Numerical study of the feasibility of injecting CO2-containing off-gas in an ironmaking blast furnace

The injection of CO2-containing blast furnace top gas (BFTG) to replace reducing gas partially in an ironmaking blast furnace (BF) is a promising approach to achieve carbon neutralisation while potentially maintaining or improving BF performance. However, the feasible injection operating strategy for using CO2-containing BFTG and its effects on in-furnace phenomena are not well understood. In this study, a multi-fluid industrial-scale BF model with a tuyere injection submodel is developed to investigate the impacts of injecting CO2-containing BFTG at the BF tuyere on the in-furnace phenomena in terms of gas flow, temperature field, iron oxides distribution, and BF performance. The results show that: the maximum reducing gas replacement ratio by BFTG is similar to 15 %, and a further increase leads to an unacceptable flame temperature. As more reducing gas is replaced by the BFTG, the start temperature of the intensified reduction for hematite and magnetite increases while those for wustite and iron decreases; the indirect reduction of iron oxides is improved in 1073-1273 K. The coke rate is increased by around 0.87 kg-coke/tHM with every 1 % reducing gas replaced by the BFTG. The top CO2 emission rate is decreased. This work provides a cost-effective tool to understand the flow-thermal-chemical behaviours inside a BF when CO2-containing gases are recycled in the BF ironmaking process.