Researchers at Tohoku University, working with Tata Steel Europe, Delft University of Technology, and AIST, have developed a way to predict how iron ore pellets deform inside a blast furnace at high temperatures. The method combines high-energy X-ray CT, chemical analysis, and particle-based simulations to estimate the yield stress of the iron-rich shell that forms around pellets during reduction, softening, and melting. This gives a more detailed picture than older measurements of overall bed shrinkage and gas pressure loss. Understanding pellet behavior matters for lower-carbon steelmaking because blast furnaces will still handle a large share of iron production while hydrogen-based routes and scrap recycling scale up. More stable furnaces with better gas permeability can cut fuel use and emissions per ton of iron. The team plans to test the approach on other iron ore types and hydrogen-rich reducing conditions, which could help operators choose raw materials and tune operating conditions for cleaner production.
