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<p>The pore structure in the iron ore sinter significantly influences the gas flow and hence the permeability, softening, and melting kinetics in the blast furnace. Traditional methods like mercury intrusion porosimetry and optical microscopy fail to fully characterize pore networks, particularly closed pores. Recent advancements in X-ray computed tomography (XCT) enable non-destructive, high-resolution 3D imaging, offering deeper insights into sintered ore morphology. However, the effects of bed layer position and biochar substitution on pore characteristics remain underexplored. Therefore, this study investigates the pore structure of sintered ore under different conditions, focusing on (1) upper vs. lower portion of the bed comparisons and (2) biochar substitution ratios (0%, 40%, 50%). With the advanced image processing capabilities of XCT, we got better insights into the porosity, pore size distribution, and pore connectivity. Results show that the lower portion of the bed, with higher temperatures and longer melting durations, has lower total porosity and more large pores (&gt; 1&#xa0;mm), which dominate pore volume despite constituting only 2.8% of pores. Increasing biochar substitution raises total porosity by 15.55% at 50% substitution, due to reduced melt generation and shorter melting durations, hindering bubble coalescence and forming smaller pores. The upper layer exhibits higher permeability and more uniform gas flow than the lower layer. Biochar substitution reduces tortuosity from 1.48 to 1.26, improving flow uniformity but compromising structural integrity. This study combines XCT and advanced modeling to link pore structure evolution to sintering performance, providing insights for optimizing biochar substitution to reduce carbon emissions and enhance sustainability in iron and steel production.</p> Graphical Abstract <p></p>

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Visualizing the Effect of Biochar on the Pore Structure of Iron Ore Sinter Using 3D X-Ray Computed Tomography

  • 期刊论文

  • 发表日期：

    2025年10月15日

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  • Laiquan Lv,
  • Jianguo Zhao,
  • Jiankang Wang,
  • Hanxiao Meng,
  • Hao Zhou

摘要

The pore structure in the iron ore sinter significantly influences the gas flow and hence the permeability, softening, and melting kinetics in the blast furnace. Traditional methods like mercury intrusion porosimetry and optical microscopy fail to fully characterize pore networks, particularly closed pores. Recent advancements in X-ray computed tomography (XCT) enable non-destructive, high-resolution 3D imaging, offering deeper insights into sintered ore morphology. However, the effects of bed layer position and biochar substitution on pore characteristics remain underexplored. Therefore, this study investigates the pore structure of sintered ore under different conditions, focusing on (1) upper vs. lower portion of the bed comparisons and (2) biochar substitution ratios (0%, 40%, 50%). With the advanced image processing capabilities of XCT, we got better insights into the porosity, pore size distribution, and pore connectivity. Results show that the lower portion of the bed, with higher temperatures and longer melting durations, has lower total porosity and more large pores (> 1 mm), which dominate pore volume despite constituting only 2.8% of pores. Increasing biochar substitution raises total porosity by 15.55% at 50% substitution, due to reduced melt generation and shorter melting durations, hindering bubble coalescence and forming smaller pores. The upper layer exhibits higher permeability and more uniform gas flow than the lower layer. Biochar substitution reduces tortuosity from 1.48 to 1.26, improving flow uniformity but compromising structural integrity. This study combines XCT and advanced modeling to link pore structure evolution to sintering performance, providing insights for optimizing biochar substitution to reduce carbon emissions and enhance sustainability in iron and steel production.

Graphical Abstract