TECHNICAL FIELD
[0001] The present invention relates to a method and an apparatus for charging raw material
to be sintered, in the manufacture of steel or iron.
BACKGROUND ART
[0002] In the operation of sintering machines, for example in the iron and steel manufacturing
industry, raw material to be sintered of not more than about 10 mm is charged from
a raw material supply machine through a raw material charging chute into a pallet
of an endless moving sintering machine. Solid fuel such as coke powder and slag-forming
flux such as lime powder is included within this raw material to be sintered, and
after finishing the charging of the raw material, the coke powder included in the
surface layer of the raw material is ignited in the ignition furnace, air is sucked
by a blower from below the pallet, and while combusting the coke powder within the
raw material layer, the iron ore is fired from the top layer towards the bottom layer.
For this reason, when charging the raw material to be sintered, it is important to
maintain favorable aeration properties with respect to the raw material layer that
is deposited in the pallet, and to ensure uniform aeration properties within the plane
of the pallet.
[0003] With respect to the particle size distribution of the sintered ore in the pallet,
coarse-grained raw material is deposited in a layer at the bottom of the raw material,
and finely grained raw material is deposited in a layer at the top of the raw material,
so that a suitable particle size distribution is achieved. Thus, a technology has
been developed, in which an improved quality of the sintered ore as well as an improved
yield and productivity has been achieved by improving the aeration properties of the
entire sintered raw material layer in the pallet. As an apparatus for segregated charging
of raw material to be sintered, which performs the charging while controlling the
particle size distribution of the sintered raw material in the pallet in the above-described
manner, a screen-type raw material charging chute is used.
[0004] The structure of a screen-type raw material charging chute is such that a multitude
of wires or rods (referred to as "wire-like members" below) are lined up in parallel
to each other in the width direction of the pallet on a surface that is slanted downward
while leaving a predetermined spacing between them, and these wires are supported
by guide members (brackets). Thus, the rod spacing of the raw material charging chute
that is formed in screen shape is set to be narrower on the upper side and wider towards
the lower side. Here, the raw material charging chute is slanted downward in a direction
that is opposite to the direction in which the pallet advances forward. Consequently,
the coarsely grained raw material passing through the wider screen gaps on the lower
side of the raw material charging chute are deposited in a raw material bottom layer
portion in the pallet, whereas the finely grained raw material passing through the
narrower screen gaps on the lower side of the raw material charging chute are deposited
in a raw material top layer portion in the pallet. Thus, the aeration properties of
the material to be sintered in the pallet can be controlled favorably.
[0005] However, the pallet width is as much as 3 to 5.5 m, and the support span of the wire-like
members is as wide as 4 to 7 m. Therefore, if there are no guiding members (brackets)
supporting the wire-like members, then the wire-like members may sag or start to oscillate
due to insufficient stiffness, so that they are shifted away from the positions at
which they should actually be arranged, and the sorting capabilities will deteriorate.
For this reason, the guide members (brackets) supporting the wire-like members are
provided sufficiently, in accordance with the pallet width and the diameters of the
wires, in such a number that no sagging or shifting of the wire-like members will
occur.
[0006] In the apparatus for charging raw material to be sintered having the above-described
structure, it is important to maintain the gaps between the wire-like members (the
screen gaps) uniform to support the sorting capabilities, but it is hindered by the
following two factors .
The first factor is the presence of the guide-members (brackets), and the other factor
is the adherence of raw material powder to the wire-like members. The following is
a detailed discussion of the problems that arise due to these factors, as well as
of how these problems are presently solved.
The Problem Caused by the Presence of the Guide Members (Brackets)
[0007] Due to the presence of the guide members (brackets), the raw material flow occurs
in which the charged raw material is divided on both sides of the guide members (brackets),
and the deposition amount of the raw material where the guide members (brackets) are
arranged is smaller than the amount where there are no guide members (brackets), so
that groove-shaped portions are formed at the surface of the deposited raw material.
While these groove-shaped portions are being formed, raw material from surrounding
areas may flow in there to some extent, but since the falling distance is too small
for the raw material to flow in, a deposition layer with low density is formed. Moreover,
when the raw material flows in from the surrounding areas, in principle, relatively
large particle size raw material is inclined to pile up.
[0008] In the groove-shaped portions thus formed, the aeration resistance in the raw material
layer is smaller than that in the flat portions where no groove-shaped portions are
formed. That is to say, there will be variations of the aeration resistance in the
pallet width direction in the layer of the raw material to be sintered. When these
variations in aeration resistance become large, then the suction of air concentrates
in the groove-shaped portions where the aeration resistance is relatively small, and
in the period in which these regions form a combustion belt in the raw material layer,
the combustion speed of the coke powder becomes large in these groove-shaped portions,
whereby insufficient combustion portions may occur in the flat portions, slowing the
firing. This leads to a drop in the yield of the sintered ore, a drop in the product
quality, and an increase in coke unit consumption, and furthermore brings about a
drop in the productivity of the sintered ore.
The above is the problem due to the presence of the guide members (brackets).
[0009] To solve this problem, a technology has been proposed to make the thickness of the
raw material layer to be sintered in the pallet constant, reducing the variations
of the raw material density by placing a scraper which has a plurality of V-shaped
raking members between the screen-type raw material charging chute and the cut-off
plate (see Patent Document 1).
Another example of a technology has been proposed wherein, in a screw-type raw material
raking apparatus acting in pallet width direction arranged downstream from the screen-type
raw material charging chute, by attaching a screw blade lifting device and a screw
blade revolution changing device, raw material is raked in from the surrounding portions
of the groove-shaped portions and the groove-shaped portions are filled without applying
pressure to the raw material layer surface portion across the entire width of the
pallet, and furthermore the raw material is lifted at this position and pressure is
applied only to this position, so that a raw material layer to be sintered that has
substantially uniform aeration properties in the pallet width direction is attained(see
Patent Document 2).
The Problem Caused by the Adherence of Raw Material Powder
[0010] The problem of the adherence of raw material powder is the problem that raw material
powder such as coal powder, coke powder or the like adheres to the wire-like members,
so that is becomes difficult to maintain the gaps between the wire-like members. When
the gaps between the wire-like members cannot be maintained, then the sorting of the
charged raw material cannot be properly performed, and as with the above-described
problem due to the presence of the guide members (brackets), the raw material deposition
layer cannot be formed appropriately, which leads to a drop in the yield of the sintered
ore, a drop in the product quality, and an increase in coke unit consumption, and
furthermore brings about a drop in the productivity of the sintered ore.
[0011] As a technology for solving this problem of the adherence of raw material powder,
it has been proposed to provide a scraper that contacts the rods forming the chute
and that moves in the chute width direction (see Patent Document 3).
In another example, it has been proposed to move the wire ropes forming the chute
at low speed in the axial direction of the wire ropes (see Patent Document 4).
PRIOR ART DOCUMENTS
PATENT DOCUMENTS
DISCLOSURE OF THE INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
[0013] In the above-described apparatuses for charging raw material to be sintered, there
are two factors that hinders keeping the gaps between the wire-like members uniform
and maintaining the sorting capabilities, namely, the problem caused by the presence
of the guide members (brackets), and the problem caused by the adherence of raw material
powder, for which respective solutions have been proposed.
However, the presently proposed solutions for these problems still leave the following
issues.
Regarding the Presence of the Guide Members (Brackets)
[0014] Regarding the formation of groove-shaped portions due to the presence of the guide
members (brackets), the solutions proposed in Patent Documents 1 and 2 recognize that
groove-shaped portions are formed at the surface of the deposited raw material, and
fill them by leveling the groove-shaped portions with a V-shaped or screw-type raking
device.
However, when the formed groove-shaped portions are filled by leveling, the particle
size distribution in the filled groove-shaped portions is not the same as that in
other regions, and even though the groove-shape disappears, the problem of variations
in the aeration resistance is not substantially solved. According to observations
by the inventors, coarse particles are deposited within and around the groove-shaped
portions, so that when they are leveled with a raking device, the groove-shaped portions
are filled with coarse particles, and the problem that the aeration resistance of
the groove-shaped portion is relatively small is not sufficiently solved.
Regarding the Adherence of Raw Material Powder
[0015] Regarding the adherence of raw material powder to the wire-like members, Patent Document
3 proposes to move scrapers inserted into the bars which constitute the chute, which
may have some effect of scraping off the raw material powder adhered to the bars.
However, in the technology in Patent Document 3, it is assumed that thick bars having
a certain stiffness are used as the wire-like members constituting the chute. Because
if the bars were such thin wires, then guide members (brackets) supporting the wires
in the chute width direction would be necessary, and if there were guide members (brackets),
then the scraper would collide with the guide members (brackets), so that it could
not move. Therefore, it seems that the technology in Patent Document 3 is based on
an assumption that there are no guide members (brackets) in the chute width direction.
Thus, there is the problem that the technology of Patent Document 3 cannot be applied
to chutes formed by wire-like members that are such that there are guide members (brackets)
in the chute width direction. Moreover, there is the problem that there is a limit
to the sorting properties and excellent sorting properties cannot be achieved when
thick bars or the like are used as the wire-like members constituting the chute.
[0016] As for the technology described in Patent Document 4, in which the wires are moved
at low speed in their axial direction, the mechanism for moving the wires at slow
speed is complex, and it cannot be advisable in view of the space and costs required.
[0017] Thus, the two factors that hinder keeping the gaps between the wire-like members
uniform and maintaining the sorting capabilities, that is, the problem caused by the
presence of the guide members (brackets) and the problem caused by the adherence of
raw material powder have not yet been solved effectively, and there is yet no technology
for solving both.
[0018] The present invention has been devised in order to solve these problems, and it is
an object of the present invention to provide a technology for keeping the spacing
between the wire-like members even and maintaining the sorting possibilities when
charging raw material to be sintered in a sintering apparatus.
MEANS FOR SOLVING THE PROBLEMS
[0019] In order to solve the above-noted problems, the inventors made the following considerations.
Fig. 10 schematically shows the groove-shaped portions formed in the sintering bed.
The influence that such groove-shaped portions have on the combustion surface was
considered.
As described in the section Background Art, the groove-shaped portions were conventionally
leveled with a screw or a scraper, and Fig. 11 is a diagram showing the leveled state
of the groove-shaped portions. In Fig. 11, the regions A are portions that are unaffected
by the brackets, whereas the regions B are regions where the groove-shaped portions
that have occurred due to the brackets have been leveled. The particle size distributions
in the regions A and the regions B are roughly as shown in Fig. 12, that is, the particle
size is coarser in the regions B, where the groove-shaped portions are leveled, than
in the regions A which are unaffected by the brackets. Moreover, the density of the
regions B is lower than that in the regions A, so that there is higher aeration in
the regions B.
[0020] Fig. 13 schematically shows the state in which the combustion surface of the sintering
bed in a given cross section advances from the top to the bottom.
As shown in Fig. 13, since the combustion speed in the regions B where the grooved-shaped
portions have been leveled is higher, its influence is higher and the difference to
the regions A that are unaffected by the brackets becomes larger the more the combustion
surface advances downward. Near the bottom of the bed, there is a step ΔF between
the regions A and the regions B. Thus, the step ΔF in the combustion surface near
the bed bottom is proportional to the depth of the regions B where the groove-shaped
portions are leveled, that is, to the length in the depth direction of the portions
affected by the groove-shaped portions, and in this case it is proportional to the
height H of the sintering bed.
[0021] Accordingly, there is a difference in the combustion speed between the portions that
are affected and the portions that are unaffected by the groove-shaped portions, and
moreover, the extent of this influence is proportional to the length in depth direction
of the portions that are affected.
In order to mitigate the influence of the brackets, the inventors conceived the solution
of moving the brackets back and forth along the wires constituting the chute.
Fig. 14 is a diagram showing the passage of time of the combustion surface at a given
cross section in a sintering bed onto which raw material has been piled while moving
the brackets along the wires at a predetermined speed. In Fig. 14, the regions enclosed
by the oblique lines correspond to the regions B, which are affected by the brackets.
In the state shown in Fig. 14, when the combustion surface passes through the regions
B, which are affected by the brackets, the combustion speed increases, and the combustion
surface advances further downward than at the unaffected portions. Therefore, when
the combustion surface moves downward, the way in which the regions B are passed determines
the position of the combustion surface near the bed bottom, and can be classified
into the three types of areas a', b' and c', in the example shown in Fig. 14. a' denotes
areas that do not pass through the regions B. b' denotes areas that do pass through
the regions B but the passage distance within the region gradually increases from
0 to h or gradually degreases from h to 0. c' denotes areas where the distance passing
through the regions B is constant, this distance being h.
[0022] In the areas a', the combustion surface advances at a predetermined speed. In the
areas b', there is a difference in the speed of the combustion surface between the
portions where the distance passing through the regions B is long and the portions
where this distance is short. In the portions where this distance is long, the combustion
surface advances fast, and in the portions where this distance is short, the combustion
surface advances slowly. Therefore, the combustion surface is slanted in the areas
b'.
Furthermore, in the areas c', the speed is faster by a predetermined speed that is
proportional to the distance h passing through the regions B.
As can be seen from Fig. 14, in the areas c', the maximum length passing through the
regions B is h, so that the step to the areas a' that are unaffected by the brackets
is proportional to h, namely the step ΔF shown in Fig. 14.
[0023] Comparing Fig. 13 with Fig. 14, it can be seen that in Fig. 13, a step ΔF in the
combustion surface occurs that is proportional to the sintering bed height H, whereas
in Fig. 14, a step ΔF in the combustion surface occurs that is proportional to the
distance h passing through the regions B. As becomes clear from Fig. 13 and Fig. 14,
h is much smaller than H, and therefore also ΔF is much smaller than ΔF.
As should become clear from the above, by moving the brackets, the influence of the
brackets on the combustion surface can be effectively reduced.
[0024] Furthermore, the inventors also examined the quantitative relation between the moving
speed of the brackets and the combustion surface.
Fig. 15 schematically shows the moving speed of the brackets and the range of influence
of the brackets as well as the position of the combustion surface near the bottom
of the sintering bed.
Fig. 15(a) shows the state when the brackets are halted, Fig. 15(b) shows the state
when the bracket moving speed is slow, Fig. 15(c) shows the state when the bracket
moving speed is medium, and Fig. 15(d) shows the state when the bracket moving speed
is fast.
If the brackets are halted as in Fig. 15(a), the combustion surface becomes U-shaped
near the bottom. If the speed is slow as in Fig. 15(b), it takes on the shape of an
inverted triangle, where the position of the apex of the inverse triangle, that is,
the lowermost location of the combustion surface, coincides with the bottom portion
in Fig. 15(a). If the speed is intermediate as in Fig. 15(c), then the shape is that
of an inverse trapezoid, and the position of the bottom edge of the inverse trapezoid
has moved above the bottom portion in Fig. 15(a). If the speed is high as in Fig.
15(d), then the lowermost location of the combustion surface has moved even further
above the bottom portion in Fig. 15(a), and is at a substantially constant position.
[0025] As can be seen from Fig. 15, as the moving speed of the brackets increases, the influence
of the brackets on the combustion surface is reduced.
Accordingly, the inventors examined at which moving speed of the brackets, or in other
words, at which inclination of the portion affected by the brackets in Fig. 15 the
effect of mitigating the influence on the combustion surface is attained.
[0026] Fig. 16 shows the state, viewed in cross section in the pallet advancing direction,
when the raw material is supplied from the drum chute 7 to the pallet 9 and piled
onto it. In Fig. 16, θ
p denotes the pile angle of the raw material, and v
p denotes the moving speed of the pallet 9.
Moreover, Fig. 17 is an illustrative diagram to illustrate the relation between the
pile speed and the pile angle θ
p (Fig. 17(a)), and the relation between the pile speed and the inclination angle θ
b of the portion affected by the brackets (Fig. 17(b)). Fig. 17(b) shows a sectional
surface of the sintering bed taken at right angles to the direction in which the pallet
advances, and in Fig. 17(b), H denotes the sintering bed height and W
b denotes the width of the portion affected by the brackets.
To confirm the used reference symbols, V
b denotes the bracket moving speed, v
p denotes the pallet speed, θ
p denotes the pile angle when the raw material is charged onto the pallet, θ
b denotes the inclination angle of the portion affected by the brackets, W
b denotes the width of the portion affected by the brackets, and H denotes the sintering
bed height.
The pile speed in the H direction of the raw material is v
p tanθ
p (see Fig. 17(a) and (b)), and on the other hand, the inclination angle θ
b of the portion affected by the brackets is determined by the relation to the bracket
moving speed V
b. As can be seen from Fig. 17(b), v
b • tanθ
b = v
p • tanθ
p, so that solving for tanθ
b, the relation of the following Equation (1) is obtained:

[0027] Here, when considering in which of the states shown in Figs. 15(a) to (d) the influence
of the brackets can be mitigated, it can be appreciated that if the moving speed of
the brackets is at least the slow speed shown in Fig. 15(b), then the influence on
the combustion speed will be smaller than in the case that the brackets are halted.
Moreover, in the state of Fig. 15(b), W
b = H / tanθ
b, so that if the bracket speed is at least that of the state shown in Fig. 15(b),
then the following Equation (2) holds:

[0028] Inserting Equation (2) into Equation (1) gives W
b ≤ H • Vb / V
p • tanθ
p, and solving this equation for v
b yields the following Equation (3):

[0029] In a typical sintering machine, the values of v
p, θ
p, H and W
b are as follows:
v
p=2m / min
θ
p = 40°
H = 600 mm
W
b = 200 mm
Inserting these numbers into Equation (3) yields Vb ≥ 0.56 m / min, so that if the
bracket moving speed is about 0.6 m / min, the effect of the present invention is
attained.
[0030] Next, the inventors considered conditions under which the influence of the brackets
becomes even smaller.
Fig. 18 is an illustrative diagram using these considerations. Fig. 18(a) is a diagram
showing a portion affected by the brackets when the brackets are moved back and forth
in the pallet width direction, seen in a top view. Fig. 18(b) is a diagram showing
a sectional view in the pallet axis direction of the sintering bed corresponding to
Fig. 18(a).
In Fig. 18, B denotes the lowermost pile portion (bottom) of the raw material, and
T denotes the uppermost pile portion (top). Furthermore, Lb denotes the length of
the projection portion when the line connecting B and T is projected onto the pallet
surface, P denotes the movement pitch of the brackets, and Pt denotes the pitch of
the portions affected by the brackets in the direction in which the pallet moves.
θ
p denotes the pile angle of the raw material and θ
t denotes the inclination angle with respect to the line at right angles to the pallet
moving direction at the point B or the point T. Furthermore, v
p denotes the moving speed of the pallet and Vb denotes the moving speed of the brackets.
[0031] In Fig. 18(a), the numbers enclosed by the square denote the number of times a region
passes through a portion affected by the brackets, from the top surface to the bottom
surface of the sintering bed, when a region associated with that number is viewed
in a cross section perpendicular to the pallet moving direction. For example, in the
cross section of the region marked by the number "1", this region passes once through
a portion affected by the brackets from the top surface to the bottom surface of the
sintering bed, and corresponds for example to the regions b' and c' in Fig. 14. The
regions marked by the number "0" are unaffected by the brackets, and the regions marked
by the number "2" are affected twice as the brackets move back and forth.
[0032] Looking at the cross section perpendicular to the pallet advancing direction, the
fact that there are regions marked by the numbers "0" and "1" in this section means
that within the same section, there are portions that are affected by the brackets
and portions that are unaffected by the brackets. Considering that, as noted above,
the influence on the combustion surface is proportional to the length in the depth
direction that is affected by the brackets, it results that in the cross section perpendicular
to the pallet advancing direction, if the number of times in which there is an influence
of the brackets is constant, then it follows logically that the combustion surface
near the bottom of the bed must be the same.
If for example the cross section perpendicular to the pallet advancing direction is
affected twice by the brackets at any position in the pallet advancing direction,
as shown in Fig. 19, then the combustion surface near the bottom of the bed can be
made the same. The conditions for achieving this were determined to be as follows.
[0033] First, it can be seen from Fig. 18 that, as a precondition, the following relations
must hold:

In order to ensure that at any position in the pallet advancing direction the cross
section perpendicular to the pallet advancing direction is affected twice by the brackets,
the condition Lb = Pt should hold, as shown in Fig. 19. Rearranging Equation (5) yields
Lb =H / tanθ
p, and if the right side in this equation is taken to be equal to the right side in
Equation (6), then the following equation is obtained:

Solving Equation (7) for v
b yields the following Equation (8):

Inserting Equation (5) into Equation (8) yields the following Equation (9):

[0034] As can be seen from Equation (8) and Equation (9), it is possible to reduce the influence
of the brackets on the combustion surface to a minimum by determining the moving speed
of the brackets in accordance with the moving speed of the pallet and the moving pitch
of the brackets.
When the bracket speed is faster than that, then the number of times that areas are
affected by the brackets becomes non-uniform again, as shown in Fig. 20, so that it
can be seen that the above-noted condition is a special condition.
[0035] The foregoing has mainly shown the influence of the brackets on the combustion surface
and the effect of the present invention on this, but the same considerations hold
also for the surface shape of the sintering bed.
That is to say, in the case of fixed brackets, grooves as shown in Fig. 10 are formed,
and when these grooves are schematically emphasized, the situation in Fig. 15(a) is
attained. If the brackets are moved and their speed is changed from slow to fast,
the groove depth decreases from Fig. 15(b) to Fig. 15(d). Incidentally, showing the
state of Fig. 15(c) for a section of the entire sintering bed yields Fig. 5(b), with
zig-zag-shaped shallow grooves as shown in Fig. 5(a) remaining in the top view. The
depth of these zig-zag-shaped grooves is microscopically proportional to the number
in the squares shown in Fig. 18(a). Consequently, if the bracket speed is maintained
at the bracket speed of Equation (8) or Equation (9), which are given to address the
combustion surface problem, then the groove depth of the zig-zag-shaped grooves becomes
uniform across the entire sintering bed, as shown in Fig. 19. That is to say, it becomes
possible to maintain a surface shape and a bed height that are as if there were no
brackets at all.
[0036] The present invention is based on the foregoing observations and findings, and specifically
encompasses the following configurations:
[0037] (1) In a method for charging raw material to be sintered in accordance with the present
invention, raw material to be sintered is sorted and charged onto a pallet below,
by supplying the raw material to be sintered to a chute in which a plurality of wire-like
members are arranged side by side, the raw material to be sintered being supplied
to the chute while moving brackets supporting the wire-like members back and forth
in an axial direction of the wire-like members.
[0038] (2) An apparatus for charging raw material to be sintered in accordance with the
present invention, in which raw material to be sintered is sorted and charged onto
a pallet below, by supplying the raw material to be sintered to a chute in which a
plurality of wire-like members are arranged side by side, comprises a plurality of
brackets supporting the wire-like members, and a bracket moving mechanism that moves
the brackets back and forth in an axial direction of the wire-like members.
[0039] (3) In the apparatus according to (2), the brackets may have a function of scraping
off raw material powder adhering to the wire-like members, when moving the brackets.
[0040] (4) In the apparatus according to (2) or (3), a supporting portion of the brackets
that supports the wire-like members may have both a function of supporting the wire-like
members, and a function of scraping off raw material powder or the like adhering to
the wire-like members.
[0041] (5) In the apparatus according to any of (2) to (4), the distances between the plurality
of brackets are set to predetermined distances, and the plurality of brackets are
arranged to move while they keep the distances.
[0042] (6) In the apparatus according to any of (2) to (5), a movement range of a supporting
portion of the brackets that supports the wire-like members may be set to cover an
entire width of the chute formed by the wire-like members, when the brackets are moved
by the bracket moving mechanism.
[0043] (7) In the apparatus according to any of (2) to (6), the bracket moving mechanism
may comprise a moving mount that is placed slidably in a width direction of the pallet
and to which the brackets are fixed, and a driving device for sliding the moving mount.
[0044] (8) In the apparatus according to (7), fixed lateral walls may be provided on both
sides of the pallet, the brackets may be arranged to move between the two fixed lateral
walls, and a distance over which the brackets can move may be set to at least a spacing
between the plurality of brackets.
[0045] (9) The apparatus according to any of (2) to (8) may further comprise a driving device
into which a pallet moving speed is entered, which calculates a bracket moving speed
based on this entered value, and which moves the brackets based on the calculated
value.
[0046] (10) In the apparatus according to any of (2) to (9), the relation

may be satisfied, where P is a movement pitch of the brackets, H is a pile height
of the raw material, v
p is a pallet speed, θ
p is a pile angle of the raw material, and v
b is a bracket moving speed.
[0047] (11) In the apparatus according to any of (2) to (10), the wire-like members may
be covered with a non-metallic organic substance.
[0048] (12) In the apparatus according to any of (2) to (11), the moving speed of the brackets
may be set to 0.6 m/min or faster.
EFFECT OF THE INVENTION
[0049] In accordance with the present invention, the raw material to be sintered is supplied
to the chute while moving the brackets supporting the wire-like members in the axial
direction of the wire-like members, so that no groove-shaped portions are formed at
the surface of the deposited raw material, adherence of raw material powder and the
like to the wire-like members can be prevented, the gaps between the wire-like members
can be kept uniform and the sorting capabilities of the wire-like members can be maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050]
Fig. 1 is an illustrative diagram of the main parts of an apparatus for charging raw
material to be sintered in accordance with an embodiment of the present invention.
Fig. 2 is an illustrative diagram illustrating the apparatus for charging raw material
to be sintered shown in Fig. 1 in detail.
Fig. 3 is an illustrative diagram illustrating a portion of the apparatus for charging
raw material to be sintered shown in Fig. 1.
Fig. 4 is a diagram showing a conventional example to illustrate the effect of embodiments
of the present invention.
Fig. 5 is an illustrative diagram to illustrate the effect of embodiments of the present
invention.
Fig. 6 is an illustrative diagram to illustrate the effect of embodiments of the present
invention.
Fig. 7 is an illustrative diagram to illustrate another embodiment of the present
invention.
Fig. 8 is an illustrative diagram to illustrate another embodiment of the present
invention.
Fig. 9 is an illustrative diagram to illustrate another embodiment of the present
invention.
Fig. 10 is an illustrative diagram to illustrate a solution of the problem and schematically
shows the conventional groove-shaped portions.
Fig. 11 is an illustrative diagram to illustrate a solution of the problem, which
shows a state in which the conventional groove-shaped portions are leveled.
Fig. 12 is an illustrative diagram to illustrate a solution of the problem, which
shows the particle size distribution in portions affected by and portions unaffected
by the brackets.
Fig. 13 is an illustrative diagram to illustrate a solution of the problem, which
illustrates the influence of the groove-shaped portions on the combustion surface
in the case that the brackets are halted.
Fig. 14 is an illustrative diagram to illustrate a solution of the problem, which
illustrates the influence of the portions affected by the brackets on the combustion
surface in the case that the brackets are moved.
Fig. 15 is an illustrative diagram to illustrate a solution of the problem, which
schematically illustrates the bracket moving speed and the range of influence of the
brackets as well as the position of the combustion surface near the bottom of the
sintering bed. Note that this figure also schematically shows the groove-shaped portions
of the sintering bed.
Fig. 16 is an illustrative diagram to illustrate a solution of the problem, which
shows the state, viewed in cross section in the pallet advancing direction, when the
raw material is supplied from the drum chute to the pallet and piled onto it.
Fig. 17 is an illustrative diagram to illustrate a solution of the problem, which
shows a section of the sintering bed in a direction perpendicular to the pallet advancing
direction.
Fig. 18 is an illustrative diagram to illustrate a solution of the problem, which
shows, in a top view, the portions affected by the brackets when the brackets are
moved back and forth in the pallet width direction (Fig. 18(a)) as well as a section
of the sintering bed in the pallet axis direction (Fig. 18(b)) corresponding to Fig.
18(a).
Fig. 19 is an illustrative diagram to illustrate a solution of the problem, which
schematically shows a state in which the influence of the brackets is minimal.
Fig. 20 is an illustrative diagram to illustrate a solution of the problem, which
schematically shows a state viewed from the top of the portions affected by the brackets
when the bracket moving speed is faster than in the state of Fig. 19.
BEST MODE FOR CARRYING OUT THE INVENTION
Embodiment 1
[0051] Fig. 1 is an illustrative diagram of the main parts of an apparatus for charging
raw material to be sintered in accordance with an embodiment of the present invention.
This apparatus 1 for charging raw material to be sintered in accordance with the present
embodiment sorts raw material to be sintered by supplying the raw material to be sintered
from a drum chute 7 to a wire chute 5 made of a plurality of wires 3 arranged side
by side in parallel, and charging it to a pallet 9 below. The apparatus 1 includes
a moving support mechanism 13 that moves in a pallet width direction while intermediately
supporting wires 3 that are spanned between fixed lateral walls 11 erected on both
sides of the pallet 9.
The following is a detailed explanation of the configuration of the moving support
mechanism 13, which is a feature of the present invention.
[0052] The moving support mechanism 13 includes a rectangular sliding frame 15 that is arranged
straddling the top of the pallet 9 in the pallet width direction, three brackets 17,
19 and 21 that are arranged on the sliding frame 15 and support the wires 3, linear
movement bearings 23 that abut against the bottom surface of the sliding frame 15
and support the sliding frame 15 such that it is slidable in the pallet width direction,
and a hydraulic cylinder 25 that moves the sliding frame 15 in the pallet width direction.
The following is a further detailed explanation of the individual elements constituting
the moving support mechanism 13.
Brackets
[0053] The three brackets 17, 19 and 21 are placed on the sliding frame 15, spaced apart
by a predetermined spacing. The brackets 17, 19 and 21 include curved portions 17a,
19a and 21a that are sloped in a circularly curved shape, and foot portions 17b, 19b,
and 21b for fixing the brackets 17, 19 and 21 to the sliding frame 15. The curved
portions 17a, 19a and 21 are provided with a plurality of holes 17c, 19c and 21c through
which the wires 3 are inserted. Viewing the wires 3 inserted through the holes 17c,
19c and 21c provided in the curved portions 17a, 19a and 21a in a top view, the spacing
between the wires widens from the uppers side towards the lower side of the slope
of the curved portions 17a, 19a and 21a.
The wires 3 arranged between the fixed lateral walls 11 are inserted through the holes
17c, 19c and 21c in the three brackets 17, 19 and 21, and the wires 3 are supported
at their two ends by the fixed lateral walls 11 and are furthermore supported in between
by the brackets 17, 19 and 21. Moreover, the functionality is provided that when the
brackets 17, 19 and 21 are moved, raw material powder and the like adhering to the
wires 3 is scraped off by the edge of the holes 17c, 19c and 21c.
[0054] The spacing of the three brackets 17, 19 and 21 is set to an appropriate length,
such that a force supporting the wires 3 can be applied that is large enough so that
the wires 3 do not sag considerably, there are no excessive oscillations due to insufficient
stiffness, and the wires 3 do not shift from the position at which they are supposed
to be arranged. Such an appropriate length differs depending on the conditions, such
as the thickness and the tensile force of the wires 3, so that it is set in accordance
with these conditions.
It should be noted that the brackets 17, 19 and 21 are fixed to the sliding frame
15, so that the distance between the brackets 17, 19 and 21 does not change when the
sliding frame 15 is moved, and as a consequence, also the supporting force with which
the wires 3 are supported by the brackets 17, 19 and 21 does not change either.
However, the distance between the fixed lateral walls 11 and the brackets 17 and 21
placed at the two ends changes when the sliding frame 15 is moved. Therefore, it should
be ensured that the wires 3 can be properly supported also in the case that the distance
between the fixed lateral walls 11 and the brackets 17 and 21 at the two ends becomes
longest, and therefore, the maximum distance between the fixed walls and the brackets
17 and 21 at the two ends, that is, the distance between the fixed lateral wall 11
and the bracket 17 on the one side when the bracket 21 on the other side abuts against
the fixed lateral wall 11, is set such within a length range at which the wires 3
can be properly supported.
[0055] The foregoing was an explanation of the arrangement of the brackets 17, 19 and 21
from the viewpoint of properly supporting the wires 3, but for the arrangement of
the brackets 17, 19 and 21 and their movable range, one should also consider the aspect
of scraping off raw material powder adhering to the wires 3. That is to say, the raw
material powder adhering to the wires 3 should be scraped off with the holes 17c,
19c and 21c of the brackets 17, 19 and 21 by moving the brackets 17, 19 and 21, and
for this reason, it is preferable that when the sliding frame 15 is moved over one
cycle to the left and right in the drawing, the entire width of the wires 3 passes
through the holes 17c, 19c or 21c of any of the brackets 17, 19 or 21. For this reason,
the movable distance of the brackets should be set to be equal to or larger than the
distance between the brackets 17, 19 and 21. In the following, this aspect is explained
with reference to Fig. 2.
[0056] Fig. 2(a) shows the state when the brackets 17, 19 and 21 are moved furthest to the
right. Fig. 2(b) shows the state when the brackets 17, 19 and 21 are moved furthest
to the left. In Fig. 2(a), the distance between the fixed lateral walls 11, that is,
the entire width of the wires 3 is L, the distance between the leftmost bracket 17
and the fixed lateral wall 11 on the left, that is, the movable distance of the brackets
17, 19 and 21 is S, and the distance between the brackets 17, 19 and 21 is P.
When the brackets 17, 19 and 21 are moved from the state shown in Fig. 2(a) to the
state in Fig. 2(b) by sliding the sliding frame 15, the brackets 17, 19 and 21 move
by the distance S from the state shown in Fig. 2(a) to the left, so that the distance
over which each of the brackets 17, 19 and 21 passes along the wires 3 becomes S,
and the sum of the distances over which the three brackets 17, 19 and 21 pass along
the wires 3 is 3S.
Consequently, if the relation 3S ≥ L holds, the entire width of the wires 3 can be
passed by any of the brackets 17, 19 and 21. On the other hand, the relation L = S
+ 2P holds, as shown in Fig. 2(a), so that by inserting 3S ≥ L into this relation
and rearranging the resulting relation, S ≥ P is obtained as a condition that the
entire width of the wires 3 can be passed by any of the brackets 17, 19 and 21, or
in other words, "the movable distance S of the brackets is at least the distance P
between the brackets 17, 19 and 21."
It should be noted that the maximally allowable length of the distance P between the
brackets and the movable distance S of the bracket is the distance over which the
wires 3 can be properly supported, and the most efficient supporting structure is
attained when these lengths are both set to the maximally allowable length. In this
case, L = 3S = 3P results. Fig. 2 is a diagram illustrating this case.
Wires
[0057] A plurality of wires 3 are arranged between the two fixed lateral walls 11. The plurality
of wires 3 are set such that when the wires 3 are projected into the horizontal plane,
the distance between the wires widens from the obliquely upper side towards the lower
side. Thus, the raw material to be sintered that is supplied from the drum chute 7
is sorted, and a particle size distribution is attained, in which coarsely grained
raw material is deposited in the lower portion of the raw material layer on the pallet
9, whereas finely grained raw material is deposited in the upper portion.
It is preferable that the circumferential surface of the wires 3 is covered by a non-metallic
organic material (for example, by rubber, plastic or the like), so that raw material
powder does not adhere easily to the wires 3, and raw material powder can be easily
scraped off by the brackets 17, 19 and 21.
Bearings for Linear Movement
[0058] As shown in Fig. 1, linear movement bearings 23 are placed on fixing mounts 27 that
are placed on both sides of the pallets 9, and have the function of allowing smooth
movement of the sliding frame 15.
It should be noted that the linear movement bearings 23 are merely an example, and
it is also possible to use other components, as long as they have the function to
allow for smooth movement of the sliding frame 15.
Hydraulic Cylinder
[0059] The rod of a hydraulic cylinder 25 is coupled to the sliding frame 15, and the sliding
frame 15 can be moved by extending and retracting this rod.
In the present embodiment, the speed by which the rod is extended or retracted is
controlled to be 0.6 m/min or faster. By setting the speed by which the rod is extended
or retracted to 0.6 m/min or faster, the brackets 17, 19 and 21 are moved at a speed
of 0.6 m/min or faster, so that the presence of the brackets 17, 19 and 21 tends not
to exert an adverse influence on the sorting capability of the wire chute 5 when supplying
the raw material to be sintered.
[0060] Furthermore, it is preferable that the hydraulic cylinder 25 controls the extending/contracting
operation of its rod with a control device 29 as shown in Fig. 3.
The control device 29 receives the bracket movement pitch P, the pallet speed vp and
the raw material pile length Lb as input, and based on these parameters, calculates
the bracket moving speed v
b with the following Equation (9), and gives out the calculated bracket moving speed
v
b as an instruction.

It is also possible that the control device 29 receives the bracket movement pitch
P, the pallet speed v
p, the raw material charging portion pile angle θ
b and the sintering bed height H as input, and based on these parameters, calculates
the bracket moving speed v
b with the following Equation (8), and gives out the calculated bracket moving speed
v
b as an instruction.

For example, when the values v
p = 2m/min, θ
p = 40°, H = 600 mm, P = 1200 mm are used as typical values for a sintering machine,
then v
b = 6.7 m/min is attained.
[0061] It should be noted that in ordinary sintering machines, v
p is available in real-time as the pallet speed of the sintering machine, and this
signal may be used.
Moreover, also for the height H of the sintering bed, a similarly available signal
may be utilized. Needless to say, if such a signal is not available, a level sensor
detecting the height of the sintering bed may be provided and the signal from this
level sensor may be utilized.
Also the pile length Lb and the pile angle θ
p, may be determined by a level sensor or by image processing, and the resulting signals
may be utilized. Needless to say, these values hardly change at all, so that once
they have been measured, these values may also be manually entered. This is also the
same for the height H of the sintering bed.
[0062] It should be noted that instead of the hydraulic cylinder 25, it is also possible
to use an electric cylinder or a pneumatic cylinder.
[0063] The following is an explanation of a method for charging raw material to be sintered
using the apparatus 1 for charging raw material to be sintered according to the present
embodiment as explained above.
As shown by the arrows in Fig. 1, the pallet 9 moves in the opposite direction to
the direction in which the raw material slides and falls down when viewed in a top
view. Moreover, by driving the hydraulic cylinder 25, the sliding frame 15 is moved
back and forth at constant speed in the pallet width direction.
[0064] When the raw material to be sintered is fed by the drum chute 7 to the wire chute
5 in this state, the supplied raw material to be sintered slides and falls down the
oblique surface of the wire chute 5.
The gaps between the wires 3 forming the oblique surface of the wire chute 5 widen
from the upper portion to the lower portion of the oblique surface, so that in the
process of sliding and falling down the oblique surface of the wire chute 5, the raw
material is charged from the gaps between the wires 3 onto the pallet 9 starting with
the raw material of finer particle size and then gradually with the raw material of
coarser particle size.
On the other hand, the pallet 9 moves in the opposite direction to the direction in
which the raw material to be sintered is supplied, so that first the raw material
of coarser particle size is deposited onto the pallet 9, and the raw material of finer
particle size is deposited on top of that, so that a raw material layer is formed
that is segregated by particle size in the depth direction.
[0065] When the raw material to be sintered is supplied to the wire chute 5, the brackets
17, 19 and 21 are moved at a predetermined speed in the pallet width direction. Consequently,
the brackets 17, 19 and 21 supporting the wires 3 are not stopped at a constant location,
but constantly change their positions. For this reason, groove-shaped portions, which
were a problem in the conventional technology, are not formed in the surface layer
portion of the deposited raw material. Moreover, by moving the brackets 17, 19 and
21, raw material powder and the like adhering to the wires 3 is consistently scraped
off by the brackets 17, 19 and 21, and the gaps between the wires 3 are held at a
predetermined distance, so that the raw material is consistently sorted in a favorable
manner.
[0066] Thus, in the present embodiment, as the raw material to be sintered is supplied while
the wires 3 are supported by constantly moving brackets 17, 19 and 21, a deposition
layer of raw material can be formed that has a suitable segregation by particle size,
without forming groove-shaped portions in the surface layer portion of the deposited
raw material caused by the presence of the brackets 17, 19 and 21, which used to be
a problem in the conventional technology. Moreover, groove-shaped portions that have
arisen are not leveled, as in the technology of the prior art documents 1 and 2, but
such groove-shaped portions are not formed to begin with, so that also the problem
that the particle size distribution of the groove-shaped portions differs from that
at other locations when the arising groove-shaped portions are leveled does not occur.
[0067] Moreover, in the conventional examples in which the brackets do not move, the groove-shaped
portions arising due to the brackets (see Fig. 4(b), which is a sectional view along
the arrows A-A in Fig. 4(a)) are leveled, so that a scraper 31 having a V-shaped raking
body as shown in Fig. 4(a) used to be necessary, but in the present embodiment, since
the brackets are moved back and forth, the influence of the brackets is made as small
as possible (see Fig. 5(b), which is a sectional view along the arrows B-B in Fig.
5(a)), so that to level the portions affected by the brackets, it is sufficient to
provide a simple flat board as shown in Fig. 5(b). And such a flat board is usually
provided anyway in order to achieve a final adjustment of the height of the sintering
bed in ordinary sintering machines.
[0068] Moreover, by constantly moving the brackets 17, 19 and 21, the raw material powder
and the like adhering to the wires 3 is constantly scraped off by the brackets 17,
19 and 21, and the gap between the wires 3 is kept at a predetermined gaps, so that
raw material powder adhering to the wires 3 does not cause any adverse effects.
Moreover, the thinner the wires 3 are, the better the particle size distribution can
be adjusted, but conventionally, when the wires 3 are made thin, more brackets had
to be provided, and when more brackets are provided, more groove-shaped portions are
formed, so that ultimately the sorting capabilities cannot be improved. However with
the present embodiment, even though there is support by the brackets, the presence
of the brackets does not exert any adverse influence on the sorting capabilities,
so that it is possible to make the wires 3 as small as possible while increasing the
number of brackets, and more suitable sorting can be realized.
[0069] Moreover, in the present embodiment, the moving support mechanism 13 is formed by
a simple mechanism in which the brackets 17, 19 and 21 are fixed to the sliding frame
15, and the sliding frame 15 is moved back and forth, so that the effect is attained
that maintenance becomes easy and there are few malfunctions, even in an adverse environment
with a large amount of dust, namely the environment in which the raw material to be
sintered is supplied.
[0070] It should be noted that, as shown in Fig. 6, if the combustion air would flow in
the flow pattern A, the speed VB of the air flowing along the regions B, which are
the regions that are affected by the brackets, would be larger than the speed VA of
the air flowing in the regions that are unaffected by the brackets, that is, VB >
VA, which would reduce the effect of the present invention.
However, in practice, the flow path length Z
A in the case of the flow pattern A is longer than the flow path length Z
B in the case of the flow pattern B, and it is clear that the flow pattern B is attained,
in which the flow path length is short and the pressure loss is small, so that the
effect of the present invention as described can be sufficiently attained.
As will be shown in the following, in a typical sintering bed, Z
A is several times larger than Z
B.
First of all, the flow path length Z
A in case of the flow pattern A and the flow path length Z
B in case of the flow pattern B are given as follows:
ZA = H / sinθb
ZB = H
Furthermore, for a typical sintering bed, the bracket moving speed Vb, the pallet
moving speed v
p, and the pile angle θ
p are as follows.
v
b = 6.7 m/min
v
p = 2 m/min
θ
b = 40°
Z
A / Z
B = 1 / sinθ
b = (1 + (1/tanθ
b)
2)
1/2
As shown in Equation (1) noted above, the relation tanθ
b = v
p • tanθ
p / v
p holds, so that tanθ
b ≈ 2 • 0.84 / 6.7 = 0.25.
Consequently, Z
A / Z
B = (1 + (1 / 0.25)
2)
112 ≈ 4.1
[0071] It should be noted that there is no limitation to fixing the brackets to the sliding
frame 15, as a way to hold the brackets, and it is also possible that for example
the upper and lower ends of the brackets are fixed to separate wires or rods that
are arranged parallel to the wires 3 above and below the wires 3 constituting the
wire chute 5, and these wires or rods are moved in the pallet width direction.
[0072] In the above-noted example, an example was given in which the brackets 17, 19 and
21 are fixed to the sliding frame 15, and the three brackets 17, 19 and 21 are moved
unitarily, but the moving support mechanism 13 is not limited to this structure, and
a structure, in which the brackets 17, 19 and 21 are driven individually, is also
possible.
Moreover, in the above-described example, an example was given, in which three brackets
are provided, but the number of brackets is not limited to this, but can be set as
appropriate in view of such factors as the chute width, such that the condition is
satisfied that "the movable distance S of the brackets is at least the distance P
between the brackets 17, 19 and 21."
[0073] Moreover, in the above embodiment, holes 17c, 19c and 21c are provided in the brackets
17, 19 and 21, which have both the function of supporting the wires 3 with the rims
of the holes 17c, 19c and 21c and the function of scraping off raw material and the
like adhering to the wires 3. However, it is also possible to provide the location
supporting the wires 3 and the location having the function of scraping off raw material
and the like adhering to the wires 3 separately from each other on the brackets.
Furthermore, in the foregoing embodiment, an example was explained, in which wires
3 are provided as the wire-like members constituting the wire chute 5. However, the
wire-like members of the present invention may also be rods instead of wires.
[0074] Moreover, in the foregoing embodiment, an example was shown in which the hydraulic
cylinder 25 is used as the means for driving the sliding frame 15, but the driving
device according to the present invention is not limited to this. Fig. 7 is a drawing
showing another form of a means for driving the sliding frame 15. Fig. 7(a) is a perspective
view, and Fig. 7(b) is a diagram, in which the moving support mechanism 13 has been
added to the sectional view taken in longitudinal direction of Fig. 7(a).
As shown in Fig. 7, it is also possible to provide a rack / pinion mechanism, in which
a rack 35 is provided on the side of the sliding frame 15, and a pinion gear 37 rotated
by a motor meshes with the rack 35.
[0075] Moreover, as another form of a means for driving the sliding frame 15, it is also
possible to use a structure with a winch 43, having a structure in which ends of a
wire 41 are fixed to two locations in the sliding direction of the sliding frame 15,
and the wire 41 can be wound up and unwound with a wire drum 39 that is placed on
the rotation axis of a motor 38, as shown in Fig. 8.
Furthermore, a structure is also possible, in which a pair of screw shafts 45 arranged
in parallel are rotated by a motor 47, support portions 49 supporting the brackets
17, 19 and 21 are inserted onto the screw shafts, and the brackets 17, 19 and 21 are
moved in the screw shaft direction by the rotation of the screw shafts 45, without
using the sliding frame 15, as shown in Fig. 9, although this solution is inferior
with regard to durability and simplicity, compared to the solution with the slide
frame. Note that in the case of the structure shown in Fig. 9, it is preferable that
an accordion-like cover is provided at the portion of the screw.
INDEX TO REFERENCE NUMERALS
[0076]
- 1
- apparatus for charging raw material to be sintered
- 3
- wires
- 5
- wire chute
- 7
- drum chute
- 9
- pallet
- 11
- fixed lateral walls
- 13
- moving support mechanism
- 15
- sliding frame
- 17, 19, 21
- brackets
- 17a, 19a, 21a
- curved portions of brackets
- 17b, 19b, 21b
- foot portions of brackets
- 17c, 19c, 21c
- bracket holes
- 23
- linear movement bearings
- 25
- hydraulic cylinder
- 27
- fixing mounts
- 29
- control device
- 31
- scraper
- 33
- flat plate
- 35
- rack
- 37
- pinion gear
- 38
- motor
- 39
- wire drum
- 41
- wire
- 43
- winch
- 45
- screw shafts
- 47
- motor
- 49
- support portions