The new process of flue gas recirculation, which reduces coke consumption and reducing NOx emissions, is now extensively used. Compared with traditional sintering, the characteristics of circulating flue gas and coke parameters significantly affect the combustion atmosphere and coke combustion efficiency. Based on the actual complex process of sintering machine, this study proposes a relatively comprehensive one-dimensional, unsteady mathematical model for flue gas recirculation research. The model encompasses NOx pollutant generation and reduction, as well as SO2 generation and adsorption. We focus on the effects of cyclic flue gas characteristics on the sintering-bed temperature and NOx emissions, which are rarely studied, and provide a theoretical basis for NOx emission reduction. Simulation results show that during sintering, the fuel NOx is reduced by 50% and 10% when passing through the surface of coke particles and CO, respectively. During flue gas recirculation sintering, the increase in circulating gas O2 content, temperature, and supply-gas volume cause increased combustion efficiency of coke, reducing atmosphere, and NOx content in the circulating area; the temperature of the material layer also increases significantly and the sintering endpoint advances. During cyclic sintering, the small coke size and increased coke content increase the char-N release rate while promoting sufficient contact of NOx with the coke surface. Consequently, the NOx reduction rate increases. Compared with the conventional sintering, the designed flue gas recirculation condition saves 3.75% of coke consumption, i.e., for 1.2 kg of solid fuel per ton of sinter, the amount of flue gas treatment is reduced by 21.64% and NOx emissions is reduced by 23.59%. Moreover, without changing the existing sintering equipment, sintering capacity increases by about 5.56%.
The Effects of Coke Parameters and Circulating Flue Gas Characteristics on NOx Emission during Flue Gas Recirculation Sintering Process