A New Methodological Approach to the Characterization of Optimal Charging Rates at the Hydrogen Plasma Smelting Reduction Process Part 1: Method

Zarl, Michael Andreas; Ernst, Daniel; Cejka, Julian; Schenk, Johannes

doi:10.3390/ma15144767

Cited by 15 publications

(7 citation statements)

References 11 publications

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“…These observations together with the scientific findings reported here aim at supporting the development of the next generation of green steel reactors currently found in pilot‐plant scale. [ 56 ]…”

Section: Discussionmentioning

confidence: 99%

Sustainable Ironmaking Toward a Future Circular Steel Economy: Exploiting a Critical Oxygen Concentration for Metallurgical Cu Removal from Scrap‐Based Melts

Souza Filho,

da Silva,

Büyükuslu

et al. 2024

steel research int.

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A circular steel economy based on recycling scrap is severely hampered by the increasing accumulation of Cu returning from more and more electrified products, which severely limits processing, application, and safety of steels. As of yet, no viable strategies for its removal have been developed, and the increasing Cu contamination can only be diluted with fresh primary iron. This is not only evoking CO2 emissions from conventional reduction processes, but also merely delays the problem until global demands allow for a circular steel economy. However, the ongoing transformation toward green steel making may offer pathways to overcome this complex metallurgical challenge. It is demonstrated that Cu can be effectively evaporated from Fe–Cu–O melts—representing Fe ore mixed with Cu‐contaminated steel scrap—during hydrogen plasma‐based smelting reduction. This evaporation is found to be strongly influenced by the Cu activity determined by the concentration of oxygen in the liquid, with a critical O concentration of about 22 wt%. Even without the presence of hydrogen, Cu concentrations can thereby be drastically reduced from 1 to less than 0.1 wt%. Potentials and challenges for leveraging these fundamental findings on a laboratory scale for future industrial production of green steel are outlined and discussed.

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Section: Discussionmentioning

confidence: 99%

Sustainable Ironmaking Toward a Future Circular Steel Economy: Exploiting a Critical Oxygen Concentration for Metallurgical Cu Removal from Scrap‐Based Melts

Souza Filho,

da Silva,

Büyükuslu

et al. 2024

steel research int.

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“…The melting tests were performed in the hydrogen plasma smelting reduction (HPSR) reactor at the chair of ferrous metallurgy, Montanuniversität Leoben, Austria, whose layout is visualized in Figure 1. This aggregate, extensively described in [35,36], is usually applied for direct smelting reduction tests. The method itself is well established.…”

Section: Methodsmentioning

confidence: 99%

The Behavior of Direct Reduced Iron in the Electric Arc Furnace Hotspot

Pfeiffer

Ernst²,

Zheng

et al. 2023

Metals

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Hydrogen-based direct reduction is a promising technology for CO2 lean steelmaking. The electric arc furnace is the most relevant aggregate for processing direct reduced iron (DRI). As DRI is usually added into the arc, the behavior in this area is of great interest. A laboratory-scale hydrogen plasma smelting reduction (HPSR) reactor was used to analyze that under inert conditions. Four cases were compared: carbon-free and carbon-containing DRI from DR-grade pellets as well as fines from a fluidized bed reactor were melted batch-wise. A slag layer’s influence was investigated using DRI from the BF-grade pellets and the continuous addition of slag-forming oxides. While carbon-free materials show a porous structure with gangue entrapments, the carburized DRI forms a dense regulus with the oxides collected on top. The test with slag-forming oxides demonstrates the mixing effect of the arc’s electromagnetic forces. The cross-section shows a steel melt framed by a slag layer. These experiments match the past work in that carburized DRI is preferable, and material feed to the hotspot is critical for the EAF operation.

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“…The facility layout is shown in Figure 1. Various research articles used the current facility for investigating H 2 -based steelmaking [25][26][27][28]. The facility is slightly modified for the aim of this study, which is explained further.…”

Section: Methodsmentioning

confidence: 99%

Feasibility of a Plasma Furnace for Methane Pyrolysis: Hydrogen and Carbon Production

Daghagheleh,

Schenk,

Zarl

et al. 2023

Energies

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The imperative to achieve a climate-neutral industry necessitates CO2-free alternatives for H2 production. Recent developments suggest that plasma technology holds promise in this regard. This study investigates H2 production by methane pyrolysis using a lab-scale plasma furnace, with the primary objective of achieving a high H2 yield through continuous production. The plasma furnace features a DC-transferred thermal plasma arc system. The plasma gas comprises Ar and CH4, introduced into the reaction zone through the graphite hollow cathode. The off-gas is channeled for further analysis, while the plasma arc is recorded by a camera installed on the top lid. Results showcase a high H2 yield in the range of up to 100%. A stable process is facilitated by a higher power and lower CH4 input, contributing to a higher H2 yield in the end. Conversely, an increased gas flow results in a shorter gas residence time, reducing H2 yield. The images of the plasma arc zone vividly depict the formation and growth of carbon, leading to disruptive interruptions in the arc, hence declining efficiency. The produced solid carbon exhibits high purity with a fluffy and fine structure. This paper concludes that further optimization and development of the process are essential to achieve stable continuous operation with a high utilization degree.

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A New Methodological Approach to the Characterization of Optimal Charging Rates at the Hydrogen Plasma Smelting Reduction Process Part 1: Method

Cited by 15 publications

References 11 publications

Sustainable Ironmaking Toward a Future Circular Steel Economy: Exploiting a Critical Oxygen Concentration for Metallurgical Cu Removal from Scrap‐Based Melts

Sustainable Ironmaking Toward a Future Circular Steel Economy: Exploiting a Critical Oxygen Concentration for Metallurgical Cu Removal from Scrap‐Based Melts

The Behavior of Direct Reduced Iron in the Electric Arc Furnace Hotspot

Feasibility of a Plasma Furnace for Methane Pyrolysis: Hydrogen and Carbon Production

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