CFD Modelling Of The Steel Belt Sintering Process

The Outokumpu Steel Belt Sintering (SBS) Technology is used for manufacturing chromite pellets that are charged into a smelting furnace for ferrochromium production. One of the main elements in successful furnace operation is the control of gas flows inside the furnace, giving improved temperature distribution in the bed during the process. Computational Fluid Dynamics (CFD) gives excellent opportunities for studying these phenomena. An investigation using CFD can be performed relatively fast. For example, implications of different configurations can be studied within a day and an optimum design chosen. Therefore, Outokumpu Technology has developed a Steel Belt Sintering Model (SBSM), which takes advantage of a commercial CFD code. Each main physicochemical event occurring in a steel belt sintering furnace is incorporated independently in the SBS model as a sub-model, enabling every event to be studied separately. The commercial CFD code solves mass, momentum, species and energy equations for determination of the gas flow, composition and temperature. In addition, the Outokumpu SBSM takes into account the moving pellet bed, drying of pellets interms of water content, coke combustion, oxidation and reduction of chromite and the decomposition of carbonates and silicates. During the development of the model, numerous laboratory-scale tests were performed. The sub-models were validated against the laboratory tests. The reliability of the Outokumpu Steel Belt Sintering Model was validated against a pilot-scale batch-sintering furnace by comparing the modelling results against measurements. The aim of this paper is to give a brief presentation of the Outokumpu steel belt sintering model by showing some general modelling examples. Emphasis has been placed on demonstrating some of the main features of the model.