JFE Steel Corporation announced today that it has developed a sensor that measures in real time the particle-size distribution of granulated material as it is transported on conveyors for sintering. Currently in use at the Fukuyama sintering plant of JFE Steel’s West Japan Works, the new sensor has demonstrated its ability to enhance sinter productivity. Going forward, JFE Steel plans to deploy the sensor on sintering lines at other plants to further stabilize blast furnace operations and steel production.

The production of sinter involves adding moisture to iron ore fines to create granules, which are then fired at high temperatures in a sintering machine. Variations in granule size can cause uneven airflow and temperature distribution within the raw material bed of the sintering machine, impairing sinter quality and productivity. Currently, granule-size distribution is done manually by collecting and analyzing granule samples from a conveyor, then using a machine to separate granules by size. However, this process is labor intensive and time-consuming, and separation is sometimes imprecise.

The newly developed sensor uses lasers and cameras installed above the conveyor to capture the 3D surface shape of granules, using image processing to continuously calculate particle-size distribution. Monitoring in real time and making immediate adjustments ensure precise separation and more productive sintering (Figure 1).

JFE Steel plans to apply this proprietary technology to other processes as well, and offer it to steelmakers and other manufacturers as a new solutions business called Online Granulometer for Materials on Conveyors.

As part of its digital transformation (DX) strategy, JFE Steel is widely deploying Cyber-Physical Systems (CPS) to create intelligent steelworks (Figure 2). First, sensor data is collected from physical manufacturing processes and then AI analyzes the data. Next, virtual (cyber) processes are recreated in a digital space using proprietary methods. Finally, the two are connected in real time. This virtual process predicts future equipment states by revealing internal states that are invisible in reality. Applying the results of status monitoring and anomaly prediction to actual processes realizes more stable operations and improved productivity.

Going forward, JFE Steel’s DX initiatives will include the implementation of CPS in manufacturing and product-quality processes, aiming to enhance productivity and ensure stable operations. JFE Steel also intends to address other challenges in diverse areas of manufacturing and actively provide its expertise to customers through JFE Resolus^®, the company’s solutions-business brand, ultimately to contribute to a more sustainable world.

Figure 1: Granule-size Distribution Sensor and Sintering Process Flow

Figure 2: Intelligent Steelworks

Related links:

・Online Granulometer for Materials on Conveyors
https://www.jfe-steel.co.jp/en/products/solution/data-science/20-online-granulometer.html

・DX REPORT 2024
https://www.jfe-holdings.co.jp/en/common/pdf/investor/library/dxreport/2024/all_A4.pdf

About JFE Steel Corporation

JFE Steel Corporation, one of the world’s leading integrated steel producers, was established through the consolidation of NKK Corporation and Kawasaki Steel Corporation in 2003. The company operates several steelworks in Japan and numerous branch offices and affiliates throughout the world. Under the corporate vision of “contributing to society with the world’s most innovative technology,” JFE Steel leverages world-class technologies and know-how to produce a wide range of products. The company reported consolidated sales of 3,716 billion yen and consolidated crude steel output of 24.80 million tons in the fiscal year ended March 2023.

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