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<p>The blast furnace (BF) remains the most energy-efficient ironmaking route worldwide, yet achieving deep decarbonization without compromising thermal efficiency is a critical challenge. This study proposes “SimpLE” (Smart Ironmaking Process for Low Emissions), an ultra-low coke rate (CR ≈ 60&#xa0;kg/thm) concept that redefines the BF from a conventional reduction-gasifier to a high-efficiency melter coupled with a full-gas-based reduction shaft. This paradigm shift is achieved by integrating three innovations: Smart Reduction (confining reduction to the shaft for 100% gas-based reduction), Smart Charging (maintaining permeability via the coke-slit-less cohesive zone), and Smart Combustion (enabling nearly complete pulverized coal combustion without raceways). SimpLE BF thermodynamically transforms a “black-box-like 3-dimensional” mixed-reduction process into a “quasi-one-dimensional” gas-based reduction process, enabling the manipulation of critical variables such as reduction temperature. Accordingly, thermodynamic analysis, validated against industrial data, demonstrates that SimpLE reduces fossil-derived input carbon by ~ 38–41% (or ~ 53% with green-H₂), with total CO₂ reduction reaching ~ 60–68% via carbon recycling. Also, the pressure-drop head is estimated to be ~ 1/10 in the cohesive zone and decreases to ⁓43–60% in total compared to conventional BFs. This work validates the process-level feasibility of the concept and provides a scientific basis for future pilot-plant verification. Ultra-low CR BF will be a robust platform for carbon neutralization, replacing fossil fuels with circular resources such as waste materials.</p> Graphical Abstract <p></p>

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Innovative Methods to Achieve Ultra-Low Coke Rate for Carbon-Neutral Blast Furnaces

  • 期刊论文

  • 发表日期：

    2026年2月16日

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  • Takeshi Sekiguchi

摘要

The blast furnace (BF) remains the most energy-efficient ironmaking route worldwide, yet achieving deep decarbonization without compromising thermal efficiency is a critical challenge. This study proposes “SimpLE” (Smart Ironmaking Process for Low Emissions), an ultra-low coke rate (CR ≈ 60 kg/thm) concept that redefines the BF from a conventional reduction-gasifier to a high-efficiency melter coupled with a full-gas-based reduction shaft. This paradigm shift is achieved by integrating three innovations: Smart Reduction (confining reduction to the shaft for 100% gas-based reduction), Smart Charging (maintaining permeability via the coke-slit-less cohesive zone), and Smart Combustion (enabling nearly complete pulverized coal combustion without raceways). SimpLE BF thermodynamically transforms a “black-box-like 3-dimensional” mixed-reduction process into a “quasi-one-dimensional” gas-based reduction process, enabling the manipulation of critical variables such as reduction temperature. Accordingly, thermodynamic analysis, validated against industrial data, demonstrates that SimpLE reduces fossil-derived input carbon by ~ 38–41% (or ~ 53% with green-H₂), with total CO₂ reduction reaching ~ 60–68% via carbon recycling. Also, the pressure-drop head is estimated to be ~ 1/10 in the cohesive zone and decreases to ⁓43–60% in total compared to conventional BFs. This work validates the process-level feasibility of the concept and provides a scientific basis for future pilot-plant verification. Ultra-low CR BF will be a robust platform for carbon neutralization, replacing fossil fuels with circular resources such as waste materials.

Graphical Abstract