JFE Steel Corporation has developed a sensor that measures the particle-size distribution of granulated materials in real time as they move on conveyors during the sintering process. The system is already in operation at the Fukuyama sintering plant at JFE Steel’s West Japan Works, where it has demonstrated improvements in sinter productivity. The company plans to roll out the technology to additional sintering lines to help stabilize blast furnace operations and overall steel production.
In sinter production, iron ore fines are mixed with moisture to form granules before being fired at high temperatures. Variations in granule size can disrupt airflow and temperature distribution in the sintering bed, reducing product quality and efficiency. Until now, size distribution has been monitored through manual sampling and mechanical separation, a process that is labor-intensive, time-consuming, and sometimes imprecise.
The new sensor uses lasers and cameras installed above conveyors to capture the three-dimensional surface of the granules. Image-processing technology continuously calculates particle-size distribution, enabling real-time monitoring and immediate operational adjustments, resulting in more stable and productive sintering.
JFE Steel plans to apply this proprietary technology to other processes and offer it externally as part of its solutions business under the name Online Granulometer for Materials on Conveyors. The development also supports the company’s digital transformation strategy, which integrates sensor data, AI analysis, and cyber-physical systems to improve operational stability, productivity, and product quality across its steelworks.
