Optimus Sinter

Sinter plant optimization made easy

Metso has developed a holistic sinter plant optimizer, Optimus Sinter, which facilitates improved process performance and stability by holistically enabling the optimization of the overall sintering processes.

Process performance, stability
and flexibility

Reduced fuel consumption and operation cost

Reduced CO2 footprint

Operation insights and integrated best practices

Get more out of your sinter plant operations without making any hardware modifications

Maintaining an iron ore sintering plants operations is not easy. The sintering industry is faced with several challenges, such as:

Declining availability of sinter fines requests solutions for increased share of concentrates is a challenge
The sustainable treatment of iron bearing residues in integrated steel plants is also a big task
In addition, the demands from operators have also increased manifold. Not only are they expected to keep the plants up and running, but also reduce the carbon footprint of the sinter plants to enable the transition of the steel industry towards decarbonization
High-cost pressure and tightening emission levels for dust, NO_x, SO_x, dioxines and noise are other important aspects to be taken care of

Key benefits

Optimus Sinter has a thermodynamic model at its core. This was developed using Metso’s unparalleled process expertise, years of experience in designing, delivering and commissioning of hundreds of sinter plants all over the world, as well as a strong know-how of process modelling in a variety of different metallurgical processes.

Based on actual raw material data, the process data from DCS and the proprietary process model Optimus Sinter can holistically facilitate:

Up to 2% increase in gross sinter production
Up to 4% improvement in electrical energy consumption
Reliably reduce the solid fuel consumption
Deep online insights into sinter process assisting operational adjustments and onboarding of operators
Optimal dosing of solid fuel reduces emissions
Adjustment of fan operation to process requirements enables electrical energy savings
Maximize production capacity while maintaining product quality at required levels

Continuous real-time data analysis

Data insights offered by Optimus Sinter

Online, real-time process calculations
Monitoring of relevant process parameters and KPIs like energy consumption and CO₂ footprint
Visualization of chemical and physical processes and temperatures in the sinter bed
Online optimization of the feed material mix
Real-time forecast of product quality (sinter strength, Fe/Fe²⁺ content, basicity)
Improved Burn-Through-Point (BTP) calculation