Thesis (MBA)--Stellenbosch University, 2000. / ENGLISH ABSTRACT: It was found that the hot metal cost of ISCOR Newcastle's single blast furnace can significantly be reduced by the correct use of an integrated model to predict reductant cost based mainly on coal blend. The model uses coal ash chemistry, fluiidity, vitrinite rank and volatile matter to predict coke strength after reaction (CSR), coke ash and coking yield. CSR is used to predict maximum allowable coke nut- and pea consumption in the furnace as well as hot blast temperature. Pitch injection levels are predicted using CSR and blast furnace production rates. Coke ash, pitch injection and hot blast temperature is used to predict the coke rate. The above is used with imported Chinese coke cost to accurately predict reductant cost. It was found that the current optimum blends should include Australian en Nieu Zeeland coals because of price and quality conciderations. Because of its low cost of production and low quality the optimum percentage of Grootegeluk in the blend is determined largely by its transfer price. / AFRIKAANSE OPSOMMING: Die vloeiyster koste van ISCOR Newcastle se enigste hoogoond kan drasties verlaag word deur die korrekte gebruik van 'n geïntegreerde model wat reduktant koste voorspel op grond van steenkoolmengsel. Die model gebruik die chemiese samestelling van steenkool-as, fluiiditeit, vitriniet rang en vlugstof om kooks warmsterkte (SNR), kooks-as en verkooksingsopbrengs te voorspel. SNR is gebruik om die maksimum kooksneute- en -erteverbruik in die hoogoond sowel as blaastemperatuur te voorspel. Pikinspuiting is bereken met SNR en hoogoond produksietempo's. Pikinspuiting en blaastemperatuur word saam met kooks-as gebruik om kookskoers te voorspel. Bogenoemde is saam met die koste van ingevoerde Chinese kooks gebruik om reduktant koste akkuraat te voorspel. Daar was bevind dat die huidige optimum mengsels Australiese en Nieu Zeelandse steenkool moet bevat as gevolg van huidige prys- en kwaliteitsoorwegings. As gevolg van sy lae produksiekoste en lae kwaliteit word die optimum hoeveelheid Grootegeluk bepaal deur sy oordragprys.

As the largest source of iron in North America, and as the largest energy consumer in the modern integrated steel mill, the blast furnace is a critical part of modern ironmaking. Any improvements that can be made to the efficiency or emissions of the blast furnace can have far reaching environmental impacts as the production of one ton of steel results in 1.85 tons of carbon dioxide emissions. Given the concerted push to reduce greenhouse emissions, novel technologies are needed to improve efficiency. In this study the injection of preheated natural gas, precombusted syngas from a variety of feedstocks, and hydrogen injection were all modeled using computational fluid dynamics, from the tuyere through the shaft of the furnace. The impacts of these various operational changes were evaluated using CFD calculated analogs for Raceway adiabatic flame temperature (RAFT), top gas temperature (TGT), and coke rate (CR). Results indicate that a reduction of 3% to 12% in CO2 emissions is possible through the implementation of these technologies, with each possessing distinct benefits and drawbacks for industrial implementation.