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Analyzing the wetting behavior between carbon brick and molten iron in a blast furnace is crucial for understanding prolonging the furnace's lifespan. This study investigates the wetting behavior between microporous carbon brick and molten iron. The contact angle between the carbon brick and molten iron is measured at various temperatures and carbon saturation conditions, while the microscopic morphology of the reacted interface is examined. Furthermore, the wetting mechanism of molten iron on the carbon brick surface is elucidated. The findings reveal that both the microporous carbon brick and molten iron remain in a never‐wetting state within the furnace. As the temperature rises from 1150 to 1450 °C, the contact angle decreases from 138° to 128°, whereas the initial carbon content in the molten iron increases from 2.6 wt% to 4.1 wt%. Additionally, the initial contact angles gradually increase from 128.3° to 133.6°, with final equilibrium contact angles of 119.2° to 127.0°, indicating a nonwetting state. The carbon dissolution reaction occurs within the carbon matrix region of the microporous carbon brick prior to carbon saturation in the molten iron. Conversely, the presence of a ceramic phase in the ceramic area hampers both chemical erosion and physical penetration of the molten iron. [ABSTRACT FROM AUTHOR]

Investigating the presence of a Ti(C,N) protective layer in molten iron is of great significance for achieving low carbon and safe production in blast furnaces. This study focuses on analyzing the high temperature dissolution experiment of TiC0.3N0.7 in molten iron to elucidate the kinetics and mechanisms involved, as well as strategies for regulating its dissolution. The results reveal that the dissolution reaction of TiC0.3N0.7 is predominantly influenced by the temperature and flow speed of the molten iron. The dissolution process can be categorized into two stages: dissolution reaction and physical penetration. Diffusion mass transfer is the dominant factor controlling the dissolution of TiC0.3N0.7, with an apparent activation energy of 60.15 kJ/mol. Upon contact with molten iron, dendritic penetration of TiC0.3N0.7 particles occurs, starting from the edges. To enhance the stable presence of TiC0.3N0.7, recommendations include reinforcing furnace cylinder cooling, reducing the heat transfer coefficient of the blast furnace hearth's resistant material, increasing the carbon content of the molten iron, and decreasing the sulfur content of the molten iron. [ABSTRACT FROM AUTHOR]

Blast furnace smelting is a traditional iron-making process. Its product, hot metal, is an important raw material for the production of steel. Steelmaking efficiency can be improved and steel product quality can be stabilized by using proper hot metal. Sulfur is an important indicator reflecting the quality of hot metal, it is necessary to establish an accurate prediction model to predict the sulfur content of hot metal, to effectively guide the production process. There is a non-linear relationship among the factors influencing the desulfurization effect during the blast furnace smelting process, and the back propagation neural network (BPNN) model has a strong ability to solve nonlinear problems. However, BPNN has the disadvantages of slow convergence speed and easy to fall into local minima. To improve the prediction accuracy, an improved algorithm combining Kmeans and BPNN is proposed in this paper. The study showed that compared with the BPNN model and case-based reasoning (CBR) model, the Kmeans-BPNN model has the lowest RMSE and MAPE values, which indicates a high degree of fit and a low degree of dispersion. The Kmeans-BPNN model has the largest HR value, which indicates the highest prediction accuracy. The proposed Kmeans-BPNN prediction model achieves a hit rate of 96%, which is 4.5% higher than before the improvement. It can effectively improve the prediction accuracy of hot metal sulfur content. [ABSTRACT FROM AUTHOR]

This study simulated the corrosion reaction of S-carbon bricks in a hearth at different carbon contents, flow velocities and temperatures, and their macroscopic and microscopic morphologies were observed by scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS). The results showed that the dissolution of elemental carbon from carbon bricks into molten iron was a rate-controlled reaction. Increasing the temperature to around 1500 °C and decreasing the carbon content to around 4.5% reduced the saturated solubility of carbon in molten iron, and the erosion degree and dissolution rate of the carbon bricks increased correspondingly. For the flow velocity, its increase promoted mechanical flushing and led to an increase in the convective heat transfer coefficient of molten iron, which would increase the hot-side temperature of the hearth sidewall, promoting carbon unsaturation in hot metal and the dissolution reaction. [ABSTRACT FROM AUTHOR]

A new tuyere small sleeve coating structure that balances the high thermal conductivity of the copper substrate with the high wear resistance of the protective layer was developed in this paper. This structure can achieve a low-carbon blast furnace by reducing the heat loss from the tuyere. The 3D model was established via Solidworks for modeling and Ansys for numerical simulation, the temperature field of the annular wear-resistant layer structure tuyere small sleeve with different widths of the wear-resistant layer was analyzed and compared with the temperature and stress field of traditional tuyere small sleeve. The results show that the design of the annular wear-resistant layer structure of the tuyere small sleeve is more effective. The new annular wear-resistant layer structure for the tuyere small sleeve results in a decrease of 24 K in the average temperature of the wear-resistant coating. The comparison of this structure with tuyere sleeves without wear-resistant coatings shows a 16.7% reduction in heat loss, improves the wear resistance of the tuyere, providing new technological ideas for low-carbon blast furnace production. Compared with the tuyere sleeve completely covered with a wear-resistant coating, the maximum thermal stress of this structure decreased from 624.98 Mpa to 427.99 Mpa, resulting in a reduction of 31.5%, which is beneficial for the service life of the tuyere sleeve. The copper surface temperature of the new tuyere small sleeve is in a safe range when the temperature is below 2273 K. [ABSTRACT FROM AUTHOR]

Understanding the heat transfer properties of the slag crust is critical to the safe operation of copper staves. The distribution of metallic iron and bubbles in the slag crust is detected by X‐ray computed tomography. The thermal conductivity of the slag crust is modified based on an effective thermal conductivity model and laser thermal conductivity measurements to predict the effect of metallic iron and bubbles on the heat transfer in the slag crust. The results show that the average volume fractions of metallic iron and air bubbles in the slag crust are 3% and 4.5%, respectively. The measured value is consistent with the trend of the effective thermal conductivity calculation model, and the calculation result of the Maxwell–Eucken effective thermal conductivity model is very accurate. Variations in the volume fraction of metallic iron in the slag crust have a greater effect on the thickness of the slag crust, while variations in the volume fraction of bubbles have a smaller effect on the thickness of the slag crust. It is recommended to keep it between 10 and 30 mm in blast furnace production to help improve the operational life of the copper stave. [ABSTRACT FROM AUTHOR]

The sulfur content of hot metal in a blast furnace is an important index that reflects the production effects and quality of the hot metal. Establishing an accurate prediction model for hot metal sulfur content can guide the production process. In the present study, the blast furnace production data were collected and then preprocessed using box plotting. Cross-validation was used in the training process of the model to improve the generalization performance and robustness of the model. Two models for predicting the sulfur content in hot metal were established based on extreme gradient boosting (XGBoost) and multilayer perceptron (MLP) algorithms. The results show that coal consumption (CC), coal ratio (CLR), and sinter consumption (SC) are all positively correlated with hot metal sulfur content. The oxygen enrichment rate (OER) was negatively related to hot metal sulfur content. Both the extreme gradient boosting (XGBoost) and multilayer perceptron (MLP) models predicted hot metal sulfur content effectively; however, the extreme gradient boosting (XGBoost) model had a higher hit rate, accuracy, and stability, with the hit rate achieving 95.07%. [ABSTRACT FROM AUTHOR]

[Display omitted] • The dissolution limit content of CaO dissolved in coal-coke-slag was characterized. • The dissolution rate of CaO and properties evolution of coal-coke-slag were analyzed. • The dissolution mechanism of CaO dissolved in coal-coke-slag was revealed. • The injected content of CaO in the blast furnace tuyere was quantified. In the pursuit of optimizing smelting efficiency and minimizing carbon emissions in blast furnace operations, the strategic introduction of the tuyere alkaline flux injection, particularly in managing the viscosity of the coal-coke-slag in the bird's nest region, is investigated. This study focused on exploring the dynamics of CaO dissolution within the slag of the coal-coke-slag in the bird's nest area of a 2200 m3 blast furnace in China, particularly under conditions of instability. Quantitative analysis revealed that at 1550 °C, the CaO maximal dissolution capacity reached 62.05 wt%, with an average rate constant of dissolution observed at 4.65 × 10−4 s−1. The dissolution mechanism was characterized by interfacial dissociation, mass transfer diffusion, and the attainment of a dynamic equilibrium, predominantly influenced by the Ca2+ concentration gradient within the slag. This process facilitates the depolymerization of the slag's network structure, heavily influenced by the aluminum oxide tetrahedron, effectively reducing slag viscosity. Further, the study quantified the optimal CaO injection content through the tuyere, suggesting a range of 4.00–5.32 kg/tHM, contingent on the use of high-quality raw fuel and advanced high wind temperature technology. This work contributes valuable theoretical insights towards enhancing the efficiency and sustainability of smelting operations, applicable to both conventional and high pellet blast furnaces, marking a significant step forward in the development of low-carbon metallurgical processes. [ABSTRACT FROM AUTHOR]

• The distribution characteristics of CaS in the radial direction of the hearth were analyzed. • The formation mechanism and migration process of CaS in the hearth were analyzed. • The interface reaction between slag and coke is the main source of CaS formation in the furnace hearth. As the main occurrence form of sulfur element in blast furnace hearth, high content of CaS within the blast furnace hearth have a certain impact on low-carbon smelting of blast furnace. In this paper, the micro-morphology and distribution of CaS in the hearth area are studied by scanning electron microscopy and industrial CT, and the formation process of CaS in the deadman is clarified by drilling core samples of residual iron in the hearth of 3200 m3 blast furnace in China. The research results indicate that CaS in the hearth is mainly formed by slag-coke interface reaction and slag-iron interface reaction. Based on an analysis of the relative difficulty of these two pathways, it was observed that CaS is more readily generated through the slag-coke interface reaction. Based on the analysis of the difficulty of the two generation paths, it is found that CaS in the blast furnace hearth is more easily generated through slag coke interface reaction. The CaS particles generated in the hearth take the slag as the growth matrix, and with the flow of slag and iron and the renewal of the deadman coke, they are finally enriched and precipitated in the edge area of the deadman in the form of agglomerates. Based on the formation mechanism of CaS in the hearth, it is analyzed that the formation of CaS aggregates in the hearth is mainly affected by three factors: sulfur load, slag basicity and hearth temperature. This study provides a certain theoretical reference and guidance for steel enterprises aiming to reduce fuel consumption and achieve green production practices. [ABSTRACT FROM AUTHOR]

The thickness of the carbon bricks is one of the important factors of the longevity of the blast furnace. Herein, a large number of brittle carbon bricks in the hearth sidewall and the continuous rectangle‐shape floating refractory in residual iron are found during the blast furnace hearth dissection. The occurrence state of the carbon brick is characterized through chemical analysis, X‐ray diffraction (XRD), and scanning electron microscope (SEM)–energy‐dispersive X‐ray spectroscopy (EDS). The contents of K, Na, Cl, Zn, and Fe in brittle carbon bricks are relatively high, and a large number of large‐scale Al2O3 phases and nepheline appear in the floating carbon brick. It indicates that K, Na, Cl, Zn, and Fe are major causes for the serious erosion of the carbon brick, and the floating carbon brick may come from brittle carbon bricks on the sidewall. In addition, the source of Al2O3 and the consumption pathway of SiO2 and ZnO in floating refractory in residual iron are analyzed. Finally, the disappearing mechanism of carbon brick is proposed, which is that the carbon bricks floated up to the tuyere and burnt. [ABSTRACT FROM AUTHOR]

• The temperature field in the bird's nest area of blast furnace tuyere is characterized. • The phase composition of coal-coke-slag is quantitatively characterized. • The radial physicochemical properties of coal-coke-slag are analyzed. • Modification suggestions of coal-coke-slag are proposed. Understanding the occurrence of phases and the evolution of physicochemical properties in coal-coke-slag powder within the blast furnace tuyere's bird's nest area is crucial for reducing carbon emissions and energy consumption in the blast furnace. By dissecting a 2200 m3 blast furnace in China, the temperature field and high-temperature physicochemical properties of coal-coke-slag powder in the tuyere bird's nest area along the radial direction were determined. Firstly, the temperature range in the tuyere bird's nest area spanned from 1523 °C to 1709 °C, with the maximum temperature near the end of the bird's nest area. Secondly, the mass proportions of coal, coke and slag in coal-coke-slag powder were 42.16 %, 25.90 % and 31.94 %, respectively. Along the radial direction of the blast furnace, the degree of graphitization of carbon components of coal-coke-slag increased gradually, and the melting temperature and viscosity of the slag phase also exhibited a gradual increase. Finally, the modification suggestions of the physicochemical properties of coal-coke-slag were put forward, with a focus on three factors: fuel, slag, and temperature. By employing tuyere injection operations with Ca-Fe flux, and using fuel with low ash content, larger particle size, fewer harmful elements, and excellent combustion performance, more heat input was provided to the front of the bird's nest area, which contributed to improved furnace efficiency and performance. [ABSTRACT FROM AUTHOR]

• Occurrence state of cinder multiphase components in the bird's nest area is reviewed. • Formation mechanism of tuyere cinder is proposed. • Modification methods of tuyere cinder are reviewed. • Future research directions of tuyere cinder are proposed. The presence of cinder in the tuyere bird's nest region poses a significant obstacle to the energy-saving production of blast furnaces by impeding the penetration of high-temperature gas into the charge column. This paper provides a comprehensive review of the multiphase occurrence state, formation mechanism, and modification methods of cinder. Firstly, the phase composition and high-temperature performance of cinder are investigated from various perspectives, including tuyere coke, tuyere slag, coal ash slag, and the interaction between residual carbon and coal ash slag. These aspects shed light on the characterization of cinder and its behavior at elevated temperatures. Secondly, the formation mechanism of cinder is explored, aiming to unravel the factors contributing to its generation. Understanding the underlying mechanisms is crucial for devising effective strategies to mitigate or modify its formation. Thirdly, the paper examines the modification methods of cinder from three aspects: tuyere flux injection technology, tuyere hydrogen-rich injection technology, and tuyere sequence impulse injection technology. These approaches offer potential means to alter the characteristics and behavior of cinder. Finally, future research on cinder can focus on the characterization and performance analysis, depth analysis of formation mechanisms, and exploration of the modification mechanisms. [ABSTRACT FROM AUTHOR]

• The physicochemical properties of cinder slag in the birdnest region are characterized. • The modification effects of Ca2+, Mg2+ and Fe2+ on the cinder slag are analyzed. • The interaction modification of Ca2+ and Fe2+ is more strongly. • The injection content of alkaline flux from the tuyere is clarified. An important factor in increasing gas utilization and lowering carbon emissions is the removal of cinder from the tuyere birdnest region of the blast furnace. Based on a 2200 m3 blast furnace in China, the physicochemical characteristics of cinder are investigated in this paper. Alkaline flux's chemical modification and flux injection content are examined to alter the fluidity of cinder slag. Firstly, the basicity and aluminum content of cinder slag are 0.80 and 40.33%, respectively. The melting characteristic of cinder slag is high and the liquid phase fluidity is poor. Secondly, as the content of CaO, MgO, and FeO grow while the viscosity keeps declining, the melting temperature of the cinder first decreases and then rises, rises, and decreases. Compared to Mg2+, Ca2+ and Fe2+ have higher diffusion rates and a stronger interaction modification impact. The potential of flux modification is CaO + FeO > CaO + MgO > CaO > FeO > MgO. Finally, the optimum chemical modification occurs when the basicity of cinder slag is 1.05 and the FeO content is 0.40%. During regular blast furnace operation, 1.62 kg/tHM of limestone and 5.92 kg/tHM of basic oxygen furnace (BOF) slag are injected into the tuyere. [ABSTRACT FROM AUTHOR]

• Systematic classification of concepts in the oxygen blast furnace. • Reported the recent advancements in industrial oxygen blast furnaces. • Explored future development directions for oxygen blast furnace based on practices. • Analyzed the smelting of vanadium-titanium magnetite in the oxygen blast furnace. Climate change poses a shared global challenge. Given its substantial contribution to CO 2 emissions, the steel industry must shoulder a significant responsibility for the carbon neutrality goal. Achieving carbon neutrality in the iron and steel industry is a complex and gradual endeavor, requiring sustained efforts rather than offering a swift resolution in practical terms. Despite the ambitious development of numerous non-blast furnace processes, the traditional blast furnace (TBF) is poised to persist as the dominant ironmaking process in the upcoming decades. Conversely, the oxygen blast furnace (OBF) process, distinguished by its exceptional emission reduction potential and low retrofit costs, emerges as one of the most promising ironmaking technologies for the future. Therefore, this review comprehensively explores the origin and evolution of the OBF process, elucidating technological advancements across various historical periods. Furthermore, the review puts forth a comprehensive analysis of the feasibility of employing the OBF process for smelting vanadium-titanium magnetite (VTM), considering the benefits of the OBF and the challenges it encounters. Looking ahead, the advancement of the OBF should concentrate on pivotal domains like enhancing furnace condition control technology, exploring and innovating coke substitutes, and developing new materials with high-temperature and oxidation resistance. Concurrently, the Carbon Capture, Utilization, and Storage (CCUS) technologies are vigorously developed to further enhance the carbon reduction potential of OBF. This review aims to ignite readers' research curiosity regarding the OBF process and its application in smelting VTM. It also endeavors to propel the industrialization process and foster the sustainable development of the OBF. [ABSTRACT FROM AUTHOR]

The slag, iron and coke in the deadman are extremely difficult to obtain in regular production. In this study, a commercial blast furnace was shut down and the samples were adopted systematically through a dissection study. The image processing method was also involved to clarify the macroscopic morphology of the deadman coke and the coke size distribution as well as the variation of the deadman voidage. It was found that the average size of coke was distributed in "M-shape" and voidage of deadman decreased with the increase of distance to the hearth wall in the horizontal direction. The voidage in the middle and lower of the vertical deadman was the largest and the average size of coke decreased with the increase of the distance to the taphole centerline in the height direction. In addition, the formation mechanism was analyzed, including carburization with hot metal, coke graphitization, the erosion of slag, hot metal, gas flow, etc., which provided an important reference for the high efficiency and low carbon smelting of the blast furnace. • Coke size decreased gradually and the deadman voidage increased in the height direction of the hearth. • Coke size distributes in "M-shape" while voidage in "V-shape" in the horizontal direction. • Main ways of coke consumption are carburization reaction and consumption in the raceway zone, followed by graphitization and the washing of hot metal. • The consumed coke was replaced by the "new" coke falling from the upper loose coke zone to update the deadman. [ABSTRACT FROM AUTHOR]