Sustainable Iron Ore Sintering for Reducing Energy Consumption and CO 2 Emissions - A Comprehensive Review

Sintering and pelletizing are two widely used agglomeration techniques for utilizing iron ore fines, concentrates, and wastes. Both processes are heavily dependent on fossil fuels. Although the sintering process generates higher CO2 emissions than pelletizing, it is expected to continue as long as the blast furnace (BF) route remains in operation. Pelletizing, on the other hand, is likely to play an even more significant role in next-generation steelmaking technologies. Despite many developments to reduce fossil fuel consumption and CO2 emissions, further advanced development is required to minimize these in both processes. This paper presents a comprehensive review of developments in iron ore sintering aimed at reducing energy and emissions. A corresponding review of pelletizing will be presented in a separate paper. The review critically examines the key factors influencing energy consumption. Major developments reported in the literature, such as solid fuel reduction and substitution, raw materials preparation, operating practice, and heat recovery, are systematically analyzed with critical observations. Many innovative developments having strong potential for plant-scale implementation are also discussed. Based on the review, practical insights are derived to support plant operators in adopting effective energy-reduction strategies, which will support future energy-efficient and low-carbon ironmaking routes toward net-zero emissions.