Blast Furnace Process Control

By improving process control of the blast furnace system operating conditions can be optimized, hot metal quality can be improved, and energy consumption and operatioal costs can be reduced. Modern expert process control systems continuously monitor certain parameters in the blast furnace and by using various process models (including burden control, burden distribution, mass and energy balances, silicon prediction and kinetic process models) calculate and diagnose process disturbances. They then suggest, or take, corrective actions such as modification of the rate of reducing agents or changes to the burden distribution (APP, 2010. p.51). Current third generation control systems allow even further improvements than their predecessors (Worrell, et al., 2010. p.83). 

Chinese flag Indian flag US flag This measure is regarded to have high application potential in China, India and the United States. However, in most cases the blast furnace design, lack of necessary hardware for better control plus cost of control system can act as a limitation for the use of modern, computer based control systems.

Development Status Products

Blast Furnace Process ControlCosts & Benefits

Parent Process: Blast Furnace System
Energy Savings Potential

By implementing this technology, coke consumption was reduced to approximately 0.458 ton/t-HM in an Austrian steel plant in 2001 (Worrell et. al., 2010, p.87).

CO2 Emission Reduction Potential

US flagEmissions reduction potential of the technology is 24.4 Kg CO2/t-HM (US EPA, 2010. p.9).


Blast Furnace Process Control Publications

Energy Efficiency Improvement and Cost Saving Opportunities for the U.S. Iron and Steel Industry

The U.S. Environmental Protection Agency’s (EPA) energy guide, Energy Efficiency Improvement and Cost Saving Opportunities for the U.S. Iron and Steel Industry, discusses energy efficiency practices and technologies that can be implemented in iron and steel manufacturing plants. This guide provides current real world examples of iron and steel plants saving energy and reducing cost and carbon dioxide emissions.

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The State–of-the-Art Clean Technologies (SOACT) for Steelmaking Handbook


The State–of-the-Art Clean Technologies (SOACT) for Steelmaking Handbook is developed as part of the Asia-Pacific Partnership on Clean Development and Climate program and seeks to catalog the best available technologies and practices to save energy and reduce environmental impacts in the steel industry. Its purpose is to share information about commercialized or emerging technologies and practices that are currently available to increase energy efficiency and environmental performance. 

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