Method of operating a sinter plant

Abstract

The invention concerns a method of operating a sinter plant, where a sinter mix is fired in a sintering machine, the method including crushing fired sinter to below an upper particle size limit; screening the crushed sinter to remove fines and separate at least two sinter size fractions, typically smaller, intermediate and upper size fractions; storing each of the at least two sinter size fractions in a respective, separate storage bin, where
the screened sinter fractions are not mixed again at the sinter plant but are forwarded to the blast furnace plant, where they are stored in respective, separate storage bins, and the screened sinter fractions can be intermediately stored in separate bins at the sinter plant, before being forwarded to the blast furnace.

Claims

1. A method of operating a blast furnace in a blast furnace plant comprising a blast furnace stock house, wherein said stock house includes storage bins for sinter, wherein said storage bins for sinter are fed with sinter forwarded from a sinter plant, said sinter being size-classified according to a method of operating the sinter plant, wherein a sinter mix is fired in a sintering machine, said method comprising the following steps: (a) crushing fired sinter to below an upper particle size limit in the range of 40 to 100 mm; (b) screening the crushed sinter to remove fines and separate at least two sinter size fractions; and (c) storing each of said at least two sinter size fractions in a respective, separate storage bin, wherein each size fraction has a predetermined particle size range that is distinct from the other sinter fractions without overlapping; wherein said blast furnace is charged according to a predetermined blast furnace charging sequence implementing sinter size classification; and wherein sinter from a desired size fraction, as withdrawn from the corresponding storage bin, is charged separately from other size fractions in the blast furnace, to form a material layer at a desired location.

2. The method according to claim 1, wherein step (b) further comprises separating an intermediate size fraction that is returned, at least in part, to the sintering machine as hearth layer, excess quantities of said intermediate size fraction being stored in a respective, separate storage bin.

3. The method according to claim 2, wherein said lower size fraction includes said intermediate size fraction and a smaller size fraction.

4. The method according to claim 3, wherein said upper size fraction includes sinter particles having a size in the range of about 20 to 50 mm; said intermediate size fraction includes sinter particles having a size in the range of about 10 to 20 mm; and said smaller fraction includes sinter particles having a size in the range of about 5 to 10 mm.

5. The method according to claim 1, wherein said upper and lower size fractions are directly stored after said screening step b).

6. The method according to claim 1, wherein at step b) crushed sinter is passed through screening units and step c) comprises collecting the screened sinter fractions to directly forward them to the storage bins.

7. The method according to claim 1, wherein said storage bins are part of a blast furnace stock house and the screened sinter fractions are directly forwarded to said storage bins.

8. The method according to claim 1, wherein said storage bins are part of the sinter plant and screened sinter fractions are intermediately stored therein before being forwarded to a blast furnace charging installation or blast furnace stockhouse storage bins.

9. The method according to claim 1, wherein removed fines have a particle size in the range of 2 to 8 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:

(2) FIG. 1: is a flowchart illustrating the delivery of crushed sinter in a prior art sinter plant;

(3) FIG. 2: is a flowchart illustrating an embodiment of the method according to the present disclosure.

DETAILED DESCRIPTION

(4) As explained in the background section and summarized in FIG. 1, different sinter size fractions are produced in the conventional sinter plant operation before being mixed again in order to form the final sinter product with a broad particle size distribution.

(5) The present disclosure takes advantage of these different sinter size fractions produced in the conventional sinter plant operation and use them as such in the blast furnace instead of using them in a single product mix. As a result a more flexible blast furnace operation and especially a reduced pressure loss in the blast furnace shaft can be achieved.

(6) An embodiment of the present method will now be described with reference to FIG. 2, where same or similar elements are designated by same reference signs. Sinter plant 18′ comprises a sinter stock house 16, a sinter mix preparation section (not shown) to prepare raw sinter nodules or granulates to be fired in the sinter machine 10, as is known in the art and briefly described above in the background art section.

(7) The nodules or granulates are fired (heat treated/hardened) in the sinter machine 10 and the obtained sinter cake is preferably typically broken down into smaller size by means of a sinter breaker and cooled down to a moderate temperature of e.g. 100° C. in a sinter cooler (not shown).

(8) The cooled product is then passed through a comminuting/crusher device 12, where the size of sinter is further reduced into smaller size, here below 50 mm. Crusher device 12 may be any appropriate comminuting or crushing machine, in particular a jaw crusher, toothed crusher or cone crusher. The crushed sinter is subjected to screening with high performance screens of e.g. 20 mm, 10 mm and 5 mm, respectively indicated 14a, 14b and 14c. By way of this screening system, the crushed sinter is technically separated into four size fractions: i. the 20 to 50 mm fraction, forming the larger class/fraction; ii. the 10 to 20 mm fraction: a part of this middle size fraction is recycled in the sinter machine as hearth layer; iii. the 5 to 10 mm fraction, here forming the smaller fraction; iv. the below 5 mm fraction: these fines are recycled to the raw material section (sinter stock house 16) of the sinter plant 18′.

(9) It shall be appreciated that in the present process, the different size fractions i), ii) and iii) are not re-mixed upon screening in the sinter plant to form a single sinter product, but each size fraction is stored individually in bins (hoppers or silos), e.g. at the blast furnace plant 20′. That is, one separated size fraction is stored in a dedicated bin. In other words, one bin contains only one of the separated size fractions, but there can be two or more bins containing the same size fraction.

(10) Reference signs 40, 42 and 44 designate such separate sinter hoppers provided to contain given size fractions of sinter as obtained from the screens 14a, 14b and 14c of the sinter plant 18′.

(11) It shall be noticed that the screening is carried out in such a way that the different sinter fractions (or size classes) are distinct from each other and do not overlap. Hence, the blast furnace plant comprises bins 40, 42 and 44 comprising different size sinter fraction, which will allow blast furnace charging strategies implementing sinter size classification.

(12) In the present embodiment, the three bins 40, 42 and 44 may be typically arranged in the blast furnace stock house, where: bin 40 contains the 5-10 mm sinter fraction; bin 42 contains the 10-20 mm sinter fraction; bin 44 contains the 20-50 mm sinter fraction.

(13) For example, the screened sinter fraction is directly forwarded from the screens 14a, 14b, and 14c to the respective bins 40, 42 and 44 via dedicated, respective conveyor arrangements 46a, 46b, 46c. Conventionally, a fines-screen can be arranged to remove fines particles, e.g. below 5 mm, when drawing the size-classified sinter from the respective bins 40, 42, 44.

(14) The availability of different size classes of sinter in separate bins at the blast furnace stock house allows charging size-classified sinter into the blast furnace. That is, layers of sinter from a desired size-class can be charged individually in the blast furnace, at desired locations in the furnace.

(15) Overall, charging size-classified sinter in the blast furnace will allow charging sinter of different particle size class (as discharged from the bins 40, 42 or 43) into different radial positions of the blast furnace and thereby adjust gas flow distribution.

(16) Some of the benefits of the present disclosure are summarized below. Increasing the void in the sinter fraction in the blast furnace (BF) allowing flexible utilization according to user situation, for example: Increase in BF productivity, Use of finer sinter fractions reducing the return fine rate, Allow reduced sinter quality in BF, with the possibility of using low cost sinter raw materials, Use of cheaper coke. Better control of radial segregation due to reduced grain size variation in each sinter fraction/class results in better process control of the BF, providing: increased BF process stability, reduced coke consumption and better cooling element protection.