Strengthening Process of Hydrogen‐Based Gas Coupled Injection for Iron Ore Sintering Based on Dual‐Zone Intensification

Hydrogen‐based decarbonization is a key direction for iron ore sintering. This study proposes an innovative process of coupled injection of coke oven gas (COG, a hydrogen‐containing byproduct) and steam (H 2 O) onto the sinter bed surface, focusing on its effects on bed permeability, sinter quality/yield, combustion efficiency, mineral phase composition, and metallurgical properties. A dual‐zone intensification mechanism (combustion zone and over‐wet zone) is proposed, with carbon reduction and cost‐saving potential elucidated. Experimental results (at 0.6% steam concentration) show that sinter performance is significantly improved with increasing COG concentration. At 0.7% COG concentration: the end‐point temperature rises from 498°C to 526°C; solid fuel consumption decreases by 14.24 kg t −1 (from 71.68–57.44 kg t −1 ); yield and tumbler index increase by 3.66% and 3%, respectively; productivity improves by 0.1 t m −2 h −1 . Steam promotes complete fuel combustion and thins the over‐wet zone, increasing the average air flow rate at 1650s from 81 to 151 m 3 h −1 . Flue gas emissions (CO, NO x , SO 2 ) are reduced by 36.23%, 18.0%, and 3.2%, respectively; the combustion ratio decreases from 0.111 to 0.084. Calcium ferrite (CF) content in sinter increases from 29.23% to 38.91%, while metallurgical properties are enhanced (RI: 73.32%→79.33%; RDI +3 . 15 : 65.15%→69.87%). This coupled injection technology achieves the dual goals of improving sinter quality and reducing energy consumption/emissions, providing a theoretical basis for hydrogen‐based intensified sintering.