In this study, char image analysis techniques have been employed to investigate the morphology of chars obtained from a Drop-Tube furnace. Char image analysis results have been incorporated as inputs to a char burnout model based on Hurt's CBK model. It has been observed that the char combustion rate was strongly affected by char structural parameters and the inclusion of char morphology has led to a better prediction of char burnout. It has also been suggested by the model that the inclusion of ash inhibition overestimates the resistance attributed by ash film and the consideration of ash film resistance should be undertaken in a different way to give a better prediction at the later stages of char combustion. (C) 2003 Elsevier Ltd. All rights reserved.