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<p>A sintering double-stage cooling unit (SDCU) was proposed to address the issues of material segregation and unclear particle motion mechanisms in the sintered ore vertical cooler as well as the low efficiency of energy recovery in the circular recirculating cooler (CRC). The proposed SDCU improves traditional waste heat recovery and enhances steady-state heat transfer efficiency under gas–solid conditions. Comparative analyses of exergy and exergy efficiency between the SDCU and CRC were presented. The effects of key parameters, including the gas–solid volume-to-mass ratio, inlet air temperature, and inlet sinter temperature, on system performance were examined. Furthermore, the integration of the SDCU with Joule-Brayton cycle-based phase-change thermal energy storage and supercritical CO<sub>2</sub> Brayton cycle systems was explored. The results indicate that the SDCU outperforms the CRC in exergy recovery and efficiency by 6.73% and 6.26%, respectively. The optimal gas–solid mass ratio in the recirculating cooling unit is 1.08 m<sup>3</sup>/kg, leading to improvements in SDCU exergy by 2.1 and 2.3 GJ/h for every 10&#xa0;K increase in inlet ore and air temperatures, respectively. The phase-change thermal energy storage system stores 423.7&#xa0;kW of thermal energy, while the supercritical CO<sub>2</sub> system recovers 12.2&#xa0;MW of thermal energy.</p>

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Numerical modeling and comparative analysis of sintering double-stage cooling unit for improved gas–solid heat transfer and exergy recovery

  • 期刊论文

  • 发表日期：

    2026年1月17日

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  • Xue-Zhi Hao,
  • Liang Zhao,
  • Zhen Zhang,
  • Xiao-Hu Zhang,
  • Wen-Chang Wu,
  • Jun-Sheng Feng,
  • Hui Dong

摘要

A sintering double-stage cooling unit (SDCU) was proposed to address the issues of material segregation and unclear particle motion mechanisms in the sintered ore vertical cooler as well as the low efficiency of energy recovery in the circular recirculating cooler (CRC). The proposed SDCU improves traditional waste heat recovery and enhances steady-state heat transfer efficiency under gas–solid conditions. Comparative analyses of exergy and exergy efficiency between the SDCU and CRC were presented. The effects of key parameters, including the gas–solid volume-to-mass ratio, inlet air temperature, and inlet sinter temperature, on system performance were examined. Furthermore, the integration of the SDCU with Joule-Brayton cycle-based phase-change thermal energy storage and supercritical CO2 Brayton cycle systems was explored. The results indicate that the SDCU outperforms the CRC in exergy recovery and efficiency by 6.73% and 6.26%, respectively. The optimal gas–solid mass ratio in the recirculating cooling unit is 1.08 m3/kg, leading to improvements in SDCU exergy by 2.1 and 2.3 GJ/h for every 10 K increase in inlet ore and air temperatures, respectively. The phase-change thermal energy storage system stores 423.7 kW of thermal energy, while the supercritical CO2 system recovers 12.2 MW of thermal energy.