Green steel at its crossroads: hybrid hydrogen-based reduction of iron ores

TL;DR

This paper explores a hybrid hydrogen-based reduction process combining solid-state direct reduction and plasma reduction to improve efficiency and sustainability in green steel production, addressing hydrogen resource limitations.

Contribution

It introduces a knowledge-based hybrid reduction method that optimizes hydrogen and energy use by combining two distinct reduction technologies for iron ore.

Findings

Efficient reduction of hematite to wustite via DR at 700°C

Smooth and efficient plasma reduction of semi-reduced oxides

Identification of the optimal transition point between the two technologies

Abstract

Iron- and steelmaking cause ~7% of the global CO2 emissions, due to the use of carbon for the reduction of iron ores. Replacing carbon by hydrogen as the reductant offers a pathway to reduce emissions. However, production of hydrogen using renewable energy will remain a bottlenecks, because making the annual crude steel production of 1.8 billion tons sustainable requires a minimum amount of ~97 million tons of green hydrogen per year. Another fundamental aspect to make ironmaking sector more sustainable lies in an optimal utilization of green hydrogen and energy, thus reducing efforts for costly in-process hydrogen recycling. We therefore demonstrate here how the efficiency in hydrogen and energy consumption during iron ore reduction can be dramatically improved by the knowledge-based combination of two technologies: partially reducing the ore at low temperature via solid-state direct reduction (DR) to a kinetically defined degree, and subsequently melting and completely transforming it to iron under a reducing plasma (i.e. via hydrogen plasma reduction, HPR). Results suggest that an optimal transition point between these two technologies occurs where their efficiency in hydrogen utilization is equal. We found that the reduction of hematite through magnetite into wustite via DR is clean and efficient, but it gets sluggish and inefficient when iron forms at the outermost layers of the iron ore pellets. Conversely, HPR starts violent and unstable with arc delocalization, but proceeds smoothly and efficiently when processing semi-reduced oxides. We performed hybrid reduction experiments by partially reducing hematite pellets via DR at 700{\deg}C to 38% global reduction (using a standard thermogravimetry system) and subsequently transferring them to HPR, conducted with a gas mixture of Ar-10%H2 in an arc-melting furnace, to achieve conversion into liquid iron.