furnace steelmaking involves heating iron ore, fuel (typically coke), and limestone in a blast furnace to produce molten iron. The molten iron is then combined with oxygen (and optionally scrap steel) in a basic oxygen furnace to oxidize impurities and produce steel. This is currently the dominant process for primary steel production worldwide.

Minimizing the fuel rate in blast furnace steelmaking can maximize the blast furnace’s energy efficiency and minimize emissions. By decreasing the amount of fuel used per ton of hot metal produced, the blast furnace’s overall energy efficiency is increased.

This helps lower the operating costs. It also lowers the carbon dioxide and other emissions generated from the combustion of the fossil fuel.

Controlling fuel rate is challenging because blast furnace process chemistry and transport phenomena are too complex to analyze with simple physics-based models.

With Fero Labs providing visibility into this part of the furnace, operators can proactively drive the furnace.

With a full adoption of Fero on the blast furnace, an average sized furnace operator can expect up to 3% in fuel cost savings.

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