Optimized Design and Numerical Analysis of Dust Removal in Blast Furnace Nozzle Based on Air Volume-Structure Coordinated Control

Blast furnace tuyeres are the primary dust emission source in ironmaking facilities (accounting for over 30% of total pollutants). High-temperature dust plumes with intense thermal energy are prone to dispersion, while China’s steel industry ultra-low emission standards (particulate matter ≤ 10 mg/m3) impose strict requirements on capture efficiency. Existing technologies often neglect crosswind interference and lack coordinated design between air volume regulation and hood structure, leading to excessive fugitive emissions and non-compliance. This study established a localized numerical model for high-temperature dust capture at blast furnace tuyeres, investigating air volume’s impact on velocity fields and capture efficiency, revealing crosswind interference mechanisms, and proposing optimization strategies (adding hood baffles, adjusting dimensions, installing ejector fans). Results show crosswind significantly reduces efficiency—only 78% at 1.5 m/s crosswind and 400,000 m3/h flow rate. The optimal configuration (2.5 m side flaps plus1.4 m baffles) achieves 99% efficiency, maintaining high performance at lower flow rates: 350,000 m3/h (1.5 m/s crosswind) and 250,000 m3/h (0.9 m/s crosswind). This study provides technical support for blast furnace tuyere dust control and facilitates ultra-low emission compliance in the steel industry. This study supports blast furnace tuyere dust control and aids the steel industry in meeting ultra-low emission standards. Notably, the proposed optimization scheme boasts simple structural adjustments, low retrofitting costs, and good compatibility with existing production lines, enabling direct industrial promotion and notable environmental and economic gains.