to
reducing energy consumption in the sintering process.
14. Safety Measures
Fire safety, temperature control, explosion prevention, and PPE usage are integral to the
safe operation of a sinter plant.
Fire safety, temperature control, explosion prevention, and PPE usage are integral to the
safe operation of a sinter plant.
Fire safety, temperature control, explosion prevention, and PPE usage are integral to the
safe operation of a sinter plant.
15. Maintenance Practices
Scheduled maintenance of sinter machines, strand pallets, ignition hoods, and coolers
ensures high availability and efficiency of the plant.
Scheduled maintenance of sinter machines, strand pallets, ignition hoods, and coolers
ensures high availability and efficiency of the plant.
Scheduled maintenance of sinter machines, strand pallets, ignition hoods, and coolers
ensures high availability and efficiency of the plant.
16. Common Operational Challenges
Operational issues include poor bed permeability, inadequate sinter strength, and high
return fines. Root cause analysis and process optimization are key to resolving them.
Operational issues include poor bed permeability, inadequate sinter strength, and high
return fines. Root cause analysis and process optimization are key to resolving them.
Operational issues include poor bed permeability, inadequate sinter strength, and high
return fines. Root cause analysis and process optimization are key to resolving them.
17. Role of Sintering in Blast Furnace Performance
High-quality sinter improves gas flow, reduces coke rate, and enhances hot metal
productivity in the blast furnace.
High-quality sinter improves gas flow, reduces coke rate, and enhances hot metal
productivity in the blast furnace.
High-quality sinter improves gas flow, reduces coke rate, and enhances hot metal
productivity in the blast furnace.
18. Quality Parameters of Sinter
Important quality parameters include TI (Tumbler Index), RI (Reduction Index), RDI
(Reduction Degradation Index), and basicity. Each affects downstream furnace efficiency.
Important quality parameters include TI (Tumbler Index), RI (Reduction Index), RDI
(Reduction Degradation Index), and basicity. Each affects downstream furnace efficiency.
Important quality parameters include TI (Tumbler Index), RI (Reduction Index), RDI
(Reduction Degradation Index), and basicity. Each affects downstream furnace efficiency.
19. Innovations and Trends
Technologies like selective granulation, use of biomass, and AI-driven sinter modeling are
revolutionizing the sintering process.
Technologies like selective granulation, use of biomass, and AI-driven sinter modeling are
revolutionizing the sintering process.
Technologies like selective granulation, use of biomass, and AI-driven sinter modeling are
revolutionizing the sintering process.
20. Conclusion
Sintering is a crucial process in integrated steelmaking. It provides cost-effective, energy-
efficient, and environmentally sustainable preparation of iron-bearing materials.
Sintering is a crucial process in integrated steelmaking. It provides cost-effective, energy-
efficient, and environmentally sustainable preparation of iron-bearing materials.
Sintering is a crucial process in integrated steelmaking. It provides cost-effective, energy-
efficient, and environmentally sustainable preparation of iron-bearing materials.
