Abstract In order to reveal the impact factors resulted in the whisker or nodule products in the reduction of iron ore particles, iron oxide reduction was numerically simulated by COMSLO software, and the influence of fluid temperature and particle shape on the reaction process were investigated. The results showed that reaction process was in line with the unreacted core model when the particle was spherical and the particle was evenly heated, and the side with high temperature would give priority to reaction when the spherical particle was unevenly heated. When the irregular particle was evenly heated, reaction process was in line with the unreacted core model likewise, but the part of large curvature would give priority to reaction. When the irregular particle was unevenly heated, the part of large curvature and the fluid and particle tangent would give priority to reaction. Uneven heating or irregular shape of the particle would cause the product layer shift. The product layer would shift to the side with high temperature and the part of large curvature, which could increase whiskers and nodules in the reaction process.
