Coke Layer Research Articles

Effect of combined ferrous burden composition and ore-coke interaction on blast furnace burden distribution

The distribution of burden materials at the blast furnace throat is highly correlated with the combined ferrous burden with different mass percentages of sinter, pellet, and lump ore. In this work, the motion behavior of the burden particles was studied under different combined ferrous burden composition, and an analysis was conducted on the cooperative influence of the combined ferrous burden composition and ore-coke interaction on the burden distribution characteristics. The results indicate that the particle flow trajectory is stable when the total mass fraction of pellet and lump ore is less than 32 %. Central coke charging can minimize the radial segregation of the combined ferrous burden. At the ore-coke layer interface, the accumulation and percolation behaviors of ore particles are observed. When the pellet ratio is high, the ore particles can easily penetrate into the void structure of the coke layer.

Nonprecious Single Atom Catalyst for Methane Pyrolysis.

The development of a suitable catalytic system for methane pyrolysis reactions requires a detailed investigation of the activation energy of C-H bonds on catalysts, as well as their stability against sintering and coke formation. In this work, both single-metal Ni atoms and small clusters of Ni atoms deposited on titanium nitride (TiN) plasmonic nanoparticles were characterized for the C-H bond activation of a methane pyrolysis reaction using ab initio spin-polarized density functional theory (DFT) calculations. The present work shows the complete reaction pathway, including energy barriers for C-H bond activation and dehydrogenated fragments, during the methane pyrolysis reaction on catalytic systems. Interestingly, the C-H bond activation barriers were low for both Ni single-atom and Ni-clusters, showing the energy barriers of ~1.10 eV and ~0.88 eV, respectively. Additionally, single-atom Ni-TiN showed weaker binding to adsorbates, and a net endothermic reaction pathway indicated that the single-atom Ni-TiN was expected to resist coke formation on its surface. However, these Ni single-atom catalysts can sinter, aggregate into a small cluster, and form a coke layer from the highly exothermic reaction pathway that the cluster takes despite the facile reaction pathway.

Application of High‐ and Low‐Reactivity Cokes in Hydrogen‐Rich Blast Furnaces

The effects of two cokes with different reactivity on the lump ore's metallurgical properties and coke's solution loss are investigated under the high‐temperature load reduction. The work used an improved test device for softening‐melting and dropping characteristics of iron ores in both CO2 and CO2H2O atmospheres. The deterioration behavior of highly reactive cokes is expounded under hydrogen‐rich conditions. High‐reactivity cokes under hydrogen‐rich conditions are more favorable for enhancing the breathability of charge and the penetration of the coke layer. However, it increased the thickness of the softening zone. High‐reactivity cokes had obvious internal and external reaction gradients. The solution loss reaction mostly occurred on the surface, with selectivity. The longitudinal stacking height, layer number, and order degree in the carbon structure decreases after the reaction. The carbon‐structure difference weakens between the shell and core. The enhancement of coke's reactivity, however, results in the significant loss of coke powders on its surface. Unreduced FeO and refractory Fe2SiO4 are more likely to appear in the droplets, which is not conducive to the reduction of Fe and the generation of slag crust in the furnace. The difficulty in separating lump ores and cokes is aggravated, and more iron‐containing charge remain in the furnace.

Revealing patterns in reducing the fire-hazardous properties of insulation made from plant raw materials

An issue related to the use of hemp bundle insulation for building structures is to ensure their fire resistance under the action of a low-calorie ignition source. Therefore, the object of research was the change in the properties of the insulation during fire protection with its compositions capable of forming a layer of pinocoke under the influence of high temperature. On the basis of experimental data, it was established that at fire protection of insulation with a fire retardant agent, hydrolytic stable ethers containing phosphorus and nitrogen atoms are formed on the surface of the fibers. According to the temperature values and the shape of peaks on the DTA curve, it was established that at fire protection, the height of the peaks decreases and the width increases, which characterize the flow of exothermic transformations and the destruction of hemp fibers. At the same time, it was established that the formed residue has 13.3 % for impregnation and 26.6 % for coating. It has been proven that in the process of thermal action on the fire-resistant coating, the heat insulation process of the insulation consists in the formation of soot-like products on the surface of the material. So, it was determined that the sample did not catch fire, it was charred in the place of the radiation panel, and the burning was not recorded. On the other hand, for a sample of insulation treated with a coating during thermal action, the formation of a heat-insulating layer of foam coke occurred, which inhibits the penetration of heat, the temperature of flue gases did not exceed 100 °C, and the flammability index was 0. The practical significance is that the results were taken into account when designing buildings and structures. So, there are reasons to assert the possibility of targeted regulation of fire protection processes of insulation by applying coatings that form a protective layer on the surface of the material

Elastomeric Fire and Heat-Protective Materials Containing Functionally Active Microheterogeneous Systems.

This research aims to explore how functionally active structures affect the physical, mechanical, thermal, and fire-resistant properties of elastomeric compositions using ethylene-propylene-diene rubber as a base. The inclusion of aluminosilicate microspheres, microfibers, and a phosphorus-boron-nitrogen-organic modifier in these structures creates a synergistic effect, enhancing the material's heat-insulating properties by strengthening coke and carbonization processes. This results in a 12-19% increase in heating time for unheated sample surfaces and a 6-17% increase in residual coke compared to existing analogs. Microspheres help counteract the negative impact of microfibers on composition density and thermal conductivity, while the phosphorus-boron-containing modifier allows for controlling the formation of the coke layer.

Performance and microbial community in a constructed rapid infiltration system with hydrochar and coke as filler for advanced treatment of N, N-dimethylformamide

In this study, the treatment of wastewater with N, N-dimethylformamide (DMF) was carried out by a constructed rapid infiltration system (CRIS). The decontamination efficiency of the system with different fillers was investigated and the microbial communities and metabolic pathway were also analyzed. It was indicated that the removal of COD and DMF in the hydrochar-coke group (RA) and coke group (RB) were 58.91–59.93 % and 71.89–51.46 %, respectively. Compared with the influent, the average NH3-N concentration in the effluent increased by 77.04 % and 55.09 %, and the average removal rate of NO3--N by the two group was 72.95 % and 62.04 %, respectively. The abundance of DMF-degrading Paracoccus (5.10 %, 21.01 %) in the hydrochar and coke layers in RA was higher than the coke layer of RB (0.44 %), indicating that hydrochar promoted the growth and propagation of DMF-degrading bacteria. Hydrochar promoted the expression of gene PFK (0.2113 %), GADPH (0.3038 %), IDH (0.1832 %) and MDH (0.1758 %). In nitrogen metabolism, the relative abundance of glutamine synthetase was the highest. This research provided a theoretical foundation and technical support for the treatment DMF wastewater by CRIS.

Feasibility of sustainable reusability of Ni/char catalyst for synthetic gas production via catalytic steam gasification

Ni/char catalyst is one of the most promising catalysts for enhancing gas production, particularly syngas from catalytic steam gasification of biomass. In the current study, one unmodified (Ni/MMchar) and two modified catalysts (Ni/NaMMchar and Ni/NaAceMMchar) were utilized to investigate the reusability potential of Ni/char catalyst for catalytic steam gasification of bamboo in a two-stage fixed-bed reactor including the changes in catalyst characteristics. N2 adsorption-desorption by BET, scanning electron microscope connected with energy-dispersive X-ray spectrometer (SEM-EDS), X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS) analyses were utilized for examining their characteristics. The findings indicated that the three catalysts could maintain the reusability potential in catalytic steam gasification of bamboo for twice cycles. The syngas reduction percentages in the second cycles of the catalysts ranged between 11.0 and 22.8 %. H2/CO ratios of all spent catalysts lined in the range of 4.10 − 2.45. The low heating values of syngas products were in the range of 8.83–8.19 MJ/Nm3. Considering the catalyst characteristics, the increasing cycles of catalyst operations induced carbon deposition, resulting in the reduction of specific surface areas. SEM-EDS images of the used catalysts appeared the coke layer and the Ni metal sintering on the surfaces. The uses of catalysts encouraged the transformation of Ni metal active site into NiO, Ni2O3 and Ni3C forms. These phenomena were the major causes of catalyst deactivation. The changes in the characteristics and catalyst activity controlled the gasification reactions, resulting in the catalyst deactivation and gaseous products.

Transient simulation of conjugate heat transfer of kerosene with thermal oxidative and surface coking reactions at a supercritical pressure

The regenerative cooling technology in aerospace applications often involves supercritical-pressure heat transfer of a hydrocarbon fuel, in which thermal oxidative reactions of the fuel would lead to surface coke accumulation on the cooling channel wall. In this paper, the long-term transient conjugate heat transfer of kerosene has been numerically investigated in a circular mini tube at a supercritical pressure of 3 MPa. The modified chemical mechanism and kinetics of thermal oxidative and surface coking reactions of kerosene are proposed, which, with an additional surface reaction, are capable of treating large coke deposition in regions with sharp temperature gradients. Transient surface coke accumulation and its effect on heat transfer are handled by a dynamic mesh technique. A series of numerical studies are conducted to elucidate the influences of surface heat flux, dissolved oxygen mass fraction, inlet fuel mass flow rate, and coke layer thermal conductivity on the supercritical-pressure heat transfer and thermal oxidative reactions. The effects of different reaction pathways on surface coke accumulation are analyzed comprehensively, and it is revealed that the oxygen-consuming surface coke deposition is initiated only at the high fuel temperature at around 590 K. The present numerical results would enhance fundamental understanding of the long-term transient heat transfer process of a hydrocarbon fuel at supercritical pressures in the regenerative cooling applications.

Study on the High-Temperature Interaction between Coke and Iron Ores with Different Layer Thicknesses.

Coke plays a key role as the skeleton of the charge column in BF. The gas path formed by the coke layer in the BF has a decisive influence on gas permeability. At high temperatures, the interface between coke and ore undergoes a melting reaction of coke and a reduction reaction of ore. The better the reducibility of the ore, the more conducive it is to the coupling reaction of ore and coke. The melting loss reaction of coke becomes more intense, and the corresponding strength of coke will decrease, which will affect the permeability of the blast furnace and is not conducive to the smooth operation of the blast furnace. Especially with a deterioration in iron ore quality, BF operation faces severe challenges, which makes it necessary to find an effective way to strengthen BF operation. In this study, a melting-dropping furnace was used to develop and clarify the high-temperature interaction between coke and iron ores with different layer thicknesses. The influencing factors were studied by establishing a gas permeability mathematical model and observing the metallographic microscope images of samples after the coke solution loss reaction. The relationships between coke layer thickness, distribution of gas flow, and pressure drop were obtained. The results showed that, under certain conditions, the gas permeability property of a furnace burden has been improved after the coke layer thickness increased. Upon observing the size of coke particles at the interface reaction site, the degree of melting loss reaction can be determined. A smaller particle size indicates more melting loss reaction. A dripping eigenvalue for molten metal was introduced to evaluate the dynamic changes in the comprehensive dripping properties of molten metal of furnace burden, which showed that the dripping eigenvalue for the molten metal could deteriorate because of the unruly thickness and the coke layer thickness should be limited through considering the operational indicators of the blast furnace.

Establishing patterns in reducing fire-dangerous properties of sip panels fire-protected with reactive coating

An issue related to using SIP panels for building structures is to ensure their stability and durability during operation in wide ranges. Therefore, the object of research was the change in the properties of wood-polymer material in case of fire and its protection when applied with a reactive coating capable of forming a pinocoke layer under the influence of high temperature on the coating. It has been proven that in the process of thermal action on the fire-resistant coating, the heat insulation process of SIP panels involves the formation of soot-like products on the surface of the material. Thus, under the action of the radiation panel on the surface of the OSB sample, after 120 s of thermal exposure, the process of intensive formation of a layer of foam coke, which thermally insulated the wood-polymer material, began; instead, after the radiation panel was exposed to the fire-resistant polystyrene foam sample, the process of destruction began at a temperature of about 100 °C polystyrene foam. When determining the flammability of a fire-resistant SIP panel, it was established that the temperature of the flue gases during the tests was no more than 110 °C, the length of the damaged sample did not exceed 460 mm. At the same time, the mass loss did not exceed 200 g, and independent combustion of the SIP panel sample did not occur despite the high temperature. According to these data, the SIP panel, fire-resistant with a reaction coating, belongs to group G1 (low flammability) and is a non-flammable material. The practical significance is that the results were taken into account during the design of buildings from SIP panels. So, there are reasons to assert the possibility of targeted regulation of the fire protection processes of SIP panels through the use of reactive coatings capable of forming a protective layer on the surface of the material that inhibits the rate of heat transfer

Evolution and process analysis of the hearth activity in hydrogen-rich blast furnace

Blast furnace (BF) hydrogen-rich smelting is an important way for the green and low-carbon development of iron and steel industry. The injection volume of hydrogen-rich gas is limited due to the need for hearth activity, which is related to the stable and smooth operation of BF. In this study, the change of coke properties after hydrogen-rich smelting was summarized, the detailed evolution process of hearth activity after hydrogen-rich smelting was analyzed. The results show that: the pores on the surface of coke are enlarged after hydrogen-rich smelting. The gasification rate of coke with H2O is significantly higher than that of CO2 due to the lower activation energy and smaller molecular diameters of H2O and H2. The interlayer spacing of coke decreases and the stacking height further increases rapidly, the degree of coke graphitization is the highest after hydrogen-rich smelting. The weakening of carbon anisotropy is the fundamental reason for the increase in the degree of graphitization of coke. The strong gasification reaction causes the coke to lose a lot of carbon, and its matrix becomes loose and incomplete, so the strength after reaction decreases sharply. The wetting model is established to analyze changes in wettability. The rough surface of coke improves the wettability between slag iron and coke at high temperature. The good wettability makes it easier for slag iron to adhere to the surface of coke. The smoothness of slag iron passing through coke is reduced, the retention amount of liquid slag iron in coke layer increases. It leads to a decrease in hearth activity, the stable and smooth operation of BF is difficult to guarantee. This is the main issue limiting the injection volume of hydrogen-rich gas in BF.

Determining patterns in the formation of an insulation layer of foam coke when protecting concrete against fire by reactive coating

An issue related to using concrete for building structures is to ensure their stability and durability during operation within wide limits. Therefore, the object of research was the change in the properties of concrete in case of fire and its protection when applied with a reactive coating capable of forming a foam coke layer under the influence of high temperature on the coating. It has been proven that in the process of thermal action on the fire-resistant coating, the process of heat insulation of concrete involves the formation of soot-like products on the surface of the material. Thus, under the influence of the flame of the burner, a temperature arose on the surface of the sample, which led to the swelling of the coating by more than 18 mm. The measured temperature on the surface of the concrete sample under the layer of foam coke was no more than 140 °C, which indicates the formation of a fire barrier. In this regard, modeling of the process of heat transfer through the formed layer of foam coke in the process of its protection with a reactive coating was carried out and dependence was established, which makes it possible to estimate the coefficients of temperature conductivity and thermal conductivity during high-temperature action. According to the experimental data and the established dependences, the coefficient of temperature conductivity and heat conductivity of foam coke was calculated, which is 9.17·10–7 m2/s and 0.17 W/(m∙K). The assessment of the maximum possible penetration of fire through the layer of foam coke was carried out. A temperature was formed on the surface of the sample, which significantly exceeded the temperature of the destruction of concrete, and on the surface of concrete under the coating it did not reach 250 °C. So, there are reasons to assert the possibility of targeted regulation of concrete fire protection processes by using reactive coatings capable of forming a protective layer on the surface of the material that inhibits the rate of heat transfer

Investigation on the evolution of structure and strength of iron coke during carbonization: Carbon structure, pore structure, and carbonization mechanism

Iron coke has attracted great interest in low-carbon ironmaking due to its environmental friendliness and efficient utilization of resources. However, the low strength of iron coke limits the potential applications. Herein, the evolution mechanism of the structure and strength of iron coke during carbonization was examined to elucidate the impact of iron ore on iron coke strength. The findings indicate a significant reduction in the tensile strength of iron coke when the iron ore addition exceeds 15%, and improving carbonization temperature positively impacts the tensile strength of iron coke. Additionally, XRD and Raman analyses demonstrate that iron ore destroys the microcrystalline layers of iron coke, thus weakening the cohesiveness of carbon structure. The volume expansion resulting from crystal transformation during iron ore reduction generates cracks within the carbon matrix, which further destroys the structural integrity of iron coke. Furthermore, the panorama reveals that the coupling reactions of iron ore reduction and carbon gasification intensify the consumption of carbon matrix, causing the erosion and dissolution of pore walls. The porosity and heterogeneity of macroscopic pores are hence increased, which reduces the iron coke strength. Compared to macroscopic pores, the influence of micropores on iron coke strength is relatively insignificant.

Role of active oxygen species in Fe-doped ZrO2 catalyst during CO2 assisted ethane dehydrogenation reaction

CO2 assisted ethane dehydrogenation provides a promising route for the utilization of shale gas and greenhouse gas. This study investigates the role and evolution of active oxygen species over Fe-doped ZrO2 catalysts in distinct dehydrogenation reactions via Mars-van Krevelen mechanism. Fe doping led to an increase in active oxygen species (from 12.9% to 23.4%) benefitted from the phase transformation of ZrO2. This enhancement significantly boosted ethane dehydrogenation activity from 5.0 to 16.1 mmolEthene/gCat/h. In the absence of CO2, the ethane conversions rapidly decreased with a deactivation rate constant (kd) of 0.930 h−1 due to the irreversible oxygen species loss and coke deposition. Although the catalytic stability of the optimal catalyst was greatly improved (kd = 0.006 h−1) after CO2 introduction, a decrease in ethane conversion occurred when CO2 could not supplement oxygen species due to the formation of coke layers. A simple O2 oxidation can effectively restore stable activity during 5 reaction-regeneration cycles for 3600 mins.

DEM study of the porosity distribution of sinter and coke layers in the throat region of a blast furnace

The porosity distribution of burden beds has an important influence on the gas flow distribution and chemical reactions in the blast furnace, while the initial porosity distribution in the top part of the furnace is determined by the original burden distribution. In this work, the layers of sinter and coke in the throat region were established to investigate the effect of multiple particle sizes on the porosity distribution by the discrete element method. The porosity calculation models for the layers are obtained by defining the dispersion degreed, and the porosity decreases with increasing dispersion of the materials. For the burden layers, the porosity of the coke layer is larger than the sinter layer, but the coordination number is reversed. The results also indicate that faster descending velocity and lower layer height have a significant effect on the reduction of porosity.

Functional assignment of technological accessories for woodworking

Forming a heat and sound insulation board from wood using non-combustible binders can increase the fire protection of the material by forming a protective layer of coke. This will make it possible to develop a new type of fireproof roofing products for building structures. It is not always advisable to treat the surface of a heat and sound insulation board with fireproof coatings, since after prolonged thermal exposure, the combustion stage can be transferred to the interior of the material by smoldering. Therefore, the manufacture of fire-resistant heat- and sound-insulating wood materials, the study of fire protection and the impact of their components on this process is an unresolved component of ensuring the fire resistance of building structures. And, accordingly, they determine the need for such research.
 The paper presents the results of research into the process of protecting wood wool boards with binders based on fire-resistant coatings. Tests on model samples of a wooden board showed that the material based on wood wool and an inorganic binder is characterized by heat absorption and inhibition of oxidation in the gas and condensed phase and the formation of a thermally protective ceramic layer on the surface of the wood. Experimental studies have confirmed that a material based on wood wool and an inorganic binder at a ratio of 1:1 refers to combustible materials, since its smoldering was recorded during exposure to temperature. So, by thermal action for 90 s, the material ignited and the flame spread over the first three zones for 41 s. On the other hand, an increase in the amount of an inorganic-based binder and the use of an organic-mineral binder does not lead to a material fire. In this case, the maximum temperature of the flue gases was about 120 °C, and the flammability index was 0 due to the decomposition of fire retardants under the influence of temperature with the release of incombustible gases, which inhibit the oxidation of the material and significantly increase the formation of a heat-protective layer of coke on the surface of the material. This leads to inhibition of heat transfer of the high-temperature flame to the material. Due to this, it became possible to determine the conditions of fire resistance of the material by forming a barrier for thermal conductivity. The obtained results indicate the possibility of targeted regulation of high temperature transfer processes to organic material by using special binders for wood products.

Three-dimensional coking simulation of endothermic hydrocarbon fuels in rectangular cooling channels

Coking deposition is a critical phenomenon for endothermal hydrocarbon fuel cooling that can significantly affect the performance of a regenerative cooling system. Because of the complicated interactions between fluid flow, heat transfer, fuel cracking, and precursor coking kinetics, previous numerical studies have been limited to simplified two-dimensional circular channels, which cannot reveal the actual spatial distribution with consideration of buoyancy effect in rectangular cooling channels. This work proposes a novel framework for shrinking motion with an O-type hybrid mesh, permitting the direct three-dimensional simulation of coke deposition in complex channels and the visualization of both the axial and circumferential deposition distributions. The concept is tested in a rectangular channel using n-decane as an example, combining a detailed pyrolysis kinetic model with the MC-II coking model, and predictive results have been obtained. Results indicate two locations with heavy deposition rates. The buoyancy effect is weakened due to the acceleration resulting from the reduced cross-sectional area of the channel by the coke layer. The coupling of the flow and pyrolysis is discussed in terms of the dimensionless Damköhler number. The maximum temperature after coking can be 138 K higher than the initial. However, the conversion of n-decane at outlet is decreased due to the reduced flow residence time. The decreased total heat sink per temperature increment and the higher pressure drop are also the penalties from coking. The new framework for the direct three-dimensional simulations of coking is significant for the comprehensive investigation of the efficiency of regenerative cooling.

Anti-coking performance of Al/Si/Cr/Ce ceramic coating during naphtha steam cracking applied on Cr25Ni35Nb alloy

To reduce the coke formation, a novel Al/Si/Cr/Ce composite ceramic coating was prepared on the surface of the Cr25Ni35Nb alloy substrate by pack cementation. The microstructure, phase composition, surface morphology and element distribution of substrate and coating were characterized by X-ray diffractometer (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). The results reveal that the outer layer of the coating forms a protective layer with a high proportion of AlN and Cr3Si and trace amounts of Ce. The inter-diffusion layer is mainly aluminide coating (AlNi and AlFe) and transition layer contains a small amount of AlN. The anti-coking performance of the coating was assessed using naphtha steam cracking. To study coking behavior, the morphology and microstructure of the coke layer were analyzed and characterized by SEM and Laser Micro-Raman Spectrometer. The coke layer on uncoated sample has a higher focal density and is more likely to spall and peel off when subjected to coking experiment. A large number of filamentous and granular cokes appear on the surface of the uncoated sample, whereas only less granular cokes appear on the surface of the coated sample, and the coke on the uncoated sample has a more disordered and amorphous carbon structure. The coating significantly inhibited the growth of filamentous coke and reduced coke accumulation.

Analysis of the impact of carbon dissolution and energy transport on the flow in the hearth of an ironmaking blast furnace by transient CFD simulations

In the ironmaking blast furnace, layers of coke, ferrous burden (sinter, pellets, lump ore) and additions are heated by an uprising gas flow. While the layers are descending, the iron ore is reduced and begins to melt. The liquid products slag and hot metal trickle downwards into the hearth, where they prevail as two immiscible phases filling the voids within the coke bed and with the slag floating on top of the hot metal. As the hearth is lined with carbon blocks, which are eroded by the passing hot metal flow, this region has a major impact on the campaign length of the blast furnace. The blast furnace hearth is drained intermittently by opening the taphole and closing it to end the tap. Hence, the fluid phases in the hearth are in a transient state with the liquid levels constantly varying and the flow conditions being determined by the tapping/non-tapping state. In addition, dissolution of carbon into the hot metal and cooling applied to the refractory affect the local hot metal flow. This work presents a CFD-model, which is capable to calculate the multiphase flow in a 3-dimensional hearth at an industrial scale. The tool allows for modelling of the transient transport processes, including multiple tapping cycles by utilizing new approaches for the transition between tapping/non-tapping and the inflow of liquids into the hearth. Furthermore, the dissolution of carbon, energy transport in the liquids and the locally varying density of hot metal depending on temperature and carbon content are included. With this approach, thermal stratification and circulation effects induced by buoyancy can be described over a period of nearly 8 h, thus covering 4 tapping cycles. In addition to an analysis of energy, carbon content and velocity fields, the transient evolution of tapped hot metal properties (temperature, carbon) are obtained and compared to available plant data.

Pressure Drop and Gas Flow in an Oxygen Blast Furnace Analyzed by a Combination of Experimentation and a Porous Model

As a modification of the conventional blast furnace (BF), the top gas recycling-oxygen blast furnace (TGR-OBF) has been continuously studied in the context of the technological transformation of low-carbon metallurgy. As it has a set of new gas inlets in the stack and changes the blast operation system in the hearth, the pressure drop and the in-furnace gas flow are the primary problems to be solved in the TGR-OBF’s industrialization. In this paper, a two-dimensional model of a whole blast furnace, based on a softening-and-melting experiment and porous-medium theory, is established. The in-furnace pressure drop and the gas velocity with different oxygen concentrations and tuyere heights are studied. The results show that the suitable height of the stack tuyere is the same as that of the elevation as the cohesive zone inside the furnace. With the gradual increase in oxygen enrichment, the permeability of the cohesive ore layer (COL) increases, while the gas flow through the coke layer (CL) decreases gradually up to 10%. The simulation results provide a theoretical basis for the TGR-OBF to reduce the coke rate and keep the pressure drop from increasing, or even to enable it to decrease.