What question did this study set out to answer?

The goal is to develop a comprehensive model for the direct reduction of iron ore in a shaft furnace.

January 22, 2026Open Access

An Integrated Two-Scale Numerical Model for the Direct Reduction (DR) Shaft Furnace

NKNishant KumarSeoul National University MEMarie-Aline Van EndeSeoul National University IJIn-Ho JungSeoul National University

Key Points

The goal is to develop a comprehensive model for the direct reduction of iron ore in a shaft furnace.
Integrated one-dimensional model combining pellet and furnace scale dynamics.
Utilized shrinking core model to simulate iron ore reduction stages.
Included multiple gas inlets and extraction points for diverse operational conditions.
Model accounted for key reactions involving reducing gases and temperature effects.
Model accurately predicted reduction degree and gas composition without fitting parameters.
Simulated HYL process at temperatures above 1090 °C and pressures of 10 atm.
Results matched experimental data for single-pellet and industrial furnace operations.

Abstract

Abstract A one-dimensional shaft furnace process model for direct reduction (DR) of iron ore was developed in the present study by integrating both pellet scale reduction model and furnace scale gas–solid numerical model. The downward moving bed is assumed to be comprised of pellets of iron ore, whose reduction rate is primarily affected by temperature, gas composition, and pressure. The shrinking core model with three interfaces is employed to simulate the reduction of the iron ore pellet in three steps (Fe 2 O 3 → Fe 3 O 4 → FeO → Fe) by the reducing gas composed of CO, CO 2 , H 2 , H 2 O, CH 4 , and N 2 , allowing to investigate a wide range of reducing gas composition. Ten solid–gas and gas–gas reactions including all reduction reactions, carburization reaction by CH 4 to form C and Fe 3 C, water–gas shift reaction, etc. were counted in the model. It can accommodate multiple gas inlets for reducing and cooling gases, multiple gas extraction points, as well as high pressure conditions, making it a very flexible tool for investigating various furnace designs for MIDREX and HYL ENERGIRON processes. The integrated model can predict the reduction degree, carburization and temperature of iron ore pellet, and gas composition and temperature in the shaft furnace depending on the operation conditions. With no fitting parameters, the present model can accurately reproduce all available experimental data for single-pellet experiments and DR shaft furnace plant data. For the first time, HYL shaft furnace process operating above 1090 °C and 10 atm pressure is simulated and compared with plant data. Graphical Abstract

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