Analytical Investigations to Support Optimisation of Ironmaking
REQUIREMENT
Our client was looking for opportunities to improve the ironmaking process in their blast furnace.
We undertook a programme of materials characterisation using our specialist equipment along with supporting advanced data analysis.
We have an extensive suite of analytical equipment which was used to assess the following materials:
• Flue dust
• Sludge
• PCI coal
• Raw coal
• Coal char
ANALYSIS
This analysis focused on:
• Thermogravimetric analysis (TGA)
• Particle size distribution (PSD)
• Powder flowability testing
• Optical microscopy
• Scanning electron microscopy (SEM)
Additionally, data analytics and machine-learning approaches were introduced to establish correlations between the blast furnace input variables.
OUTCOMES
The key outcomes delivered in this project included:
• Improved understanding of material behaviour
• Enhanced coal and pulverised coal injection (PCI) performance knowledge
• A microscopy investigation of coal char produced using our drop tube furnace (DTF)
• Integration of blast furnace modelling techniques with operational activities
• Understanding and adoption of additional data-driven process optimisation opportunities
• Risk reduction and cost efficiency
This project has identified opportunities to reduce process variability, improve efficiency, and support more stable furnace operation, leading to productivity gains and cost savings for the client.
3 March 2026
