Coke Production and Gasification Mechanics in Ironmaking Systems

Coke production lies at the heart of traditional ironmaking, transforming carefully blended coals into a porous, carbon-rich material through high-temperature carbonisation in coke ovens. The resulting coke must exhibit sufficient mechanical strength to support the burden within a blast furnace while simultaneously showing controlled reactivity to participate in the reduction of iron oxides. Gasification mechanics describe the reaction of coke with oxidising gases—predominantly carbon dioxide—in the high-temperature zones of the furnace. This gasification, governed principally by the Boudouard reaction (C + CO₂ ↔ 2 CO), not only generates the reducing CO but also alters coke microstructure, porosity and strength. A balance between reactivity and physical integrity is essential: overly reactive coke degrades too rapidly, compromising furnace permeability, while insufficient gasification limits reduction efficiency and carbon utilisation. Recent advances span from characterisation of microstructural evolution under reactive atmospheres to the development of predictive models for coke quality, with growing interest in alternative carbon sources such as biocarbon. Improvements in understanding the interplay between coke texture, pore distribution and reaction kinetics underpin efforts to enhance furnace performance and reduce carbon emissions in iron and steelmaking globally.

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Coke Production and Gasification Mechanics in Ironmaking Systems publication trend

The graph below shows the total number of articles in coke production and gasification mechanics in ironmaking systems across all publications each year (not limited to Nature Index journals).

Technical terms

Coke: A porous, carbonised solid produced by heating coal blends in the absence of air, used as both support and reductant in blast furnaces.

Gasification: The reaction of carbonaceous material with oxidising agents (typically CO₂) at high temperature, producing CO and altering structure and strength of the solid phase.

Boudouard Reaction: The reversible high-temperature equilibrium between carbon, carbon dioxide and carbon monoxide (C + CO₂ ↔ 2 CO) that governs coke gasification in ironmaking.

Coke Reactivity Index (CRI): A measure of coke’s propensity to react with CO₂ under standard conditions, indicative of its gasification rate.

Coke Strength after Reaction (CSR): The residual mechanical strength of coke following a standard gasification test with CO₂, reflecting its resistance to degradation.

Cohesive Zone: The region within a blast furnace where burden materials soften, agglomerate and initiate direct reduction, critical for gas–solid interactions and coke performance.

References

1. Evolution of biocarbon strength and structure during gasification in CO2 containing gas atmosphere. Fuel Communications (2023).
2. Influence of unburned pulverized coal on gasification reaction of coke in blast furnace. High Temperature Materials and Processes (2019).
3. A comprehensive investigation of the reaction behaviorial features of coke with different CRIs in the simulated cohesive zone of a blast furnace. PLOS ONE (2021).