Abstract
Iron and steel industry is the pillar industry of the national economy, but it is also the source of highest carbon emission in manufacturing industry. With the proposal of China’s goal of peaking carbon emissions and achieving carbon neutrality, the steel industry urgently requires substantial technological breakthroughs in carbon reduction. About 90% of China’s crude steel production is produced through the blast furnace-basic oxygen furnace process, and blast furnace carbon consumption accounts for more than 70% of steel process carbon consumption. Therefore, blast furnace carbon reduction is the focal point of China’s steel industry’s efforts to mitigate carbon emissions. The hydrogen-rich gas injection to blast furnace and blast furnace with top gas recycling process are effective ways to reduce carbon emissions. However, these approaches still rely heavily on the fossil fuel coal-dominated energy structure. With the rapid development of renewable energy hydrogen production in China, hydrogen-rich oxygen blast furnace technology, which replaces carbon with hydrogen, can significantly reduce carbon emissions from ironmaking at the source. This article establishes a multizone constrained mathematical model for hydrogen-rich oxygen blast furnaces, calculates energy balance based on the constraint conditions of each zone, and systematically studies the influence of hydrogen injection, burden metallization rate on the coke ratio, top gas recycling injection volume, reducing gas composition, and CO2 emission reduction of hydrogen-rich oxygen blast furnaces. The research results show that at maximum hydrogen injection rate of about 600 N·m3 H2·t−1-HM (ton-hot metal), a replacement ratio of about 0.4 kg-coke·(N·m)−3-H2 was achieved with about 27% CO in the reduced gas of the shaft, 68% H2, 90% burden metallization rate. Coke ratio of the hydrogen-rich oxygen blast furnace is reduced to 203 kg and the CO2 emission is reduced to 501 kg·t−1-HM, 55% lower than that without hydrogen injection with a very significant CO2 reduction at the source.
1 Introduction
The iron and steel industry, the highest carbon emission manufacturing industry in China, contributes about 15% of the total national carbon emissions. Consequently, reducing carbon emissions represents a shared technological challenge that iron and steel enterprises must confront [1,2,3,4]. Traditional iron and steel metallurgy is a carbon metallurgical process based on fossil energy, i.e., coal. With the rapid development of hydrogen production from renewable energy sources such as photovoltaic power generation and wind power in China [5,6], the iron and steel industry is gradually transitioning from carbon metallurgy to hydrogen metallurgy. This shift primarily revolves around technologies such as hydrogen-based shaft furnace direct reduction and blast furnace hydrogen-enriched smelting. About 90% of China’s crude steel is produced by blast furnace-basic oxygen furnace process, among which the blast furnace, the largest carbon consumption process, accounts for more than 70% of the carbon consumption in the iron and steel process, so reducing the carbon consumption of the blast furnace smelting is the key for reducing carbon emissions in the iron and steel industry [7,8,9,10,11,12]. The most effective methods for reducing carbon emissions in blast furnace smelting include injecting the hydrogen-rich gas at the tuyere and implementing blast furnace with top gas recycling. The European Union and Japan have initiated the “ULCOS” program and “COURSE50” project [13,14,15], respectively. Both initiatives focus on the technologies such as hydrogen-rich gas injection and oxygen blast furnace to significantly decrease carbon emissions from long-process iron and steel enterprises. In 2020 ThyssenKrupp, Germany took the lead in completing the hydrogen injection test on a blast furnace with the ultimate goal of decreasing carbon emissions from the blast furnace by 30–50%. In 2021, Central Iron & Steel Research Institute carried out the industrialized test of hydrogen-rich gas injection on blast furnace in Shanxi Jinnan Iron and Steel Group. It showed that at the hydrogen injection rate of about 65 m3 H2·t−1-HM, the replacement ratio of about 0.49 kg-coke·(N·m)−3-H2 was achieved and CO2 emission was reduced by about 80 kg·t−1-HM with 5.6% lower in CO2 emission of blast furnace [16]. In 2022, China Baowu Bayi Iron and Steel Company carried out the first test of 430 m3 blast furnace with top gas recycling in the world with the aim of reducing the carbon emissions of the blast furnace by over 50% [17,18,19]. China is gradually moving from experimentation to industrialized applications in the technology of blast furnace hydrogen-rich low-carbon ironmaking.
Although hydrogen-rich gas injection to blast furnace can reduce the carbon emission from blast furnace, the carbon emission reduction is limited by the theoretical combustion temperature at the tuyere on the amount of hydrogen-rich gas injection, and the maximum carbon emission reduction is only about 10%. Despite declining CO2 emissions to certain extent through CO2 removal and storage, blast furnace with top gas recycling is actually the decarbonization at the end which cannot reduce CO2 emissions from the source. With the rapid development of hydrogen production from renewable energy in China, the carbon-replacing hydrogenous gas oxygen blast furnace technology can significantly reduce carbon emissions from the source of blast furnace ironmaking. A large number of theoretical and experimental research works have been conducted both domestically and internationally on blast furnace with top gas recycling [20,21,22,23,24,25,26,27,28]. However, there are few research on the hydrogen-enriched oxygen blast furnace where coke is replaced by hydrogen on a large scale. It is known that coke acts as the skeleton of the stock column, carburizing agent, and heat source in blast furnace, among which the reducing and heating agents could be replaced by hydrogen injection, but not the role of the skeleton and hot metal carburization. Therefore, under the conditions of ensuring stable and smooth operation of the oxygen blast furnace, maximum acceptable hydrogen injection and the maximum CO2 emission reduction of the oxygen blast furnace are required to be studied in depth. In this study, the impacts of hydrogen injection volume and burden metallization rate in the shaft on the coke ratio, top gas recycling amount, the reducing gas composition, and reduced CO2 emission of the hydrogen-rich oxygen blast furnace have been systematically investigated by establishing a multi-zone constrained mathematical modeling of the hydrogen-rich oxygen blast furnace where energy balance calculations are made based on the constraints of various zones, so that the adjustment range of coke replacement with hydrogen in the oxygen blast furnace is proposed, providing technical guidance and design support for the industrialization test and application of hydrogen production from renewable energy–hydrogen-rich oxygen blast furnace low-carbon metallurgy technology in China.
2 Hydrogen enrichment oxygen blast furnace process flow
In combination with the technologies of full oxygen blast furnace and top gas recycling, a process flow of electricity/heat/hydrogen cogeneration-hydrogen enrichment oxygen blast furnace is proposed, as depicted in Figure 1. This approach aligns with the low-carbon metallurgy technology trend of renewable energy hydrogen production and large-scale hydrogen application in iron and steel industry. The low-carbon metallurgical process comprises two primary units: the electricity/heat/hydrogen cogeneration hydrogen production unit and hydrogen metallurgy unit. The electricity/heat/hydrogen cogeneration hydrogen production unit primarily utilizes renewable energy like wind and solar power to generate heat and electricity, and hydrogen production by water electrolysis provides a large amount of low-cost “green hydrogen” resources for iron and steel smelting. Hydrogen metallurgy unit is mainly designed to reduce the consumption of fossil energy for ironmaking in blast furnaces by replacing carbon with hydrogen, i.e., coke and pulverized coal consumed in blast furnace ironmaking are substituted by large quantities of “green hydrogen.” In hydrogen-rich oxygen blast furnace, hydrogen and top gas recycling are injected via shaft tuyere and oxygen via hearth. In order to make up for the heat insufficiency in the shaft and increase the pre-reduction rate of the charge, the top gas is recycled. After dust removal and CO2 removal processes, a portion of the top gas is mixed with the hydrogen generated from the hydrogen production unit and then heated up to about 950°C before the injection to blast furnace via shaft tuyere while other partial top gas is recycled back as the fuel for heating. Huge amounts of hydrogen injected into the shaft is beneficial for the substantial increase in the charge indirect reduction in the shaft and for the decrease of the direct reduction in the hearth, thus considerably reducing the coke consumption, improving the primary utilization of the fuel, realizing the substitution of hydrogen for carbon, and lowering the carbon emission of ironmaking in the blast furnace.

Flow process of renewable energy hydrogen production-hydrogen rich oxygen blast furnace.
3 Mathematical modeling of hydrogen-rich oxygen blast furnace
3.1 Model establishment
According to the physical-chemical reaction of the burden in different areas of the furnace, a multizone constrained mathematical model of the hydrogen-rich oxygen blast furnace was established [29] with three different zones: high temperature zone, solid burden zone, and top gas recycling zone. Theoretically, increasing the number of zones improves the accuracy of calculation results. However, excessive zone divisions can lead to challenges in determining boundary conditions and computational complexity. Based on the characteristics of carbon solution loss reaction (CO2 + C = 2CO) and water gas shift reaction (H2O + C = CO + H2), the isotherm of 1,000°C is used as the dividing line between the high temperature zone above 1,000°C and the solid burden zone below 1,000°C. In the solid burden zone, heating and indirect reduction of the burden are exclusively conducted, while all other reactions occur in the high-temperature zone. The recycled top gas is primarily heated in the top gas heating zone. Each zone is constrained by physical and chemical constraints. The loss of heat and material input and output temperatures in each zone are limited by physical constraints which determine the amount of physical heat in each zone. Chemical constraints include thermodynamic constraints and kinetic constraints among which the equilibrium conditions of the chemical reaction are decided by thermodynamic constraints, representing the limits that the reaction is likely to reach. The reaction rate, limited by kinetic constraints, depends on the fuel composition and the furnace operating conditions and determines the pre-reduction rate of the ores and the slag iron composition. The heat-income items in each zone are organized into a number set
The heat balance condition that satisfies the actual production is

Calculation flow of hydrogen-rich oxygen blast furnace mathematical model.
3.2 Calculation conditions
In the mathematical model, the fuel consumption per ton consumed for hot metal production serves as the baseline for calculations and under the assumption of the ore metallization rate and hydrogen utilization (
Chemical analysis of pellet (wt%)
Elements | TFe | FeO | SiO2 | CaO | MgO | Al2O3 | MnO | TiO2 | P | S |
---|---|---|---|---|---|---|---|---|---|---|
Content | 67.30 | 0.52 | 2.40 | 0.32 | 0.69 | 0.47 | 0.07 | 0.26 | 0.005 | 0.008 |
Chemical analysis of limestone (wt%)
Elements | CaO | MgO | SiO2 | Al2O3 | Fe2O3 | LOI |
---|---|---|---|---|---|---|
Content | 52.78 | 1.32 | 1.98 | 0.67 | 0.82 | 42.43 |
Chemical analysis of coke (wt%)
Elements | C | Ash | Volatile | H | S | P | H2O |
---|---|---|---|---|---|---|---|
Content | 85.73 | 12.50 | 1.25 | 0.18 | 0.52 | 0.023 | 0.62 |
Chemical analysis of hot metal (wt%)
Elements | Fe | C | Si | Mn | P | S |
---|---|---|---|---|---|---|
Content | 94.21 | 4.40 | 0.5 | 0.05 | 0.05 | 0.02 |
Under the above given conditions, the energy balance of high temperature zone, solid burden zone, and top gas heating zone is established via the calculation flow of hydrogen-rich oxygen blast furnace mathematical model and based on material balance and energy balance. First, the iron ore consumption is set up mainly in accordance with the hot metal composition and slag basicity balance and second, the fuel consumption is determined according to the energy balance of each area and finally the material and energy balance of each area is established. In the calculation process of material and energy balance of various zones, physical constraints and chemical constraints in each zone must be satisfied and the calculation results could not be real and credible until the material and heat balance is satisfied in each zone.
4 Calculation results and analysis
4.1 Analysis of minimum coke ratio in hydrogen-rich oxygen blast furnace
Coke acts as the skeleton of the stock column, reducing agent, hot metal carburization, and heat source in blast furnace, among which reducing and heating agent could be replaced by hydrogen injection, but not the role of the skeleton and hot metal carburization. Therefore, the minimum coke consumption in the oxygen blast furnace must satisfy the requirements for both skeleton and hot metal carburization, which stabilize at 40–45 kg per ton of saturated hot metal, roughly equivalent to 50 kg coke. Skeleton role of coke is mainly to bear the burden load which could be described by the modified Janssen pressure formula:
where
Due to coke’s lower specific gravity compared to ore, the average volumetric weight of the burden increases as the coke ratio decreases. According to Janssen’s formula, the maximum pressure that the coke can withstand in the furnace is calculated at 71 kPa at coke ratio of 400 kg, increasing to only 100 kPa when the ratio is reduced to 160 kg. In consideration of the normal cold compressive strength of modern metallurgical coke at 5,000–6,000 kPa, much higher than the above calculated value, the load increase of the skeleton coke after the injection of hydrogen will not aggravate the coke crushing, but the coke solution loss will cause serious damage to the skeleton coke. After huge hydrogen injection in the oxygen blast furnace, the contents of H2O and CO2 produced by indirect reduction in the shaft are elevated which could exacerbate the reaction of coke solution loss and thus destroy the skeleton role of coke. The amount of coke solution loss significantly correlates with the initial quality of the coke. The coke with poor reactivity and high strength is endowed with low coke solution loss and excellent strength at high temperature, lowering the minimum coke ratio of the oxygen blast furnace a little bit; the coke with good reactivity and low strength is portrayed with high coke solution loss and susceptibility to crushing due to the loads imposed by effective weight of the burden at the hearth and making it necessary to increase the minimum coke ratio of the oxygen blast furnace a little bit. The coke ratio limit value in the gas injection blast furnace is calculated by Lan et al. [31] at 124.76 kg·t−1-Fe with only consideration of the direct reduction and heat consumption of the blast furnace, not the skeletal role of coke on the coke ratio requirements. Bao steel No.1 Blast Furnace is reported to have a stable coal ratio of 230–240 kg·t−1 and a minimum coke ratio of about 265 kg·t−1 from 1999 to 2002 [32], realizing economic PCI and low fuel ratio production. Based on considerations for stable production in a hydrogen-rich oxygen blast furnace and referring to the minimum coke ratio operation results from domestic blast furnaces, the minimum coke ratio of 200 kg·t−1 is determined for hydrogen-rich oxygen blast furnace.
4.2 Effects of hydrogen injection volume on coke ratio and reducing gas CO/H2
The volume of hydrogen injection impacts both the coke ratio of the hydrogen-rich reduction furnace and CO/H2 ratio in the reducing gas of the shaft. With the increase in hydrogen injection, the hydrogen reduction in the replacement of carbon decreases the coke consumption, and H2 enlargement in the reducing gas of the shaft increases hydrogen reduction ratio and reduces the CO2 emission in the reduction process. The relation of changes among coke ratio, top gas recycling injection, and CO and H2 content of the shaft gas in the hydrogen-rich reduction furnace is studied for every 100 m3 increase in hydrogen injection per ton of HM with the calculation results shown in Figures 3 and 4.

Effects of H2 injection on coke ratio and oxygen consumption.

Effects of H2 injection on top gas recycling and CO/H2 content in the shaft gas.
As seen from Figures 3 and 4, it is observed that increasing hydrogen injection per ton of HM in the hydrogen-rich oxygen blast furnace results in gradual reductions in both the coke ratio and oxygen consumption. Simultaneously, top gas recycling (including hydrogen) injection in the shaft is increased step by step with slowly increasing H2 and declining CO in the reducing gas. For each 100 N·m3 increase of hydrogen injection per ton of HM, the average coke ratio is reduced approximately by 40 kg with about 20 N·m3 less average oxygen consumption and about 0.4 kg·(N·m)−3 replacement ratio of hydrogen and coke. With the hydrogen enrichment, top gas recycling injection to the shaft also gradually increases. Without hydrogen injection to hydrogen-rich reduction furnace, the coke ratio and top gas recycling injection reach respectively 441 kg and 951 N·m3 per ton of HM with the indirect reduction dominated by CO whose content accounts for about 95%. At hydrogen injection of 100 N·m3 per ton of HM, the indirect reduction of the burden in the shaft is improved, the coke ratio of the hydrogen-rich reduction furnace comes down to 402 kg, top gas recycling injection in the shaft increases up to 1,010 N·m3 per ton of HM, CO content in the shaft gas comes down to 81%, and H2 increases up to 15% or so; when hydrogen injection is increased to 400 N·m3 per ton of HM, the coke ratio of the hydrogen-rich reduction furnace decreased to 283 kg, top gas recycling injection in the shaft increases to 1,210 N·m3 per ton of HM, CO content in the shaft gas comes down to about 46%, and H2 increases up to 50% or so, exceeding CO in the proportion of reduction gas and dominating the reduction; as hydrogen injection continuously rises to 600 N·m3 per ton of HM, the coke ratio of the hydrogen-rich reduction furnace decreased to 203 kg, top gas recycling injection in the shaft increases up to 1,350 N·m3 per ton of HM, CO content in the shaft gas comes down to about 27% and H2, dominating the reduction of the shaft, increases up to 68% or so. However, reducing the coke ratio of the reduction furnace to 203 kg affects the skeleton role of coke. Due to the low coke ratio, it is hard for the coke to support the burden column and the permeability of the burden column in the furnace is deteriorated, affecting the reliable and smooth operation of the reduction furnace. For the stability of hydrogen-rich reduction furnace, the lowest coke ratio is controlled at about 200 kg·t−1, so the maximum hydrogen injection is about 600 N·m3 per ton of HM.
4.3 Effects of burden metallization on coke ratio and reducing gas CO/H2
The objective of top gas recycling and hydrogen injection is to enhance the indirect reduction of the burden in the shaft and to reduce the direct reduction of the hearth where only carburization and slag-iron fusion separation occur, so burden metallization at various zones correspond to distinctive coke ratios and hydrogen injections with different top gas recycling injection, CO and H2 contents in the shaft gas. Through calculations, the effects of different metallization on coke ratio, hydrogen injection, and CO/H2 content in the shaft gas are illustrated in Figures 5 and 6.

Effects of metallization on coke ratio and oxygen consumption.

Effects of metallization on top gas recycling and CO/H2 in the shaft gas.
Figures 5 and 6 illustrate that as burden metallization increases in the hydrogen-rich reduction furnace, several trends emerge: the coke ratio decreases, the hydrogen consumption increases, the top gas recycling injection (including hydrogen) to the shaft gradually goes up with slowly increasing H2 and declining CO in the reducing gas. At 55% metallization of burden in the shaft, the coke ratio of the hydrogen-rich reduction furnace is observed at 441 kg, making hydrogen injection unnecessary, and the top gas recycling injection to the shaft is 951 N·m3 with the indirect reduction dominated by CO whose content accounts for about 95%. At 60% metallization of burden in the shaft, the indirect reduction of the burden in the shaft is improved, the coke ratio of the hydrogen-rich reduction furnace decreased to 408 kg, requiring hydrogen injection of 85 N·m3 per ton of HM, total top gas recycling injection increased to 1,005 N·m3 per ton of HM, CO content in the shaft gas decreased to 75%, and H2 increased to 21% or so; At 70% metallization of burden in the shaft, the coke ratio of the hydrogen-rich reduction furnace decreased to 342 kg, requiring hydrogen injection of 255 N·m3 per ton of HM, total top gas recycling injection increased to 1,115 N·m3 per ton of HM, CO content in the shaft gas decreased to about 46%, and H2 increased to 49% or so, exceeding CO in the proportion of reduction gas; with the metallization of burden in the shaft continuously rising up to 90%, the coke ratio of the hydrogen-rich reduction furnace decreased to 210 kg, requiring hydrogen injection of 570 N·m3 per ton of HM, total top gas recycling injection increased to 1,335 N·m3 per ton of HM, CO content in the shaft gas decreased to about 29%, and H2, dominating the reduction of the shaft, increased to 66% or so. With the view of the influence of coke solution loss on high temperature strength, continuous decline of coke ratio could cause the coke unable to support the stock column. Therefore, the lowest coke ratio of hydrogen-rich oxygen blast furnace is controlled at about 200 kg·t−1 with 90% burden metallization, basically realizing the full indirect reduction of iron ore.
4.4 Effects of hydrogen injection and top gas recycling on CO2 emission reduction
The hydrogen-rich reduction furnace is primarily characterized by hydrogen injection and top gas recycling to realize the replacement of carbon with hydrogen, so as to reduce the carbon emission of long-process blast furnace ironmaking. The CO2 emissions from the hydrogen-rich reduction furnace, encompassing the CO2 generated from gas reduction and the CO2 produced during the heating of reduced gas, are directly influenced by the hydrogen injection volume per ton of HM. The variations in CO2 emissions from the hydrogen-rich reduction furnace under different hydrogen injection conditions have been investigated, and the calculation results are depicted in Figure 7.

Effects of H2 injection on CO2 emission.
As shown in Figure 7, with the increase in hydrogen injection per ton of HM, CO2 emission is gradually reduced, averagely by about 100 kg for every 100 N·m3 hydrogen injection per ton of HM. Without hydrogen injection, the largest CO2 emission of carbon cycle hydrogen-rich reduction furnace is observed, reaching about 1,108 kg·t−1-HM. At 100 N·m3 hydrogen injection per ton of HM, CO2 emission is reduced by 112 kg to 1,006 kg·t−1-HM, mainly owing to replacement of coke by hydrogen in the reduction and coke ratio is cut down and consequently CO2 emission decreased. At 400 N·m3 hydrogen injection per ton of HM, CO2 emission is substantially reduced by 400–707 kg·t−1-HM. In the consideration of minimum coke ratio of about 200 kg·t−1 for carbon cycle hydrogen-rich reduction furnace, CO2 emission could decline to 501 kg·t−1-HM at 600 N·m3 hydrogen injection per ton of HM, 55% less than that without hydrogen injection, obtaining considerable gain of CO2 emission reduction at the source. If CO2 removed from the top gas is used for end resource utilization or storage, its emission per ton of HM can be reduced by more than 80%, which can help China’s iron and steel industry to achieve the goal of “carbon neutrality.”
5 Conclusion
In hydrogen rich oxygen blast furnace, coke acts as the skeleton of the stock column, hot metal carburization, reducing agent, and heating agent, among which reducing and heating agents could be replaced by hydrogen injection, but not the role of the skeleton and hot metal carburization. Carburized coke consumption is about 50 kg·ton−1 HM and after coke ratio drops, the load increase of the skeleton coke will not cause the coke crushing, but the coke solution loss will cause serious damage to the skeleton coke. In the consideration of stable production, the minimum coke ratio of 200 kg·t−1 is determined for hydrogen-rich oxygen blast furnace.
With the hydrogen enrichment in hydrogen rich oxygen blast furnace, coke ratio gradually decreases with about 0.4 kg·(N·m)−3 replacement ratio of hydrogen and coke. The maximum hydrogen injection rate of about 600 N·m3 H2·t−1-HM is determined and coke ratio of the hydrogen rich oxygen blast furnace is reduced to 203 kg with CO content in the shaft gas decreasing to about 27% and H2 increasing to 68%, realizing hydrogen-rich smelting with hydrogen instead of carbon.
With the rising of the burden metallization in the shaft, the coke ratio of the hydrogen-rich reduction furnace decreases and the hydrogen consumption increases. At 90% metallization of burden in the shaft, the coke ratio of the hydrogen-rich reduction furnace decreased to 210 kg, requiring hydrogen injection of 570 N·m3 per ton of HM, total top gas recycling injection up to 1,335 N·m3 per ton of HM, which basically realizes full indirect reduction of the iron ores.
With the increase in hydrogen injection per ton of HM, CO2 emission is gradually reduced, averagely by about 100 kg for every 100 N·m3 hydrogen injection per ton of HM. At 600 N·m3 hydrogen injection per ton of HM, CO2 emission is cut down to 501 kg·t−1-HM, 55% less than that without hydrogen injection, obtaining considerable gain of CO2 emission reduction at the source.
Acknowledgements
The authors gratefully acknowledge the fundamental support from the National Key Research & Development Program of China (2023YFB4204005).
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Funding information: This research was financially supported by the National Key Research & Development Program of China (2023YFB4204005).
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Author contributions: Jianjun Gao: conceptualization, validation, formal analysis, and writing – review and editing. Bin Wang: methodology, visualization, and writing – review and editing. Fei Teng: supervision and resources. Yuanhong Qi: resources and investigation. Yingyi Zhang: formal analysis and supervision.
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Conflict of interest: The authors state no conflict of interest.
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Data availability statement: All authors confirm that all data used in this article can be published by the Journal “High Temperature Materials and Processes.”
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- Preparation of MoO3 powder by hydrothermal method
- The comparative study of Ti-bearing oxides introduced by different methods
- Application of MgO/ZrO2 coating on 309 stainless steel to increase resistance to corrosion at high temperatures and oxidation by an electrochemical method
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