Influence of sulfur dioxide-related interactions on PM_2.5 formation in iron ore sintering

The formation of PM_2.5 (aerosol particulate matter less than 2.5 µm in aerodynamic diameter) in association with SO₂ emission during sintering process has been studied by dividing the whole sintering process into six typical sampling stages. A low-pressure cascade impactor was used to collect PM_2.5 by automatically segregating particulates into six sizes. It was found that strong correlation existed between the emission properties of PM_2.5 and SO₂. Wet mixture layer (overwetted layer and raw mixture layer) had the function to simultaneously capture SO₂ and PM_2.5 during the early sintering stages, and released them back into flue gas mainly in the flue gas temperature-rising period. CaSO₄ crystals constituted the main SO₂-related PM_2.5 during the disappearing process of overwetted layer, which was able to form perfect individual crystals or to form particles with complex chemical compositions. Besides the existence of individual CaSO₄ crystals, mixed crystals of K₂SO₄-CaSO₄ in PM_2.5 were also found during the first half of the temperature-rising period of flue gas. The interaction between fine-grained Ca-based fluxes, potassium vapors, and SO₂ was the potential source of SO₂-related PM_2.5.

The emission property of PM_2.5 and SO₂ throughout the sintering process exhibited well similarity. This phenomenon tightened the relationship between the formation of PM_2.5 and the emission of SO₂. Through revealing the properties of SO₂-related PM_2.5 during sintering process, the potential interaction between fine-grained Ca-based fluxes, potassium vapors, and SO₂ was found to be the source of SO₂-related PM_2.5. This information can serve as the guidance to develop efficient techniques to control the formation and emission of PM_2.5 in practical sintering plants.