Sintered Ore Pallet Speed Control via Infrared Analysis
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Solution Overview
Problem
Existing methods for manufacturing sintered ore face challenges in maintaining stable sintering reaction temperatures, leading to equipment issues due to variations in component concentrations and segregation during the charging process, which affects the quality and productivity of sintered ore.
Innovation Solution
Continuous measurement of component concentrations in sintered ore using an infrared analyzer to adjust the pallet speed of the sintering machine, preventing excessive temperature increases and ensuring stable operation by correlating FeO and C concentrations with sintering temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the sintering reaction temperature is increased to improve production speed, then productivity increases, but equipment damage and abnormal stoppages occur due to excessive temperature
Solution Approach 1:
The patent implements a feedback control system where component concentrations in sintered ore are continuously measured, and pallet speed is automatically adjusted based on measured FeO and C concentrations. This closed-loop feedback mechanism prevents excessive temperature increases by detecting compositional changes and adjusting process parameters in real-time, thereby maintaining both high productivity and equipment reliability.
Solution Approach 2:
The patent dynamically changes the pallet speed parameter based on measured component concentrations. When FeO concentration indicates high sintering temperature, the system reduces pallet speed to extend residence time and control temperature. This parameter adjustment allows the system to optimize productivity while preventing equipment damage from excessive temperatures.
2Reliability
If the pallet speed is reduced to maintain stable sintering temperature, then equipment reliability improves, but productivity decreases
Solution Approach 1:
The patent transitions from static pallet speed operation to dynamic speed adjustment. The system continuously adapts pallet speed based on real-time measurements of FeO and C concentrations, allowing the process to maintain optimal temperature for equipment reliability while maximizing productivity through intelligent control rather than conservative constant speed operation.
Solution Approach 2:
The system dynamically adjusts the pallet speed parameter in response to measured component concentrations. By changing speed only when necessary (when concentrations indicate temperature deviations), the system maintains high average productivity while ensuring equipment reliability through targeted speed reductions only when compositional analysis warrants it.
3Device complexity
If component concentrations in sintering raw material are not monitored, then device complexity is reduced, but manufacturing precision deteriorates due to temperature variations
Solution Approach 1:
The patent replaces complex mechanical sampling and laboratory analysis systems with infrared absorption spectroscopy for continuous online measurement. This substitution provides precise component concentration data (FeO, C, and other components) without requiring complex mechanical sampling equipment or manual laboratory procedures, thereby achieving high manufacturing precision with relatively simple measurement instrumentation.
Solution Approach 2:
The measurement system is integrated directly into the sintering process flow, where the sintered ore itself serves as the measurement medium. The infrared analyzer measures component concentrations directly from the moving material stream, eliminating the need for separate sampling and preparation systems. This self-service approach achieves precise quality control while minimizing additional device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach inhibits equipment problems such as abnormal stoppages and breakdowns by maintaining optimal sintering temperatures, improving the quality and consistency of sintered ore production while reducing the risk of equipment damage.
Implementation Method 1
component concentrations in sintered ore are continuously measured by using an infrared analyzer
Implementation Method 2
In a sintering reaction, thermal dissociation, in which hematite in sintered ore transitions into magnetite, progresses with an increase in temperature
Implementation Method 3
thermal dissociation, in which hematite in sintered ore transitions into magnetite, progresses with an increase in temperature
Data Source
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AI summary
Provided is a method for manufacturing sintered ore with which it is possible to inhibit equipment problems from occurring, even when there is a variation in the sintering reaction temperature, by promptly detecting such a variation. A method for manufacturing sintered ore, in which a sintering raw material containing an iron-containing raw material, a CaO-containing raw material, and a bonding agent is mixed with water and granulated, and the granulated sintering raw material is sintered in a sintering machine to manufacture sintered ore, the method includes a measuring process of continuously measuring component concentrations in the sintered ore, and a pallet speed-adjusting process of adjusting a pallet speed in accordance with the component concentrations in the sintered ore measured in the measuring process.