The ironmaking blast furnace is regarded as one of the biggest and most complex industrial reactors, because it includes various materials like gas, lump granular materials, liquids and powders and more than 30 major reactions and phase changes in a single reaction vessel. The mathematical simulator of this process developed in this study used the multi-fluid treatment as its framework, since the motions of these materials were governed by different flow mechanisms. The rates of the interactions among the phases and the chemical reactions were evaluated based on kinetic theories. The model successfully reproduced the fields of velocity, temperature and reaction in the furnace and its validity was confirmed. The simulator was also applied to a novel operation, namely the top gas recycling combined with the carbon-composite iron-ore charging and the waste plastics injection, and the advantages in furnace efficiency and environmental load were quantitatively indicated. (c) 2005 Elsevier Ltd. All rights reserved.