In order to analyze two-layer sintering process and its energy-saving benefit

a two-dimensional unsteady mathematical model of iron ore sintering process

which considered major physical changes and chemical reactions was developed based on porous media theory. Employed with FLUENT software and C language programming via custom code

the sintering process was simulated and a sinter pot test was used to validate the model. Both conventional sintering process and two-layer sintering process were simulated. Distributions of temperature and melt fraction in sintering bed were analyzed. Results showed that heat efficiency became higher

temperature and melt fraction distributed more evenly in two-layer sintering when coke rate was kept the same as in one-layer sintering. Besides

the yield increased 10% when coke rates were 5% in the upper layer and 3.4% in the lower layer while two layers had the same heights. Reducing the height of the upper layer the yield of the sintering could be further increased when the height ratio of the upper and lower layer was 5:9 and coke rates were 5% and 3.756% respectively.