IMGS®: Intensive Mixing and Granulation System

Primetals Technologies has developed a special iron ore raw mix preparation system for sinter plants, known as the IMGS® (Intensive Mixing and Granulation System). The entire raw mix is treated in such a way that up to 80% iron ore concentrate (pellet feed, ultrafines) can be used to produce a high-quality sinter at higher productivity levels. This can be achieved while assuring excellent product and process parameters related to productivity, the physical characteristics and chemical quality of sinter, low fuel consumption, and stable sintering operations.

Unlike conventional sinter raw mix preparation systems, the Intensive Mixing and Granulation System from Primetals Technologies requires no pre-blending on blending yards, reducing space requirements for the iron ore raw mix preparation system in sinter plants. The IMGS® operates exclusively with a bin blending system, resulting in lower investment costs. The proportioning system allows increased flexibility in selecting raw materials, specifically increased ultrafine portions. In connection with the intensive mixer, this results in improved homogeneity of the sinter raw mix.

Economic reuse of in-plant reverts, such as dust, sludge, scales, and others, can be included. Due to this homogeneity, optimal solid fuel distribution is achieved, reducing consumption. Even when using high portions of ultrafine iron ores, excellent sintering results are obtained. The IMGS® provides high and stable sinter quality, ensuring subsequent high blast furnace performance.

The IMGS® consists of an intensive mixer and granulation aggregate. Sinter raw materials include coarse and fine iron ores, ultrafine ores or pellet feed, additives, dusts, solid fuels, return fines, and recycled materials from the steel plant. These materials are continuously fed into a high-speed intensive mixer. Here, macro- and micro-mixing of high- and low-density particles and fine-to-coarse particles of the sinter raw mix occurs. After mixing, the material is transported to the drum or horizontal granulator, where granulation takes place. The system can be individually adjusted to meet changing requirements.

Benefits of the Intensive Mixing and Granulation System for Sinter Plants

• High mixing quality and improved homogeneity: ensures consistent sinter quality and enhanced blast furnace performance.
• Flexibility in raw material usage: allows for a higher ratio of fine iron ore and residuals, including pellet-feed concentrates, dusts, and sludge.
• Space and cost efficiency: eliminates the need for a blending yard, leading to lower investment costs.
• Increased sinter plant productivity: achieves higher productivity levels with reduced fuel, lime, and water consumption.
• Environmental sustainability: reduces the environmental footprint by optimizing resource usage and integrating recycled materials.
• Enhanced sintering of ultrafine materials: maintains high productivity and quality even with a high proportion of ultrafine iron ores.