Integration of Open Slag Bath Furnace with Direct Reduction Reactors for New-Generation Steelmaking

Cavaliere, Pasquale; Perrone, A.; Silvello, A.; Stagnoli, Paolo; Duarte, Pablo

doi:10.3390/met12020203

Cited by 15 publications

(4 citation statements)

References 14 publications

(12 reference statements)

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“…As a consequence, carburization is needed. [ 27 ] DR under CO atmosphere is often accompanied by carbon deposition due to an inverse Boudouard reaction at temperatures <1000 °C.…”

Section: Introductionmentioning

confidence: 99%

Hydrogen‐Based Direct Reduction of Iron Oxides Pellets Modeling

Cavaliere

Perrone

Marsano

et al. 2023

steel research int.

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The present study deals with the analyses of the direct reduction kinetics during the hydrogen reduction of industrial iron oxide pellets. Various types of pellets with different percentage of total iron content and metal oxides are examined. They are reduced at different temperatures and pressure (700–1100 °C and 1–6 bar) in hydrogen atmosphere. The reduction behavior is described in terms of time to reduction, rate of reduction, and kinetics constant. All the obtained results are analyzed through the employment of a commercial multiobjective optimization tool to precisely define the weight that each single parameter has on the reduction behavior. It is shown that from the point of view of the processing conditions, temperature is the main factor influencing the time to total reduction. From the point of view of the pellets properties, it is mainly influenced by the total iron percentage and then by porosity and basicity index. Also, the kinetics behavior is largely influenced by the reduction temperature even if it is mainly governed by the porosity and pores size from the point of view of the reduced pellets. The reduction rate is also mainly influenced by temperature and then by iron percentage, gas pressure, basicity index, and porosity.

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“…As a consequence, carburization is needed. [ 27 ] DR under CO atmosphere is often accompanied by carbon deposition due to an inverse Boudouard reaction at temperatures <1000 °C.…”

Section: Introductionmentioning

confidence: 99%

Hydrogen‐Based Direct Reduction of Iron Oxides Pellets Modeling

Cavaliere

Perrone

Marsano

et al. 2023

steel research int.

Self Cite

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“…Note, however, that even though some limited pilot experiments were carried out by Tenova [34], there are no industrial references yet of using that technology in connection with an H 2 -DR shaft.…”

Section: Raw Materialsmentioning

confidence: 99%

Net-Zero transition in the steel sector: beyond the simple emphasis on hydrogen, did we miss anything?

Birat

2023

Matériaux & Techniques

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There is an explosion of publications and of various announcements regarding the use of hydrogen in the steel sector as a way to arrive at Net-Zero steel production − particularly in Europe. Most of them describe process technologies on the one hand and commitment to implement them quickly in the steel sector in the form of roadmaps and agendas, on the other hand. The most popular process technology is H2 Direct Reduction (H2-DR) in a shaft furnace. Available technical literature, as abundant as it may be, is still fairly incomplete in making the pathway to Net-Zero explicit and credible. This paper tries to identify important issues which are not openly discussed nor analyzed in the literature, yet. Process-wise, open questions in technical papers are: (1) what are the best-fitted iron ores for H2-DR, (2) what downstream furnace, after H2-DR, can accommodate various raw materials, (3) how and how much carbon ought to be fed into the process, (4) what is the best design for the shaft, (5) should it be designed for both natural gas and H2 operations, or simply for H2, (6) how should the progress of R&D be organized from pilot plants up to full-scale FOAK plants and then to a broad dissemination of the technology, (7) what kind of refractories should be implemented in the various new reactors being imagined, etc. Cost issues are also widely open, as a function of green hydrogen, green electricity and carbon prices. How is hydrogen fed to the steel mill and what exactly is the connection to renewable electricity? Is the infrastructure that this calls for planned in sufficiently details? What is still missing is a full value chain picture and planning from mining to steel mills, including electricity and hydrogen grids. Two years after our last review paper on hydrogen, the overall picture has changed significantly. Countries beyond Europe, including China, have come up with roadmaps and plans to become net-zero by 2050, plus or minus 10 years. However, they do not rely as much on H2 alone, as Europe seems to be doing. What is most likely is that several process routes will develop in parallel, including, beyond H2-DR, Blast Furnace ironmaking and NG Direct Reduction with CCS, electrolysis of iron ore and scrap-based production in EAFs fed with green electricity, which would single-handedly support the largest part of production by the end of the century; as more and more scrap is to become available and be actually used. There is also a question for historians. The influence of Climate Change on Steel has been discussed continuously for more than 30 years. Why has the commitment to practical answers only solidified recently?

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“…Now, the pellets reduced via pure hydrogen are carbon free leading to an increase in the melting temperature of the sponge iron (1538°C). As a consequence, carburisation is needed [33]. DR under CO atmosphere is often accompanied by carbon deposition due to an inverse Boudouard reaction at temperatures <1000°C.…”

Section: Introductionmentioning

confidence: 99%

“…Figure33. Scatter matrix describing the behaviour of kinetics constants in the case of reducing atmosphere of 50% CO + 50% H2.…”

mentioning

confidence: 99%

Critical analysis of variable atmosphere gaseous reduction of iron oxides pellets

Cavaliere

Perrone

Marsano

2023

Ironmaking & Steelmaking

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The paper deals with the analyses of the direct reduction kinetics of industrial iron oxide pellets. Various types of pellets were reduced at different temperatures and pressure (700-1100°C and 1-6 bar) in various atmospheres with different contents of hydrogen and carbon monoxide. The reduction behaviour was described in terms of time to reduction, rate of reduction, and kinetics constant. For those pellets reduced in presence of carbon monoxide, also the carbon percentage in the reduced pellets was taken into account. All the obtained results were analysed through the employment of a commercial multi-objective optimisation tool (modeFrontier) in order to precisely define the weight that each single parameter has on the reduction behaviour of the pellets. The performed analyses allowed also to correlate the different processing parameters and the pellets properties in order to define the kinetics conditions as well as the factors limiting the reduction process.

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Integration of Open Slag Bath Furnace with Direct Reduction Reactors for New-Generation Steelmaking

Cited by 15 publications

References 14 publications

Hydrogen‐Based Direct Reduction of Iron Oxides Pellets Modeling

Hydrogen‐Based Direct Reduction of Iron Oxides Pellets Modeling

Net-Zero transition in the steel sector: beyond the simple emphasis on hydrogen, did we miss anything?

Critical analysis of variable atmosphere gaseous reduction of iron oxides pellets

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