Numerical study on the behaviour and distribution of sinter during charging of a blast furnace with Bell-Less top

In blast furnaces, the burden distribution directly impacts gas flow, productivity, and energy consumption. A thorough understanding of particle behaviour during the charging process is essential for accurate design of the charging system and for control of the burden distribution, but current research on the behaviour of the particles in the whole charging system has been limited. In this study, a scaled-down model of a bell-less blast furnace charging system was simulated using the Discrete Element Method. The charging process of sinter particles with a ternary particle size distribution was simulated, eventually forming a sinter layer on the burden surface onto a pre-distributed coke layer. The behaviour of sinter particles through the charging system was analysed both temporally and spatially. The results revealed distinct particle behaviour characteristics for different-sized particles, including particle size, velocity distribution, in the different components of the charging system. The burden distribution in the throat was assessed both radially and axially, revealing that the spatial and temporal characteristics of particle flow influenced the burden distribution. The upper and lower surfaces of the sinter layer show pronounced particle segregation. The study provides a comprehensive analysis of the charging process from the top hopper to the burden surface, highlighting the significant impact of spatial and temporal particle behaviour on the burden distribution in bell-less blast furnaces.