Study on Effect of Material Layer Thickness on Pollutant Emissions

from Sintered Flue Gas

Chen Zhang

, Yutao Cui

, Yun Shu

, Li Yang

and Jinwei Zhu

Chinese Research Academy of Environmental Sciences, Beijing 100012, China

Keywords: Sintered, Flue Gas, Emission, Material Layer.

Abstract: Herein, a 210-m

sintering machine was tested under different material layer thickness conditions to

investigate the effect of the thick layer sintering technology on the emissions of flue gas pollutants from the

sintering machine. The relationship between the material layer thickness and pollutant emission

concentration, sinter output and drum index was studied using a flue gas analyser (MH3200). The results

show that the discharge of gaseous pollutants has a positive linear correlation with the material layer

thickness during the sintering process of SO

, NO and CO. Furthermore, the emission of pollutants per

tonne of product decreases as the layer thickness increases. When the thickness of the material is increased

from 550 to 650 mm, the emissions of SO

, NO and CO per tonne of the sintered ore can be reduced by

0.22, 0.07 and 1.7 kg/t, respectively.

1 INTRODUCTION

As a major steel country, China’s steel industry

output has ranked first in the world for many years.

According to statistics from the China Iron and Steel

Association, China’s steel output exceeded 900

million tonnes in 2018, accounting for 50% of the

world’s steel output. The iron and steel industry is

an industry with high energy consumption and high

pollution. Besides, environmental pollution has

received much attention. With the continuous

deepening of pollution control work requirements in

China’s iron and steel industry, the industry has

shifted from the traditional mode of re-production

and high-efficiency to the direction of production

and environmental protection. However, the steel

industry has become the largest source of gaseous

pollutants due to several companies, the large

amount of pollutant emissions and the uneven level

of corporate management and environmental

protection. In 2017, sulphur dioxide (SO

), nitrogen

oxide (NOx) and particulate matter (PM) emissions

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from the iron and steel industry accounted for 7%,

10% and 20% of the total national emissions (Li

2018, Yan 2015, Yu 2017). For this reason, in 2019

the ‘Opinions on Promoting the Implementation of

Ultra-Low Emissions in the Iron and Steel Industry’

jointly issued by the Ministry of Ecology and

Environment and other five ministries and

commissions included access to new reconstruction

and expansion projects of iron and steel enterprises,

the promotion of ultra-low emission transformation,

the elimination of outdated production capacity and

the strengthening of pollution emission monitoring

and monitoring new corresponding requirements put

forward in other aspects.

The iron and steel industry mainly adopts the

conventional blast furnace converter technology in

China. The sintering process, which is an important

link in steel production and also the main process for

emitting gaseous pollutants in iron and steel

enterprises (Liao 2018, Wang 2013, Zhu 2014),

provides more than 70% of the charge to the blast

furnace. Sintering flue gas has the characteristics of

large flue gas volume and high pollutant

concentration. According to relevant literature

reports, the emission of SO

, NOx and PM in the

sintering process can account for ~60%, 50% and

20% of the total emissions of iron and steel

enterprises (Wang 2017, Chen 2015, Taira 2019).

Among them, SO

in the flue gas of the sintering

448

Zhang, C., Cui, Y., Shu, Y., Yang, L. and Zhu, J.

Study on Effect of Material Layer Thickness on Pollutant Emissions from Sintered Flue Gas.

DOI: 10.5220/0011215600003443

In Proceedings of the 4th International Conference on Biomedical Engineering and Bioinformatics (ICBEB 2022), pages 448-454

ISBN: 978-989-758-595-1

machine mainly comes from the sulphides (such as

FeS

and CuFeS

) and sulphates (such as BaSO

and

CaSO

) in the iron ore, and partly comes from the

elemental and organic sulphur in the fuel. Note that

the elemental sulphur is the main component.

Sulphide reacts with organic sulphur and oxygen to

generate SO

, which is released after sulphate

decomposition. The NO

from the combustion

process is mainly divided into three types: thermal,

fuel and fast types. (1) Thermal-type nitrogen oxides

are generated by the reaction of N

and O

in air

during combustion. (2) Fuel-type nitrogen oxides are

generated by the oxidation of N in the fuel during

combustion. (3) Rapid nitrogen oxides are produced

by the reaction of N

in air with hydrocarbon groups

in the fuel to generate HCN, CN and other NO

precursors, which are then further oxidised. During

sintering, the combustion temperature is <1500°C,

and the thermal NO

is minute. Therefore, the NO

in the flue gas of the sintering machine mainly

comes from the combustion process of solid fuel,

that is, fuel-based NO

, usually >90% of NO

. CO

generation mainly comes from the incomplete

combustion of solid fuels in the sintering process,

mainly in the combustion zone and the preheating

drying zone. Also, the reaction of C with CO

and

Fe will also generate CO (Liu 2013, Williams 2012,

Li 2014).

Presently, treatment technology for sintering

machine flue gas is mainly divided into three

categories: raw material control, sintering process

control and end flue gas treatment technology (Chun

2017, Xing 2014). The end treatment technology

mainly adopts the FGD + SCR denitrification

technology. Among them, the desulphurisation

technology mainly applies to wet desulphurisation

and semi-dry desulphurisation. A few companies

adopt the activated carbon adsorption-integrated flue

gas purification technology. These treatment

technologies can effectively control the SO

and

emission in the flue gas. However, with the

implementation of ultra-low emission standards in

the steel industry, the ultra-low emission of sintering

flue gas through the upgrading and transformation of

desulphurisation and denitrification facilities will

significantly increase the production of enterprises.

Operating costs are not conducive to the long-term

development of enterprises (Long 2016, Wang 2020,

Cheng 2019). Faced with dual pressures of

production and environmental protection, several

new sintering technologies for energy saving and

emission reduction have emerged, such as thick

material layer sintering technology, combustible gas

auxiliary combustion technology, fuel distribution

technology, material surface steam injection

technology and low-temperature sintering

technology, Hot air circulation sintering technology

has been widely used in the actual production

(Huang 2019, Zhang 2019, Fan 2014, Lu 2015).

Herein, the influence of the material layer thickness

changes on the emission of pollutants is studied

using the actual flue gas. The current research in this

direction is mainly focused on the impact of the

material layer thickness on the production cost of the

sintering machine and the improvement of the

quality of the sintered ore. However, few studies

exist on the gaseous pollutant emission of the

sintering machine, and the research is mainly limited

to the sinter cup test—actual on-site monitoring. To

deeply analyse the influence of the material layer

thickness on the air pollutant emission from the

sintering machine, a sintering machine with a scale

of 210 m

of a certain enterprise was selected as the

experimental platform, and the NO, SO

, CO and

other pollution in the airbox and sintering flue of the

sintering machine. The changes in the concentration

of the substances and O

before and after the

changes in the material layer thickness are

monitored and analysed to clarify the changing law

of gaseous pollutant emissions from the sintering

machine under different material layer thicknesses

and provide data support for the subsequent

environmental protection of the flue gas of sintering

machines.

2 MATERIALS AND METHODS

2.1 Sintering Machine Parameters

Herein, a 210-m

sintering machine was selected as

the research object for industrial testing. The

composition analysis of 22 wind boxes and sintering

flue gas on one side of the sintering machine was

performed. Figure 1 shows the monitoring points.

By changing the material layer thickness of the

sintering machine (550 mm × 600 mm × 650 mm),

the pollutant emission was analysed. Table 1

presents the main chemical components of the

sintering raw materials.

Study on Effect of Material Layer Thickness on Pollutant Emissions from Sintered Flue Gas

449

Table 1: Chemical composition of main raw materials.

Raw material TFe SiO

CaO Al

MgO H

Iron sheet 71.00 0.80 - 0.00 - 8.00

Dolomite powder - 2.50 30.00 - 20.00 3.00

Limestone powder 0.00 3.00 47.00 0.00 4.50 3.00

Miscellaneous 50.00 6.60 12.80 2.60 2.80 6.00

Mixed return mine 54.60 5.40 10.60 2.60 2.80 2.00

Steel slag 35.00 12.00 35.00 - 9.93 6.00

Coke breeze 0.00 40.00 7.00 1.60 - 10.00

Figure 1: Schematic of monitoring locations.

2.2 Detection Equipment and Methods

Qingdao Minghua Electronic Instrument Co., Ltd.

MH3200 ultraviolet differential method flue gas

analyser was was used. It adopts ultraviolet

differential absorption spectroscopy measurement.

The principle is thermal wet method, the whole

process of the gas chamber-heating design, the flue

gas is extracted from the flue after several grades of

filtration, enter the optical detection gas chamber,

the entire gas path is heated at high temperature, and

the water vapour is completely vaporised, avoiding

the interference of moisture on the gas adsorption.

3 RESULTS & DISCUSSION

3.1 Regular Distribution of Pollutants

in Wind Boxes

The material layer thickness of the sintering machine

as 600-mm (daily conditions) is selected as the

reference-working condition. Next, the distribution

law of the air box pollutants is analysed. Using the

same monitoring programme, under the premise of

maintaining a constant raw material ratio, the wind

box and sintering flue gas under the working

conditions of 550 and 650 mm material layer

thickness were detected. Figure 2 shows the change

in the wind box.

0 5 10 15 20 25

200

400

600

800

1000

1200

1400

Wind boxes number

/NO

(

mg/m

)

5000

10000

15000

20000

25000

(

mg/m

)

Figure 2: Distribution of smoke components in wind boxes.

3.1.1 SO

Emission Regular Analysis

Figure 2 shows that SO

emissions can be divided

into three distinct characteristic intervals during the

entire sintering process. The first interval is before

the 9

wind box, and the SO

emission concentration

in each wind box is low, all below 35 mg/m

. The

second interval started from the 10

wind box; the

emission concentration increased obviously,

after nine wind boxes, it culminated at the 18

wind

box position 1335 mg/m

). Afterwards, there comes

the third interval, where the SO

emission

concentration decreased rapidly. After passing

through four wind boxes, the concentration

decreased to 100 mg/m

. This trend can be ascribed

to the fact that SO

is mainly generated in the

combustion and dry preheating zones (Figure 3

shows the schematic of the change in the sintered

material layer), and its formation mechanism is the

oxidation reaction of sulphide, elemental sulphur

and sulphate. After preheating and decomposition,

will be absorbed again, forming sulphate and

sulphide due to the joint action of alkaline flux and

moisture when passing through the over-humid zone

as the flue gas moves from top to bottom. During

sintering, the over-humidity zone gradually

disappears, and SO

is released into the flue gas

again. When the combustion zone disappears, the

emission concentration decreases rapidly, thus

forming this emission characteristic. The results are

ICBEB 2022 - The International Conference on Biomedical Engineering and Bioinformatics

450

consistent with those of previous studies (Wang

2019, Fan 2019).

Figure 3: Schematic diagram of material layer changes.

3.1.2 NO Emission Regular Analysis

The emission concentration of NO

in each wind

box was <5 mg/m

, so the emission characteristics of

and NO were consistent. Thus, the emission

characteristics of NO needed to be analysed only.

Figure 2 shows that NO emissions have three

distinct characteristic intervals. The first interval is

before the 4

wind box, and the NO emission

concentration is below 40 mg/m

. Afterwards, the

second interval starts from the 4

wind box. The

concentration increased significantly and culminated

at 219.8 mg/m

in the 9

bellows, and the third

interval comes afterwards, and the NO concentration

decreased slowly. On reaching the 22

bellows, its

emission concentration was close to 10 mg/m

. This

emission law is caused because NO produced during

the sintering process is basically the fuel-type NO,

and the concentration depends on the combustion

state. At the beginning of sintering, the combustion

zone is small, so the NO emission concentration is

low. As the sintering progresses, the combustion

zone gradually stabilises, and NO emission

concentration tends to stabilise after increasing.

Towards the end of the sintering process, the

combustion zone gradually decreases, and the NO

emission concentration gradually decreases (Min

2016, Zhou 2016).

3.1.3 CO Emission Regular Analysis

Figure 2 shows that the first characteristic interval of

CO emissions occurs before the 5

wind box. At this

stage, the CO concentration in the flue gas rapidly

increases above 20000 mg/m

. The second

characteristic interval occurs from the 5

–11

box.

In this interval, the CO concentration is above 20000

mg/m

, and the concentration of the 9

bellows is

the highest at 25600 mg/m

. Afterwards, there

comes the third characteristic interval. Starting from

the 12

bellows, the CO concentration decreases

rapidly, and when it reaches the 22

bellows, the

concentration becomes as low as 1500 mg/m

less. This trend occurs because CO is mainly formed

by the incomplete combustion of solid fuels.

Therefore, the CO concentration increases rapidly

after ignition. When the combustion zone is stable,

the CO emission concentration is relatively stable.

The CO emission concentration decreases

considerably when the sintering process approaches

the endpoint (Pei 2019, Wang 2019, Zhu 2006). The

CO emission trend is similar to that of NO, which

comprises the characteristic rapid increment in the

concentration of the head of the sintering machine,

the stable concentration of the middle section, and

the rapid decrease in the concentration of the tail of

the sintering machine.

3.1.4 Response Relationship Analysis

between Material Layer Thickness and

Pollutant Discharge Concentration

0 5 10 15 20 25

100

150

200

250

300

NO emission concentration (mg/m

)

Wind boxes number

550mm

600mm

650mm

(b)

0 5 10 15 20 25

5000

10000

15000

20000

25000

30000

35000

CO emission concentration(mg/m

)

Wind boxes number

550mm

600mm

650mm

(c)

Figure 4: Comparison of air box pollutant concentration

under different material thicknesses.

Figure 4 (a)–(c) compare the concentration of SO

NO and CO of each wind box under different

material layer thicknesses. As the thickness of the

Study on Effect of Material Layer Thickness on Pollutant Emissions from Sintered Flue Gas

451

sintering material layer increases, the pollution

distribution curve significantly shifts to the right.

This trend occurs because the material layer

thickness increases as the air resistance increases.

When the wind speed and air volume passing

through the material layer decrease, the vertical

sintering speed also decreases. In Figure 4, the

concentrations of SO

, NO and CO increase as the

material layer thickness increases, which is mainly

caused by the following two reasons. First, as the

material layer thickness increases, the air resistance

increases, and the flow rate of the flue gas in the

sintering flue decreases. Second, the main sources of

, NO and CO are related to fuel combustion, and

the increase in raw materials and fuel will inevitably

increase the total amount of pollutants produced.

Under the combined action of the two, the increase

in the material layer thickness leads to a rise in the

pollutant emission concentration.

Table 2: Emission concentrations of sintered flue gas of different layer thicknesses.

Material layer thickness (mm) Test points SO

(mg/m

)

NO (mg/m

) CO (mg/m

) O

(%)

Average

flow rate

/h)

550

Sintering flue

414.6 107.1 9156.2 17.0 1043965

600 421.9 107.6 9408.8 17.0 1082944

650 441.4 109.1 10660.8 17.6 1074708

Table 2 compares the emission concentrations of

pollutants in the flue gas of the sintering flue with

different material layer thicknesses. The

concentration of NO and SO

of the sintering

machine is similar under different material layer

thicknesses. As the material layer thickness

increases, the CO emission concentration is slightly

>the other two cases when the material layer

thickness is 650 mm. This trend occurs because CO

generation is closely related to the incomplete

combustion of the fuel. Table 2 shows that the

standard flow rate of the flue gas is inversely

proportional to the material layer thickness. Under

the condition of the material layer thickness of 650

mm, the sintering machine experiences a higher

resistance of the material layer, the oxygen

participating in the reaction is reduced, and the

incomplete combustion of the fuel is aggravated, so

CO is sintering. The concentration in the flue gas of

the large flue increases significantly. From Table 2,

it can be calculated that with a material layer

thickness of 550 mm, the SO

, NO and CO emission

rates are respectively 432.8, 111.8 and 9558.8 kg/h,

respectively. With the material layer thickness as

600 mm, the SO

, NO and CO emission rates are

456.9, 116.5 and 10189.2 kg/h, respectively. Finally,

with the material layer thickness as 650 mm, the

, NO and CO emission rates are 474.4, 117.3 and

11457.3 kg/h. Figure 5(a)–(c) are the linear

relationship diagrams of SO

, NO and CO emissions

versus the material layer thickness, respectively. The

material layer thickness positively affects the

emission of the main pollutants of the flue

gas—linear correlation.

540 560 580 600 620 640 660

430

440

450

460

470

480

emission amount (kg/h)

Material thickness

（）

(a)

y=0.415x+205.410

=0.9917

Linear Fit of SO

540 560 580 600 620 640 660

111

112

113

114

115

116

117

118

NO emission amount (kg/h)

（）

Material thickness mm

(b)

y=0.054x+82.513

=0.8480

Linear Fit of NO

540 560 580 600 620 640 660

9500

10000

10500

11000

11500

CO emission amount (kg/h)

（）

Material thickness mm

(c)

y=18.985x-989.234

=0.9637

Linear Fit of CO

Figure 5: Linear relationship between pollutant emissions

and layer thickness.

ICBEB 2022 - The International Conference on Biomedical Engineering and Bioinformatics

452

3.1.5 Effect of Material Layer Thickness on

Pollutant Discharge

Table 3 shows the relevant parameters of sintering

machine products under different material layer

thickness conditions. As the material layer thickness

continuously increases, the sinter output and

utilisation factor of the sintering machine are

significantly improved. This trend occurs due to the

increment in the total batching amount after the

material layer thickness is increased. The drum index

has a small increase, which may be related to the

enhancement of the heat storage effect of the

sintering machine after the material layer thickness

of the sintering machine increases. Figure 5 shows

that as the material layer thickness increases, the

emissions of various pollutants also increase.

However, after converting the concentration of each

pollutant to the emissions per tonne of the sintered

ore, the thickness of the sintered material layer

increases, and the amount of SO

emissions

decreases from 1.79-kg/t to 1.57-kg/t-sintered ore.

Meanwhile, NO emissions decrease from 0.46-kg/t

to 0.39-kg/t-sintered ore, and CO emissions decrease

from 39.6-kg/t to 37.9-kg/t-sintered ore. As the

thickness of the sintered material layer increases, the

concentration of pollutants in the sintering flue gas

changes slightly. However, the emissions per tonne

values of the products are significantly reduced,

indicating that increasing the thickness of the

sintered material positively affects the sintered

material significantly, and the promotion effect also

positively affects the emission reduction of the

sintering flue gas pollutants (Qie 2019).

Table 3: Production of sintering machines with different layer thicknesses.

Material layer thickness (mm) Output per unit (t/h) Drum index (%)

Utilisation facto

(t/m

·h)

550 241.5 76.99 1.15

600 268.8 77.23 1.28

650 302.4 77.66 1.44

4 CONCLUSIONS

(1) The emission of SO

in the air box is low in the

middle and later stages of the sintering process, and

an obvious peak occurs in the middle and later

stages of sintering. Consequently, as the

over-humidity zone disappears, SO

is precipitated

again, and the emission increases rapidly. When the

combustion zone gradually disappears, the emission

concentration of SO

decreases rapidly.

(2) The CO emission characteristics are similar

to those of NO, in that the concentration of the

sintering machine head increases rapidly, the

emission concentration of the middle sintering stage

is stable, and the emission concentration of the

sintering machine tail decreases rapidly. Both are

directly related to the change in the combustion zone

during the fuel combustion process of the sintering

machine. As the initial combustion zone thickens

and its emission concentration increases rapidly, the

mid-term combustion zone tends to stabilise, and its

emission concentration is relatively stable. The later

combustion zone shrinks until it disappears, its

emission concentration decreases rapidly.

(3) SO

, NO and CO in the sintering flue gas

have a positive linear correlation with the material

layer thickness. The higher the material layer

thickness and the larger the batching amount, the

higher the emissions of pollutants in the sintering

flue gas. Comparing the production status of the

sintering machine under three material layer

thicknesses showed that the sintering machine has a

high utilisation factor and a large product output

under the high material layer thickness. The sinter

drum index is slightly increased, and the SO

, NO

and CO emissions can be reduced by 0.22-kg/t,

0.07-kg/t and 1.7-kg/t-sintered ore, which indicates

that the thick material layer sintering is more

conducive to improving the output and quality of

sintering, and has a positive effect on pollutant

emission reduction.

ACKNOWLEDGEMENTS

The present work is supported by the National Key

Research and Development Program of China

(No.2018YFC0213402), Major Science and

Technology Project of Inner Mongolia Autonomous

Region (No.2020ZD0013) and the Beijing

Municipal Commission of Science and Technology

(grant D171100007917001).

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453

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