Stable efficient operation of the sinter plant depends on uniformly distributing the granulated iron ore, flux and fuel mix across the width of the sinter pallets. When this is not achieved, uneven gas flow and reaction rates prevent fully utilising the available strand area, increasing the specific fuel rates, and producing sinter of lower quality. At BlueScope Steel’s Port Kembla sinter machine, raw mix is transferred to the feed bin by a shuttle conveyor that moves back and forth across the 5m width of the bin. Due to the time taken for the shuttle to reverse direction, the mass flow into the bin is higher at the ends of the shuttle travel and that induces an uneven profile that allows significant particle size segregation to occur.

The bin particle flow dynamics have been investigated using Discrete Particle Simulation (DPS) modelling the system between the shuttle conveyor, through the feed bin until discharge to the strand. The model dynamics was extensively validated against measured 3D profiles from the operating plant equipment under a range of operating conditions. The validated model was then used to evaluate alternative bin/conveyor operating setups intended to reduce the filling level variation. Subsequently a number of plant trials were conduced to quantify the improvement in feed bin control. Application of DPS validated by high quality plant measurements allowed a significant reduction amount of plant trial work, minimising the disruption to the process and reducing the length of time before the benefits of could be realised.