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ENHANCING IRON ORE SINTERING THROUGH HOT WATER-ASSISTED GRANULATION
Dhanraj Patil1
1JSW Steel Pvt. Ltd., Toranagallu, India

PAPER: 77/Iron/Regular (Oral) OS
SCHEDULED: 14:00/Wed. 19 Nov. 2025/Lotus

ABSTRACT:

Iron ore sintering is a critical agglomeration process in iron and steelmaking, enhancing the physical and chemical characteristics of raw materials to optimize blast furnace performance. The granulation stage, wherein fine iron ore particles are combined with fluxes, fuels, and binders, is pivotal in determining the quality of the final sinter. Conventional granulation methods typically employ ambient-temperature water, often resulting in suboptimal granule formation, uneven moisture distribution, and reduced permeability in the sinter bed. This study investigates the application of hot water, at temperatures ranging from 60°C to 95°C, during the granulation process to improve raw mix properties and sintering performance. The controlled addition of hot water raised the temperature of the green mix by at least 10°C, achieving final mix temperatures between 35°C and 45°C and a target moisture content of 7.5% to 8%. The modified process led to more uniform water dispersion and improved granule formation, as reflected by an increase in the balling index from 1.22% to 1.53%. The granulated mix was subsequently sintered under controlled suction conditions, resulting in enhanced sinter yield and higher production rates. Overall, the use of hot water in the granulation stage significantly improves process efficiency, granule quality, and the performance of the sintering operation.

REFERENCES:
[1] Rajak, D.K., Singhai, M., Sahu, R., & Hazra, S.S. (2021). Effect of Mixing Pre-heated Water on Granulation and Iron Ore Sinter Properties. Transactions of the Indian Institute of Metals, 74, 1611–1622. https://doi.org/10.1007/s12666-021-02251-4.
[2] Suresh, V., Sarkar, C., Vishnuvardhan, A., Sharma, M. K., & Chakraborty, S. (2020). Modification of Wet Granulation Process during Iron Ore Sintering. Transactions of the Indian National Academy of Engineering, 5, 485–490. https://doi.org/10.1007/s41403-020-00146-2.
[3] Wu, S.-L., Zhu, J., Bei, J.-C., Zhang, G.-L., & Zhai, X.-B. (2015). Effects of particle characteristics on the granulation ability of iron ores during the sintering process. International Journal of Minerals, Metallurgy and Materials, 22(9), 907–916. https://doi.org/10.1007/s12613-015-1149-0.
[4] Zhang, Gl., Wu, Sl., Zhu, J. et al. Influencing factors and mechanism of water absorption process of iron ores during sintering. Int J Miner Metall Mater 21, 122–130 (2014). https://doi.org/10.1007/s12613-014-0874-0