Iron ore sintering is governed by highly nonlinear dynamics and multiple operating conditions. The data of the process exhibits characteristics such as noise and imbalance. Traditional clustering methods, such as fuzzy C-means (FCM), often struggle to handle issues such as noise, data imbalance, and fuzzy clustering boundaries. This paper presents a multi-stage clustering framework that unifies information-granule modeling, intelligent optimization, and fuzzy clustering. Unlike conventional point-based methods, rectangular information granules are explicitly constructed to capture boundary uncertainty and subsequently optimized by particle swarm optimization, providing interpretable and adaptive data abstractions. A new weighted fuzzy-granule distance is then introduced to cluster the optimized granules, enabling precise partitions even in overlapping or weak-boundary regions. By replacing sensitive centroid estimates under noise with interpretable granules, the framework improves transitions, reduces membership ambiguity, and improves robustness. The method was benchmarked on six public UCI datasets and real-world production data of sintering process coming from an integrated steelworks. Against FCM, kernel-based FCM, spectral clustering and clustering algorithm based on bidirectional conical information granularity (CBCG), the proposed method achieved the highest average accuracy, Fowlkes-Mallows index, and rand index while retaining competitive rand index values. The main contributions of this paper are as follows: A novel industrial condition identification framework based on rectangular information granules is proposed, where rectangular information granularity is employed to replace the traditional point-based cluster center representation. A robust clustering framework combining weighted granule distance and fuzzy clustering is developed, enhancing clustering accuracy. On real-world production dataset, the proposed method improves accuracy by 22% compared to CBCG and achieves a 5.5% accuracy improvement over the field application method FCM.
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