Coal Combustion Dynamics in Blast Furnace Operations
Summary
Coal combustion in blast furnaces underpins modern ironmaking by partially replacing metallurgical coke with injected coal. Pulverised coal is carried by hot blast air through tuyeres into the raceway, where rapid heating, devolatilisation and char oxidation occur. The interplay of fluid dynamics, heat transfer and chemical kinetics governs flame temperature, burnout rate and reducing gas composition. Key challenges include quenching of the raceway flame by inert gas dilution, char agglomeration affecting permeability in the cohesive zone, and the need to sustain high thermal efficiency while reducing CO₂ emissions. Advances in computational fluid dynamics and thermogravimetric analysis have enabled detailed modelling of multi-phase reacting flows, particle trajectories and combustion kinetics. Alternative injectants such as hydrochar, syngas and hydrogen-rich gas are under evaluation to lower carbon intensity and enhance stability. Optimisation of oxygen enrichment, pre-heating of injection gas and swirler design at the tuyere level has shown promise in maintaining raceway adiabatic flame temperatures and maximising fuel utilisation. Globally, improvements in coal combustion dynamics support lower operating costs, higher productivity and compliance with increasingly stringent environmental regulations in the steel industry.
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Coal Combustion Dynamics in Blast Furnace Operations publication trend
The graph below shows the total number of articles in coal combustion dynamics in blast furnace operations across all publications each year (not limited to Nature Index journals).
Technical terms
Pulverised Coal Injection (PCI): A method of introducing fine coal particles into the blast furnace to replace part of the coke burden and reduce costs.
Tuyere: A water-cooled nozzle through which hot blast and injected fuels enter the furnace hearth to form the combustion raceway.
Raceway: The cavity immediately in front of the tuyere where gas–solid reactions and high-temperature combustion of pulverised coal occur.
Cohesive Zone: The temperature range in the furnace shaft where iron ore particles soften and fuse, affecting gas permeability.
Burnout Rate: The proportion of injected coal converted to gas and ash, indicating combustion completeness and efficiency.
References
- Use of Hydrogen–Rich Gas in Blast Furnace Ironmaking of V–bearing Titanomagnetite: Mass and Energy Balance Calculations. Materials (2022).
- Investigating char agglomeration in blast furnace coal injection. Fuel Processing Technology (2018).
- Numerical Simulation Study on the Effects of Co-Injection of Pulverized Coal and Hydrochar into the Blast Furnace. Sustainability (2022).
- Combustion Enhancement of Pulverized Coal with Targeted Oxygen-Enrichment in an Ironmaking Blast Furnace. Processes (2021).
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