Sintering Machine Ignition System: Advances in Intelligent Ignition Technology and Control Systems
2026-10-23
1 Applications of Intelligent Control Systems:
With the development of industry 4.0 With advances in technology, the application of intelligent control systems in the sintering ignition process has become increasingly widespread, emerging as a key means of enhancing ignition accuracy and efficiency. By leveraging advanced sensor technologies, real-time data analytics, and automated control, intelligent ignition systems have overcome the limitations of conventional ignition methods, delivering substantial improvements in performance and productivity.
( 1 ) The intelligent sensing system forms the foundation of smart ignition. By installing temperature sensors, pressure sensors, oxygen‑content detectors, and other instruments, the system can monitor key combustion parameters in real time, providing data to support precise control. These sensors continuously collect information on temperature distribution, airflow conditions, fuel composition, and other relevant factors within the furnace, and, through data analysis and advanced algorithmic models, enable highly accurate regulation of the ignition process.
( 2 ) The intelligent decision-making system is the core of intelligent ignition. Leveraging intelligent methods such as fuzzy control, neural networks, and expert systems, the system can automatically adjust ignition process parameters based on real-time monitoring data and predefined optimization objectives. For example, by… PIDNN Control algorithms and corrections EID With this technology, the system can precisely adjust the ignition intensity, ensuring that the ignition process remains in optimal condition at all times.
( 3 ) The actuator is the means by which intelligent ignition is implemented. By employing automated actuators—such as control valves and variable-frequency drives—the intelligent ignition system automatically adjusts parameters like fuel flow, air‑fuel ratio, and ignition temperature, eliminating the need for manual intervention. This enables the ignition process to be completed in the shortest possible time, thereby reducing start-up duration.
2 Precise Control and Parameter Optimization
The intelligent ignition system achieves optimal operation of the ignition process through precise control and parameter optimization, significantly enhancing ignition quality and efficiency.
( 1 ) Precise temperature control is a key feature of the intelligent ignition system. By continuously monitoring the ignition temperature and comparing it with the setpoint, the system automatically adjusts the supply of fuel and air, ensuring that the ignition temperature remains within the optimal range at all times. After implementing the intelligent ignition system, a major steel enterprise reduced energy consumption in its sintering process by… 15% Above, production efficiency has improved. 20% , fuel costs have dropped significantly.
( 2 ) Optimized air–fuel ratio control is key to improving combustion efficiency. The intelligent ignition system dynamically adjusts the air–fuel ratio by analyzing flue gas composition in real time, particularly the levels of oxygen and carbon monoxide, thereby ensuring complete fuel combustion. This not only reduces fuel consumption but also minimizes pollutant emissions resulting from incomplete combustion.
( 3 ) Matching ignition intensity to the burden-layer requirements is an advanced feature of intelligent ignition. By analyzing factors such as burden-layer characteristics, fuel mix ratios, and sintering rate, the system can automatically adjust the ignition intensity to achieve optimal alignment with the burden-layer’s needs. Research indicates that, under an appropriate fuel‑distribution mode on the burden surface, the ignition temperature can be reduced from… 1050 ℃ reduced to 900 ℃, the ignition gas consumption from 3.52 m ³ /t Reduce to 2.01 m ³ /t , achieving significant energy savings.
A comparison of the performance between the intelligent ignition system and conventional ignition methods is shown in the table. 2。
Table 2. Comparison of Performance Between Intelligent Ignition Systems and Traditional Ignition Methods
Performance Metrics | Traditional ignition method | Intelligent Ignition System | Magnitude of improvement |
Energy consumption | Benchmark | Reduce 15% The above | Significantly improve |
Production efficiency | Benchmark | Improve 20% | Significantly improved |
Ignition temperature control accuracy | ± 50 °C | ± 10 °C | Improved accuracy 5 times |
Gas consumption (m ³ /t) | 3.52 | 2.01 | Reduce 42.9% |
Level of human intervention | High | Low | Significantly reduce |
3. Furnace Ignition Structure and Low-Pressure Ignition Technology
3.1 Innovative Design of the Ignition Furnace Structure
Optimizing the structure of ignition furnaces is a crucial approach to enhancing ignition quality and efficiency. In recent years, advances in numerical simulation and experimental research have led to significant improvements in furnace design, resulting in more uniform ignition and higher energy‑utilization efficiency.
( 1 ) Optimization of burner arrangement is key to innovating the ignition furnace structure. Research indicates that a staggered and crossed configuration of the first two rows of burners promotes the formation of strip‑shaped high‑temperature zones within the furnace chamber; to enhance the ignition performance of the sintering bed, the third row of burners can be shifted forward toward the inlet side. 300mm This arrangement improves the uniformity of the temperature distribution within the furnace, resulting in more uniform ignition across the sintering bed.
( 2 ) The dual‑inclined‑belt burner design enhances ignition efficiency. Compared with conventional linear burners, the dual‑inclined‑belt burner demonstrates superior performance in both ignition energy consumption and overall operational effectiveness. Thermal‑performance tests conducted on the two burner types reveal that the dual‑inclined‑belt burner delivers a more uniform temperature distribution, mitigating issues of localized overheating or insufficient ignition and thereby improving overall ignition quality.
( 3 ) Optimization of the internal structure of the ignition furnace has improved the airflow distribution, as determined by computational fluid dynamics. (CFD) In the simulation, Zhongwei’s technical team analyzed the velocity, temperature, and pressure fields within the ignition furnace and used these findings to optimize the furnace’s internal structure. The results indicate that by appropriately adjusting the furnace’s internal geometry and flow‑deflecting devices, the gas‑flow distribution can be made more uniform, thereby enhancing combustion efficiency.
3.2 Low-Pressure Ignition Technology
Low‑vacuum ignition technology represents a significant innovation in the field of sintering ignition in recent years. By optimizing negative‑pressure control during the ignition process, it has markedly enhanced ignition performance and energy efficiency.
( 1 ) Technical principle: The low‑negative‑pressure ignition technology reduces the negative pressure in the ignition blower, preserving the original permeability of the sintering bed and ensuring a smoother, more efficient ignition process.
( 2 ) Application results. Practical applications demonstrate that low‑negative‑pressure ignition technology can significantly improve sintering production metrics. Specifically: (1) The material layer thickness is increased. 50mm , thereby creating favorable conditions for sintering thick material layers; (2) The main exhaust damper opening has been reduced. 5 °, reducing the main fan’s power consumption; (3) The negative pressures in the two flues converge, ensuring that the endpoint position is easy to control. (4) Increase in final temperature 50 ℃, which improved the quality of the sintered ore; (5) The specific consumption of blast furnace gas for ignition has decreased. 7.38m ³ /t , with significant energy-saving effects.
( 3 ) Comprehensive benefits. The low‑negative‑pressure ignition technology not only enhances ignition quality but also delivers significant economic gains. By improving the yield of high‑grade sintered ore, it markedly elevates the appearance quality of the product and ensures a more uniform particle size distribution of the sinter fed into the blast furnace, thereby creating favorable conditions for subsequent blast‑furnace smelting.
33 Oxygen-enriched ignition technology
Oxygen-enriched ignition technology is a novel ignition method developed to address the poor ignition performance of low-calorific-value coal gas. By increasing the oxygen concentration in the combustion-supporting air, it significantly enhances ignition efficiency.
( 1 ) Technical principle. Oxygen-enriched ignition technology enhances combustion temperature and efficiency by introducing a certain proportion of oxygen into the combustion-supporting air, thereby improving the ignition performance of low-calorific-value coal gas. Research indicates that oxygen-enriched combustion promotes the complete combustion of furnace gas and solid fuel in the surface layer of the charge, thus reducing the concentration of… in the flue gas from the head blower. CO Concentration.
( 2 ) Application results. A certain steel company 180m ² After implementing the oxygen-enriched ignition process on the sintering machine, significant results were achieved: first, coal gas consumption was reduced. 10% ; second, the ignition temperature has increased. 30 ℃; third, the strength of the surface sinter has increased. 2.27% Fourth, the sintering internal return is reduced. 1% ; Fifth, the feed rate has been increased. 5t/h ; Sixth, the per-ton ore profitability is in 1.2 Yuan /t Level.
( 3 ) Environmental benefits. Oxygen-enriched ignition technology also delivers significant environmental advantages. On the one hand, oxygen enrichment promotes complete fuel combustion, thereby reducing the levels of… in the exhaust gases from the engine’s blower. CO Concentration, contributing to the overall exhaust gas. CO Emission reduction 10% ; On the other hand, oxygen-enriched ignition reduces solid fuel consumption. 1.25kg/t It has also promoted NOx Emissions have been reduced, achieving the synergistic abatement of multiple pollutants.
5. Fuel Stratification and Composite Ignition Process
5.1 Fuel fractionation process
Fuel layering is an innovative sintering process that enhances heat supply to the surface and upper layers of the sinter bed by applying a portion of the fuel to the surface, thereby improving ignition performance and sintering quality.
( 1 ) Process principle. The staged fuel injection technology employs a straightforward operational approach to redistribute the fuel distribution; under the condition that the overall fuel ratio remains unchanged, a portion of the fuel… ( Such as 5%) It is added to the surface of the sintering burden layer to enhance heat supply to the surface and the upper layers. This distribution strategy achieves the ideal sintering outcome in which theoretical heat input decreases gradually from top to bottom, thereby addressing the issue of insufficient heat in the upper layers during thick-layer sintering.
( 2 ) Process performance. Studies have shown that, with a total fuel ratio of 3.88% , the mass fraction of fuel added to the material surface is 5% Under the given conditions, the ignition temperature can be reduced from 1050 ℃ reduced to 900 ℃, the ignition gas consumption from 3.52m ³ /t Reduce to 2.01m ³ /t , with significant energy-saving effects. Meanwhile, the yield rate and drum strength have improved from… 79.10% and 69.76% Increase to 82.70% and 70.10% , the quality of the sinter has been significantly improved.
( 3 ) Mechanism of action. The fuel‑distribution process influences the ignition process by altering the combustion characteristics of the fuel at the burden surface. Under a fuel‑distribution mode at the burden surface, the ignition temperature affects the combustion rate of the surface‑layer fuel, while both the ignition temperature and the proportion of surface‑layer fuel jointly determine the duration of the red zone on the burden surface. Appropriate parameters for fuel distribution at the burden surface can ensure good matching between the ignition intensity and the heat release rate of the surface‑layer fuel, thereby optimizing the sintering process.
5.2 Composite Injection and Dual-Point Ignition
Composite injection and dual-point ignition technologies represent the latest advances in sintering ignition, and their combined application has further enhanced ignition performance and sintering quality.
( 1 ) Technical principle. Developed by Angang Steel Co., Ltd. " A low-carbon sintering method for thick material layers based on integrated air‑blowing, and a sintering machine thereof. " Technical expertise employs a two‑stage charging and two‑stage ignition process for sintering thick material layers; the first blow is applied to the sintered surface immediately after the first ignition, and the second blow is applied after the second ignition. The blowing medium consists of a mixture of fuel gas and steam, with blow parameters determined based on the peak temperature of the sintered layer and the proportion of biomass carbon powder in the sintering fuel.
( 2 ) Technical advantages. This composite injection technology addresses the challenge of integrating non‑fossil biomass fuels into sintering production at high proportions, and overcomes the difficulties in controlling key technical parameters—such as the amount of gaseous fuel injected, its blending ratio, and the injection location—in the context of ultra‑thick sintering layers using a mixed injection of hydrogen‑rich gas and steam. As a result, it enables high‑quality sintering with low emissions.
( 3 ) Application prospects. Composite injection and dual-point ignition technologies offer a new technical pathway for the green, low‑carbon transformation of sintering production, with particularly broad application potential in biomass energy utilization and ultra‑thick‑layer sintering, and are poised to become a key direction in the future development of sintering ignition technologies.
5.3 Synergy and Economic Benefits
The synergistic application of staged fuel injection and composite ignition technologies has yielded significant energy‑saving, emission‑reduction, and economic benefits, offering a new technological pathway for sintering operations.
( 1 ) Synergistic effects. The combination of fuel staging technology with low-temperature ignition technology has resulted in a significant reduction in energy consumption. Research indicates that when the mass fraction of staged fuel at the charge surface is 5% , the ignition temperature is 900 At ℃, the gas consumption per ton of ore can be reduced from 3.52m ³ Reduced to 2.01m ³, with a decline of 42.9% ; Meanwhile, the yield and drum strength both increase. 3.6% and 0.34% , thereby achieving the dual objectives of energy conservation and quality improvement.
( 2 ) Economic benefits. The implementation of these innovative processes has yielded significant economic gains. Taking Shanxi Jianbang as an example, 360m ² Taking the sintering machine as an example, systematic technological upgrades—including gas–air preheating and micro‑negative‑pressure ignition in the ignition furnace—have led to an increase in the sintering utilization factor. 0.06t/m ²· h , the blast furnace gas consumption of the sintering system has been reduced to 46m ³ /t , achieving a reduction in blast furnace gas consumption 30% , Reduction in process energy consumption 2.4kgce/t。
A comparison of the retrofitting effects of different ignition technologies is shown in the table. 3。
Table 3. Comparison of the Effects of Different Ignition Technology Modifications
Technology Type | Energy-saving effect | Quality Improvement | Environmental benefits | Return on investment |
Intelligent Ignition System | Energy consumption reduced 15% | Increased production efficiency 20% | Emission reduction | 1-2 year |
Low-negative-pressure ignition | Reduction in gas consumption per unit 7.38m ³ /t | The material layer thickness increases. 50mm | Reduction in exhaust gas treatment costs | 1 Around the year |
Oxygen-enriched ignition | Gas consumption has decreased. 10% | Surface strength improved 2.27% | CO Emission reduction 10% | 1-2 year |
Fuel fractionation + Low-temperature ignition | Reduced gas consumption 42.9% | Yield improvement 3.6% | Early stage CO Increase requires control. | 2 Around the year |
6. Comprehensive Comparative Analysis of Improvement Effects
6.1 Economic Benefit Analysis
Improvements in sintering machine ignition technology have yielded significant economic benefits, primarily through reduced energy costs, enhanced production efficiency, improved product quality, and lower maintenance expenses.
( 1 ) Energy cost savings represent the most direct economic benefit of advancing ignition technology. Intelligent ignition systems can reduce energy consumption in the sintering process through precise control. 15% Above; the low‑negative‑pressure ignition technology reduces the specific consumption of blast furnace gas for ignition. 7.38m ³ /t ; Oxygen-enriched ignition technology reduces coal gas consumption. 10% ; The combination of staged fuel injection and low-temperature ignition further reduces gas consumption from 3.52m ³ /t Drop to 2.01m ³ /t , with a decline of 42.9% These energy-saving benefits directly translate into reduced energy costs, delivering substantial economic gains for businesses.
( 2 ) Increased production efficiency is another significant source of economic benefits. Intelligent ignition systems enhance production efficiency. 20% , reducing startup time and production interruptions; low‑negative‑pressure ignition technology enhances the sintering machine’s utilization factor by increasing bed thickness and improving endpoint control; oxygen‑enriched ignition technology increases the feed rate. 5t/h , which increased the sinter production.
( 3 ) The benefits of quality improvement should not be overlooked. Through refinements in ignition technology, key quality indicators such as sinter yield and drum strength have been significantly enhanced, while the return‑ore rate has decreased. This not only boosts effective production output but also reduces reprocessing costs. For example, the staged fuel‑addition technique has led to an increase in product yield. 3.6% , oxygen-enriched ignition enhances the strength of the surface sinter layer. 2.27% These quality improvements have directly yielded economic benefits.
6.2 Environmental Benefit Assessment
Improvements in sintering machine ignition technology have yielded significant environmental benefits by reducing pollutant emissions, lowering energy consumption, and promoting the efficient utilization of resources.
( 1 ) Pollutant reduction is a key environmental benefit of ignition technology improvements. Intelligent ignition systems achieve precise control over the combustion process, ensuring complete fuel combustion and thereby reducing emissions of harmful gases; oxygen-enriched ignition technology further promotes thorough fuel combustion, enabling… CO Emission reduction 10% , while the reduction in solid fuel consumption has also contributed to NOx Emissions are reduced; although fuel blending technology may lead to the early stage of sintering… CO Emission concentration from 0.70% Increase to 0.88% However, overall emissions can be reduced through system optimization.
( 2 ) Reducing carbon emissions is an important contribution of improved ignition technology to addressing climate change. By lowering gas consumption and solid fuel consumption, advances in ignition technology directly reduce the emissions associated with fossil fuel combustion. CO ₂ emissions. In particular, the combination of fuel‑split injection and low‑temperature ignition technology has led to a substantial reduction in gas consumption, thereby lowering carbon emissions accordingly.
( 3 ) Improving resource efficiency is also a key component of environmental benefits. By enhancing ignition efficiency and quality, the yield of finished sinter is increased while the return‑to‑furnace rate is reduced, meaning that the same input of raw materials can produce more conforming products, thereby lowering resource consumption. At the same time, the efficient utilization of low‑calorific‑value gas further cuts the consumption of high‑value energy sources, optimizing the allocation of energy resources.
7. Conclusion
( 1 ) Practical experience in improving sintering‑machine ignition technology demonstrates that, through innovations such as intelligent control, optimization of furnace design, low‑vacuum operation, oxygen‑enriched combustion, and staged fuel injection, it is possible to achieve a win‑win outcome in both economic and environmental terms. These advanced technologies not only address pressing operational challenges in sintering but also provide critical technical support for the steel industry’s transition toward green and low‑carbon production.
( 2 ) Looking back at various innovative practices, the following aspects deserve particular attention: First, the intelligent ignition system has reduced energy consumption in the sintering process through precise control. 15% Above, production efficiency has improved. 20% Second, low‑negative‑pressure ignition technology reduces the specific consumption of ignition gas. 7.38m ³ /t , the material layer thickness increases 50mm Third, oxygen-enriched ignition technology promotes the complete combustion of low-calorific-value coal gas and raises the ignition temperature. 30 °C, CO Emission reduction 10% Fourth, the fuel‑splitting combustion mode, combined with low‑temperature ignition, reduces gas consumption from… 3.52m ³ /t Drop to 2.01m ³ /t , with energy-saving performance reaching 42.9% 。
8. Outlook
( 1 ) Deep integration of intelligence and digitalization. With the rapid advancement of artificial intelligence, the Internet of Things, and big data technologies, the sintering ignition process will achieve a higher level of intelligence and automation. Intelligent ignition systems will not only enable precise parameter control but also, through self‑learning and adaptive optimization, deliver predictive control and preventive maintenance, further enhancing ignition accuracy and stability.
( 2 ) Low-carbon and zero-carbon transformation. In " Dual Carbon " Against the backdrop of strategic priorities, sintering ignition technology will accelerate its transition toward low‑carbon and zero‑carbon solutions. The adoption of low‑carbon fuels such as biomass and hydrogen is set to become a major R&D focus, with composite injection technologies offering a viable technical pathway for the large‑scale integration of biomass fuels. Meanwhile, electrified ignition technologies are also expected to achieve breakthroughs, gradually replacing fossil‑fuel‑based ignition systems.
( 3 ) Systematic and integrated innovation. Future ignition technologies will place greater emphasis on systematic innovation, integrating the ignition process with the entire sintering operation and even the full steelmaking workflow for optimized performance. Ignition technology will be synergistically optimized alongside sintering raw material blending, flue gas recirculation, waste heat recovery, and other process steps, thereby enhancing overall process energy efficiency and achieving coordinated reductions in pollutant emissions.
( 4 ) Multifunctionality and flexible adaptability. In the face of challenges posed by the diversification of iron‑ore feedstock sources and fluctuations in quality, ignition technology will evolve toward greater multifunctionality and flexibility, enabling it to accommodate variations in raw material characteristics and production conditions. In particular, for difficult-to-process feedstocks such as low‑grade ores and complex symbiotic ores, ignition technology must exhibit enhanced adaptability and regulatory capabilities.
Sintering Machine Ignition Technology: Research and Application Updates
WeChat Official Account: Zhongwei Environmental Protection, or call (also via WeChat): 13849187223
Previous:
Contact Us
Address: No. 118, Fengqing Road, Jinshui District, Zhengzhou City
Tel:+86-371-60960056
Mobile:+8613849187223
Email:zhongweigongyelu@126.com
Address: No. 118, Fengqing Road, Jinshui District, Zhengzhou City
Tel:+86-371-60960056
Mobile:+8613849187223
Email:zhongweigongyelu@126.com
Quick Navigation
Get Industry Solutions Online
If you have any product-related questions, please feel free to contact us!