Combustion behavior of co-injecting flux, pulverized coal, and natural gas in blast furnace and its influence on blast furnace smelting

The integration of advanced high-ratio pellet ore smelting technology with flux injection at the blast furnace tuyere offers significant carbon emission and air pollution reductions for iron and steel manufacturers. This study presents a comprehensive thermogravimetric analysis and burnout rate assessment of Russian Bituminous Coal (RB) and flux mixtures across varying mass ratios, alongside a detailed exploration of the catalytic mechanisms of three distinct fluxes on RB combustion. The findings reveal that lime, when added to the coal-flux blend, markedly enhances the overall combustion characteristic index and catalytic impact, more so than limestone or dolomite. The optimal lime admixture of 5 % resulted in a peak S value of 6.30 and a burnout rate of 70.63 %, constituting an increase of 7.64 % over the base case without flux. Lime's superior catalytic performance is attributed to its higher content of calcium-containing compounds, which amplify catalytic activity through increased Ca2+ ion exchange with carboxyl groups. Mathematical model calculations considering the combustion rate of the pulverized coal show that: after the addition of 5 % lime, there is a 133.43 t/d increase in iron production, compared to the 11,323.98 t/d without the addition of flux. When the lime addition amount is 7 %, the proportion of sintered ore in the blast furnace decreases by 6.53 %, and the coke saving is 2.8 kg/t. This research is expected to enhance the understanding of pulverized coal combustion when amalgamated with basic fluxes and serve as a theoretical foundation for optimizing industrial applications.