Mass and Heat Balance Model and Its Engineering Application for the Oxygen Blast Furnace Smelting Process of Vanadium–Titanium Magnetite

The oxygen blast furnace (OBF) process presents a promising low-carbon pathway for the smelting of vanadium–titanium magnetite (VTM). This study develops an innovative mathematical model based on mass and heat balance principles, specifically tailored to the OBF smelting of VTM. The model systematically investigates the effects of key parameters—including pulverized coal injection ratio, recycling gas volume, hydrogen content in the recycling gas, and charge composition—on furnace productivity, hearth activity, and the tuyere raceway zone. The results show that increasing the pulverized coal injection ratio slightly reduces productivity and theoretical flame temperature: for every 25 kg/tHM increase in the coal ratio, the theoretical flame temperature decreases by 21.95 °C; moreover, indirect reduction is enhanced and the heat distribution within the furnace is significantly improved. A higher recycling gas volume markedly increases productivity and optimizes hearth thermal conditions, accompanied by enhanced blast kinetic energy and an expanded tuyere raceway zone, albeit with a notable drop in combustion temperature. Increased hydrogen content in the recycling gas promotes productivity, but may weaken blast kinetic energy and reduce the stability of the raceway zone. Furthermore, a higher titanium content in the charge increases the difficulty of iron oxide reduction, resulting in lower CO utilization and reduced productivity.