Intensive reduction of fuel consumption in the sintering process of double-layered fuel segregation with return fines embedding

•The return fines embedding technology is proposed to reduce fuel consumption.•Return fines are recommended to embed in the lower layer of the sintering bed.•The O2 concentration in flue gas is decreased while the gas temperature is increased.•The fuel consumption can be reduced by 16% at most via the sintering pot test.•The fuel combustion is intensified due to the improved permeability.