Iron Ore Pellet Deformation Prediction Could Improve Blast Furnace Efficiency for Lower-Carbon Steel

Steelmakers are under pressure to cut CO2, but hydrogen-based steelmaking is not ready to replace blast furnaces overnight. That makes near-term efficiency gains in existing furnaces part of the decarbonization picture. New research from Tohoku University, Tata Steel Europe, Delft University of Technology, and AIST targets how iron ore pellets behave under extreme heat. The team used high-energy X-ray CT and computer simulations to track pellets as they soften, deform, and melt at temperatures from 1,300 to 1,550 C. They found a metallic iron shell helps pellets resist load at lower temperatures, while slag concentrates inside as softening progresses. The new model estimates the yield stress of that iron-rich shell, a property that is difficult to measure directly inside a working furnace. Better predictions of pellet deformation could help operators maintain gas flow and furnace stability, which can cut energy use and emissions per ton of steel. It is not a silver bullet, but it is a practical lever for the transition period.