The degree of homogeneity of the sintered ore phase structure directly determines its quality index. A sinter ore quality evaluation method based on the quantification of the homogeneity of the mineral phase structure is proposed. First, the magnetite particle size characteristics in the ore phase structures with different degrees of homogeneity were summarized under a polarized light microscope, and a criterion for evaluating the uniformity of the sintered ore phase structure based on the magnetite content of different particle size grades was determined. Second, a multiple regression model was established for the raw material composition ratio of magnetite with varying particle size grades. Finally, the multiple regression model was optimized using the second-generation non-dominated sorting genetic algorithm (NSGA2). The results show that mineral phase structure analysis categorized the magnetite particle sizes into 60 μm. The adjusted R² of the multiple regression model of the chemical composition of raw materials and the proportion of magnetite of each particle size grade were all greater than 0.95, and the p values were all <0.05, indicating a high degree of model fitting. Using model analysis, the single factor and the interaction between the multiple factors that significantly influence the proportion of magnetite in the three particle size grades were determined. The multivariate regression model was optimized using the NSGA2 algorithm to determine the ratios of Al₂O₃ mass% = 1.82, MgO mass% = 1.50, and R(CaO mass%/SiO₂ mass%) = 1.84 for the highest degree of uniformity of the sintered ores. Under this sintering condition, the micro-mineral phase structure became more homogeneous, confirming the model’s reliability.

To meet the demanding requirements of continuous casting for low-alloy peritectic steel, this study aimed to design high-performance mold fluxes with optimized properties. The melting properties, crystallization behavior, mineralogical characteristics, and heat transfer mechanism of the industrial mold fluxes and flux films were investigated by melting tester, viscometer, in situ thermal analyzer, thermal conductivity meter, polarizing microscope, X-ray diffraction, and thermodynamic software. The results demonstrate that mold fluxes suitable for low-alloy peritectic steel possess a narrow melting temperature range, low melting point (<1200 °C), and low viscosity (50 °C/s) and high initial crystallization temperature (>1350 °C), facilitating the rapid formation of a stable crystalline layer and uniform heat transfer. The flux films with outstanding characteristics have a multilayered structure and high crystallization ratio (60–80 vol%), predominantly comprising a high fraction of coarsened cuspidine crystals. Further analysis of the heat transfer mechanism reveals that the highly crystalline and coarse-grained microstructure promotes the formation of micropores and crystal boundaries in flux films, which substantially increase thermal resistance, leading to low thermal conductivity (0.47–0.67 W/m·K) and effective control of heat transfer rate. It is concluded that enhancing crystallization performance through optimizing flux composition (boosting Na₂O content and basicity) to promote cuspidine formation and tailor crystallinity, is the crucial route for acquiring the desired mineralogical structure of flux films and enabling efficient continuous casting of low-alloy peritectic steel.