Reduction of Haematite Using Hydrogen Thermal Plasma

Seftejani, Masab Naseri; Schenk, Johannes; Zarl, Michael Andreas

doi:10.20944/preprints201904.0261.v1

Cited by 5 publications

(2 citation statements)

References 20 publications

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“…Between the reduction periods, the gas atmosphere was renewed to an Ar-10% H2 mixture while the reactor was sealed entirely during the reduction time. Bäck, Plaul, Zarl, et al [2,[13][14][15] extensively researched the HPSR process with a transferred arc system. The setup consisted of a single graphite cathode with Fe-crucibles with a power input from 7-15 kW.…”

Section: (𝐹𝑒mentioning

confidence: 99%

Development of a new laboratory-scale reduction facility for the hydrogen plasma smelting reduction of iron ore based on a multi-electrode arc furnace concept

Hoffelner,

Zarl,

Schenk

2024

IOP Conf. Ser.: Mater. Sci. Eng.

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Steel production accounts for a significant share of industrial CO2 emissions. The HPSR process is a possible alternative to reduce these emissions massively if not completely negate them. In principle, Fe-ore is reduced at high temperatures in the plasma of a DC electric arc. hydrogen reacts with the oxidic melt at the gas-liquid interface. Various concepts for the hydrogen plasma reduction of iron ore have been investigated, but the process technology has not yet surpassed the demonstration scale (TRL5). Experimental setups for charging masses from a few grams to a few hundred kilograms have been realized. Further investigations on the process stability and the reaction kinetics are still necessary. An improved laboratory-scale furnace concept shall provide the basis for the fundamental research. An existing laboratory facility is the starting point for designing and constructing the new plasma furnace. There are several problems with this experimental setup. Mainly, the reactor’s dimensions and power supply limitations restrict the arc’s length. The first leads to problems with excessive refractory wear, while the latter limits the variation of process parameters. Strong cooling when using Fe crucibles and the unstable nature of the arc complicate the process control. A promising concept to deal with the problem of arc stability is the use of multiple electrodes in a direct current arc furnace. Together with an optimized furnace geometry, new potential for further investigations can open. Using a multi-cathode furnace is also promising to further explore ferroalloy production via hydrogen plasma reduction. An electric arc furnace was designed based on the requirements for the planned plasma reduction facility. The energy requirement was based on assumptions for heat transfer from the arc to the melt, walls, and lid and continuous transfer through the individual furnace parts. Considerations of power supply, hearth dimensions, refractory design, controlled gas atmosphere, and the implementation of auxiliary equipment were central to creating an ideal basis for various experimental setups.

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Section: (𝐹𝑒mentioning

confidence: 99%

Development of a new laboratory-scale reduction facility for the hydrogen plasma smelting reduction of iron ore based on a multi-electrode arc furnace concept

Hoffelner,

Zarl,

Schenk

2024

IOP Conf. Ser.: Mater. Sci. Eng.

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“…The method for identifying the optimal charging rate (described afterwards) is based on this approach. Further information concerning the theoretical background of the thermodynamics and kinetics can be found in former publications [ 24 , 25 , 26 , 27 , 28 , 29 ].…”

Section: Arc Plasma Basics For the Hpsr Processmentioning

confidence: 99%

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

et al. 2022

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The development of a carbon lean steel production process following the concept of direct carbon avoidance is one of the most challenging tasks the iron and steel industry must tackle in just a few decades. The necessary drastic reduction of 80% of the process’s inherent emissions by 2050 is only possible if a new process concept that uses hydrogen as the primary reductant is developed. The Hydrogen Plasma Smelting Reduction (HPSR) of ultra-fine iron ores is one of those promising concepts. The principle was already proven at a lab scale. The erection of a bench-scale facility followed this, and further scaled-ups are already planned for the upcoming years. For this scale-up, a better understanding of the fundamentals of the process is needed. In particular, knowledge of the kinetics of the process is essential for future economically feasible operations. This investigation shows the principles for evaluating and comparing the process kinetics under varying test setups by defining a representative kinetic parameter. Aside from the fundamentals for this definition, the conducted trials for the first evaluation are shown and explained. Several differences in the reduction behavior of the material at varying parameters of the process have already be shown. However, this investigation focuses on the description and definition of the method. An overall series of trials for detailed investigations will be conducted as a follow-up.

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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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Reduction of Haematite Using Hydrogen Thermal Plasma

Cited by 5 publications

References 20 publications

Development of a new laboratory-scale reduction facility for the hydrogen plasma smelting reduction of iron ore based on a multi-electrode arc furnace concept

Development of a new laboratory-scale reduction facility for the hydrogen plasma smelting reduction of iron ore based on a multi-electrode arc furnace concept

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

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

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