Engineering › Mechanical Engineering

Iron and Steelmaking Processes

Works Count: 39175

Wikipedia

Description

This cluster of papers focuses on the reduction kinetics of iron oxides using hydrogen and carbon monoxide in various ironmaking processes, particularly in the context of steel industry sustainability and energy efficiency. It also explores the potential applications of biomass and innovative metallurgical processes.

Keywords

Reduction Kinetics; Iron Oxides; Hydrogen; Carbon Monoxide; Steel Industry; Blast Furnace; Sustainability; Biomass Applications; Energy Efficiency; Metallurgical Processes

Gas-solid Reactions

1976-01-01

J. Szekely , James W. Evans , Hong Yong Sohn

Kinetics of reduction of iron oxides by H2

2005-11-24

A. Pineau , Ndue Kanari , I. Gaballah

The rate of reduction of iron oxides by carbon

1977-03-01

R. J. Fruehan

Determination of the reduction mechanism by temperature-programmed reduction: application to small iron oxide (Fe2O3) particles

1986-03-01

O.J. Wimmers , P. Arnoldy , J.A. Moulijn

ADVERTISEMENT RETURN TO ISSUEPREVArticleNEXTDetermination of the reduction mechanism by temperature-programmed reduction: application to small iron oxide (Fe2O3) particlesO. J. Wimmers, P. Arnoldy, and J. A. MoulijnCite this: J. Phys. Chem. … ADVERTISEMENT RETURN TO ISSUEPREVArticleNEXTDetermination of the reduction mechanism by temperature-programmed reduction: application to small iron oxide (Fe2O3) particlesO. J. Wimmers, P. Arnoldy, and J. A. MoulijnCite this: J. Phys. Chem. 1986, 90, 7, 1331–1337Publication Date (Print):March 1, 1986Publication History Published online1 May 2002Published inissue 1 March 1986https://pubs.acs.org/doi/10.1021/j100398a025https://doi.org/10.1021/j100398a025research-articleACS PublicationsRequest reuse permissionsArticle Views2809Altmetric-Citations171LEARN ABOUT THESE METRICSArticle Views are the COUNTER-compliant sum of full text article downloads since November 2008 (both PDF and HTML) across all institutions and individuals. These metrics are regularly updated to reflect usage leading up to the last few days.Citations are the number of other articles citing this article, calculated by Crossref and updated daily. Find more information about Crossref citation counts.The Altmetric Attention Score is a quantitative measure of the attention that a research article has received online. Clicking on the donut icon will load a page at altmetric.com with additional details about the score and the social media presence for the given article. Find more information on the Altmetric Attention Score and how the score is calculated. Share Add toView InAdd Full Text with ReferenceAdd Description ExportRISCitationCitation and abstractCitation and referencesMore Options Share onFacebookTwitterWechatLinked InRedditEmail Other access options Get e-Alerts

The evolution of structural order, microstructure and mineral matter of metallurgical coke in a blast furnace: A review

2014-05-23

Kejiang Li , Rita Khanna , Jianliang Zhang +4 more

Effect of gas composition on the kinetics of iron oxide reduction in a hydrogen production process

2004-11-12

K. Piotrowski , Kanchan Mondal , Hana Lorethova +3 more

Vaporization of refractory oxides during pulverized coal combustion

1982-01-01

Richard J. Quann , Adel F. Sarofim

Combustion of coal in circulating fluidized-bed boilers: a review

1999-11-01

Pallab Basu

Viscosities of ironmaking and steelmaking slags

1999-08-01

K. C. Mills , S. Sridhar

A model based on the optical basicity corrected for the cations required for the charge balance of AlO5-4 is investigated. This model has the advantage of being generally applicable and … A model based on the optical basicity corrected for the cations required for the charge balance of AlO5-4 is investigated. This model has the advantage of being generally applicable and not limited to slags of a certain composition. The calculated results were in reasonable agreement with traceable experimental data for a range of synthetic slags and industrial iron- and steelmaking slags. The latter included mould fluxes and blast furnace, steelmaking and coal slags. For most slag compositions here, the viscosities predicted with the present model were in better agreement with the measured values than those predicted by the Riboud and Urbain models; coal slags were the only exception. In the case of CaF2 containing slags, the results indicate that an optical basicity of CaF2 of 1·2 provided the best fit to the viscosity data.

Use of steelworks slag in Europe

1996-01-01

Jürgen Geiseler

Progress in catalytic naphtha reforming process: A review

2013-04-25

Mohammad Reza Rahimpour , Mitra Jafari , Davood Iranshahi

An overview of utilization of slag and sludge from steel industries

2006-07-08

Debadutta Das , S. Prakash , P.S.R. Reddy +1 more

Reduction of Fe2O3 with hydrogen

2010-04-14

Jerzy Zieliński , Ilona Zglinicka , Leszek Znak +1 more

Alternative emerging ironmaking technologies for energy-efficiency and carbon dioxide emissions reduction: A technical review

2014-03-19

Ali Hasanbeigi , Marlene Arens , Lynn Price

Hydrogen production by steam–iron process

2000-03-01

Viktor Hacker , Robert Fankhauser , Gottfried Faleschini +4 more

A review of binders in iron ore pelletization

2003-01-01

T.C. Eisele , S. Komar Kawatra

The majority of iron ores must be ground to a fine particle size to allow the iron oxides they contain to be concentrated, and the concentrate must then be agglomerated … The majority of iron ores must be ground to a fine particle size to allow the iron oxides they contain to be concentrated, and the concentrate must then be agglomerated back into large enough particles that they can be processed in blast furnaces. The most common agglomeration technique is pelletization, which requires the use of binders to hold the iron oxide grains together so that the agglomerates can be sintered into high-strength pellets. Although bentonite clay is the most commonly used binder, there are many other possibilities that could be competitive in a number of situations. This article reviews the numerous types of binders (both organic and inorganic) that have been considered for iron ore pelletization, including discussion of the binding mechanisms, advantages and limitations of each type, and presentation of actual pelletization results, so that the performance of the various types of binders can be compared and evaluated.

A literature review of titanium metallurgical processes

2011-04-19

Wensheng Zhang , Zhaowu Zhu , Chu Yong Cheng

Silico-ferrite of Calcium and Aluminum (SFCA) Iron Ore Sinter Bonding Phases: New Insights into Their Formation During Heating and Cooling

2012-10-08

Nathan A. S. Webster , Mark I. Pownceby , Ian C. Madsen +1 more

Graphitization of dispersed carbonaceous material in metamorphic rocks

1971-01-01

C. A. Landis

Effect of Change of Scale on Sintering Phenomena

1950-04-01

Conyers Herring

It is shown that when certain plausible assumptions are fulfilled simple scaling laws govern the times required to produce, by sintering at a given temperature, geometrically similar changes in two … It is shown that when certain plausible assumptions are fulfilled simple scaling laws govern the times required to produce, by sintering at a given temperature, geometrically similar changes in two or more systems of solid particles which are identical geometrically except for a difference of scale. It is suggested that experimental studies of the effect of such a change of scale may prove valuable in identifying the predominant mechanism responsible for sintering under any particular set of conditions, and may also help to decide certain fundamental questions in fields such as creep and crystal growth.

Gaseous reduction of iron oxides: Part I. Reduction of hematite in hydrogen

1971-11-01

E. T. Turkdogan , J. V. Vinters

Effect of Coal Ash Composition on Ash Fusion Temperatures†

2009-08-11

Wen J. Song , Li Tang , Xue Dong Zhu +3 more

The ash fusion temperatures (AFTs) of coal mineral matter at high temperature are important parameters for all gasifiers. Experiments have been conducted in which mixtures of selected coal ashes and … The ash fusion temperatures (AFTs) of coal mineral matter at high temperature are important parameters for all gasifiers. Experiments have been conducted in which mixtures of selected coal ashes and SiO2, Al2O3, CaO, Fe2O3, and MgO were subjected to the standard test for ash fusibility. The computer software package FactSage has been used to calculate the liquidus temperatures of coal ash samples and the proportions of the various phases present as a function of temperature. The results show that the AFTs of coal ash samples first decrease with increasing CaO, Fe2O3, and MgO contents, then reach a minimum value, before increasing once more. However, for the effect of S/A ratio, its AFTs are always increased with increasing S/A ratios. The measured AFTs all show variations with mixture composition that correlated closely with liquidus temperatures for the appropriate pseudoternary phase diagrams. The liquidus and AFTs generally showed parallel compositional trends but are displaced from each other because of the influence of additional basic components in the coal ash. The liquidus temperatures of coal ash samples are always higher than its AFTs.

Gaseous reduction of iron oxides: Part III. Reduction-oxidation of porous and dense iron oxides and iron

1972-06-01

E. T. Turkdogan , J. V. Vinters

Current situation of energy consumption and measures taken for energy saving in the iron and steel industry in China

2009-05-18

Z.C. Guo , Zhanbao Fu

Comparison of Shell, Texaco, BGL and KRW gasifiers as part of IGCC plant computer simulations

2004-11-09

Ligang Zheng , Edward Furinsky

Reaction of sulfur dioxide with limestone and the grain model

1976-05-01

Miloslav Hartman , Robert W. Coughlin

Abstract Experimental measurements of the reaction of sulfur dioxide and oxygen with limestones have demonstrated substantial influence of the geologic origin of the stone, its porosity and particle size, gaseous … Abstract Experimental measurements of the reaction of sulfur dioxide and oxygen with limestones have demonstrated substantial influence of the geologic origin of the stone, its porosity and particle size, gaseous concentration of sulfur dioxide, and temperature on the course of reaction and the conversion (that is, the degree of utilization of the limestone content of the particles as a sorbent for sulfur dioxide). A mathematical model including intraparticle transport and chemical reaction within the particles (grain theory) has been developed to simulate this sulfur dioxide sorption reaction.

Matching gasification technologies to coal properties

2005-08-10

Anne-Gaëlle Collot

Present needs, recent progress and future trends of energy-efficient Ultra-Low Carbon Dioxide (CO) Steelmaking (ULCOS) program

2015-12-05

M. Abdul Quader , Shamsuddin Ahmed , Siti Zawiah Md Dawal +1 more

Confirmation of the empirical correlation of Al in hornblende with pressure of solidification of calc-alkaline plutons

1987-04-01

L. S. Hollister , G. C. Grissom , E. K. Peters +2 more

A review of energy use and energy-efficient technologies for the iron and steel industry

2016-12-13

Kun He , Li Wang

Review on Modeling and Simulation of Blast Furnace

2017-07-07

Shibo Kuang , Zhaoyang Li , Aibing Yu

The design and control of blast furnace (BF) ironmaking must be optimized in order to be competitive and sustainable, particularly under the more and more demanding and tough economic and … The design and control of blast furnace (BF) ironmaking must be optimized in order to be competitive and sustainable, particularly under the more and more demanding and tough economic and environmental conditions. To achieve this, it is necessary to understand the complex multiphase flow, heat and mass transfer, and global performance of a BF under different conditions. Mathematical modeling, often coupled with physical modeling, plays an important role in this area. This paper reviews the recent developments in this direction. The emphasis is given to mathematical models for different BF regions from the top charging system, body, and finally down to raceway and hearth. The needs for the further research and developments are also discussed.

View PDF Chat

Assessment of hydrogen direct reduction for fossil-free steelmaking

2018-08-29

Valentin Vogl , Max Åhman , Lars J Nilsson

Climate policy objectives require zero emissions across all sectors including steelmaking. The fundamental process changes needed for reaching this target are yet relatively unexplored. In this paper, we propose and … Climate policy objectives require zero emissions across all sectors including steelmaking. The fundamental process changes needed for reaching this target are yet relatively unexplored. In this paper, we propose and assess a potential design for a fossil-free steelmaking process based on direct reduction of iron ore with hydrogen. We show that hydrogen direct reduction steelmaking needs 3.48 MWh of electricity per tonne of liquid steel, mainly for the electrolyser hydrogen production. If renewable electricity is used the process will have essentially zero emissions. Total production costs are in the range of 361–640 EUR per tonne of steel, and are highly sensitive to the electricity price and the amount of scrap used. Hydrogen direct reduction becomes cost competitive with an integrated steel plant at a carbon price of 34–68 EUR per tonne CO2 and electricity costs of 40 EUR/MWh. A key feature of the process is flexibility in production and electricity demand, which allows for grid balancing through storage of hydrogen and hot-briquetted iron, or variations in the share of scrap used.

View PDF Chat

Reduction of Iron Oxides with Hydrogen—A Review

2019-08-18

Daniel Spreitzer , Johannes Schenk

This review focuses on the reduction of iron oxides using hydrogen as a reducing agent. Due to increasing requirements from environmental issues, a change of process concepts in the iron … This review focuses on the reduction of iron oxides using hydrogen as a reducing agent. Due to increasing requirements from environmental issues, a change of process concepts in the iron and steel industry is necessary within the next few years. Currently, crude steel production is mainly based on fossil fuels, and emitting of the climate‐relevant gas carbon dioxide is integral. One opportunity to avoid or reduce greenhouse gas emissions is substituting hydrogen for carbon as an energy source and reducing agent. Hydrogen, produced via renewable energies, allows carbon‐free reduction and avoids forming harmful greenhouse gases during the reduction process. The thermodynamic and kinetic behaviors of reduction with hydrogen are summarized and discussed in this review. The effects of influencing parameters, such as temperature, type of iron oxide, grain size, etc. are shown and compared with the reduction behavior of iron oxides with carbon monoxide. Different methods to describe the kinetics of the reduction progress and the role of the apparent activation energy are shown and proofed regarding their plausibility.

View PDF Chat

Decarbonization of the Iron and Steel Industry with Direct Reduction of Iron Ore with Green Hydrogen

2020-02-09

Abhinav Bhaskar , Mohsen Assadi , Homam Nikpey Somehsaraei

Production of iron and steel releases seven percent of the global greenhouse gas (GHG) emissions. Incremental changes in present primary steel production technologies would not be sufficient to meet the … Production of iron and steel releases seven percent of the global greenhouse gas (GHG) emissions. Incremental changes in present primary steel production technologies would not be sufficient to meet the emission reduction targets. Replacing coke, used in the blast furnaces as a reducing agent, with hydrogen produced from water electrolysis has the potential to reduce emissions from iron and steel production substantially. Mass and energy flow model based on an open-source software (Python) has been developed in this work to explore the feasibility of using hydrogen direct reduction of iron ore (HDRI) coupled with electric arc furnace (EAF) for carbon-free steel production. Modeling results show that HDRI-EAF technology could reduce specific emissions from steel production in the EU by more than 35 % , at present grid emission levels (295 kgCO2/MWh). The energy consumption for 1 ton of liquid steel (tls) production through the HDRI-EAF route was found to be 3.72 MWh, which is slightly more than the 3.48 MWh required for steel production through the blast furnace (BF) basic oxygen furnace route (BOF). Pellet making and steel finishing processes have not been considered. Sensitivity analysis revealed that electrolyzer efficiency is the most important factor affecting the system energy consumption, while the grid emission factor is strongly correlated with the overall system emissions.

View PDF Chat

Material and energy flows of the iron and steel industry: Status quo, challenges and perspectives

2020-04-24

Wenqiang Sun , Qiang Wang , Yue Zhou +1 more

Integrated analysis and optimization of material and energy flows in the iron and steel industry have drawn considerable interest from steelmakers, energy engineers, policymakers, financial firms, and academic researchers. Numerous … Integrated analysis and optimization of material and energy flows in the iron and steel industry have drawn considerable interest from steelmakers, energy engineers, policymakers, financial firms, and academic researchers. Numerous publications in this area have identified their great potential to bring significant benefits and innovation. Although much technical work has been done to analyze and optimize material and energy flows, there is a lack of overview of material and energy flows of the iron and steel industry. To fill this gap, this work first provides an overview of different steel production routes. Next, the modelling, scheduling and interrelation regarding material and energy flows in the iron and steel industry are presented by thoroughly reviewing the existing literature. This study selects eighty publications on the material and energy flows of steelworks, from which a map of the potential of integrating material and energy flows for iron and steel sites is constructed. The paper discusses the challenges to be overcome and the future directions of material and energy flow research in the iron and steel industry, including the fundamental understandings of flow mechanisms, the dynamic material and energy flow scheduling and optimization, the synergy between material and energy flows, flexible production processes and flexible energy systems, smart steel manufacturing and smart energy systems, and revolutionary steelmaking routes and technologies.

View PDF Chat

Green Hydrogen‐Based Direct Reduction for Low‐Carbon Steelmaking

2020-05-13

Katharina Rechberger , Andreas Spanlang , Amaia Sasiain Conde +2 more

The European steel industry aims at a CO 2 reduction of 80–95% by 2050, ensuring that Europe will meet the requirements of the Paris Agreement. As the reduction potentials of … The European steel industry aims at a CO 2 reduction of 80–95% by 2050, ensuring that Europe will meet the requirements of the Paris Agreement. As the reduction potentials of the current steelmaking routes are low, the transfer toward breakthrough‐technologies is essential to reach these goals. Hydrogen‐based steelmaking is one approach to realize CO 2 ‐lean steelmaking. Therefore, the natural gas (NG)‐based direct reduction (DR) acts as a basis for the first step of this transition. The high flexibility of this route allows the gradual addition of hydrogen and, in a long‐term view, runs the process with pure hydrogen. Model‐based calculations are performed to assess the possibilities for injecting hydrogen. Therefore, NG‐ and hydrogen‐based DR models are developed to create new process know‐how and enable an evaluation of these processes in terms of energy demand, CO 2 ‐reduction potentials, and so on. The examinations show that the hydrogen‐based route offers a huge potential for green steelmaking which is strongly depending on the carbon footprint of the electricity used for the production of hydrogen. Only if the carbon intensity is less than about 120 g CO 2 kWh −1 , the hydrogen‐based process emits less CO 2 than the NG‐based DR process.

View PDF Chat

Development and progress on hydrogen metallurgy

2020-06-01

Jue Tang , Mansheng Chu , Feng Li +3 more

Hydrogen Ironmaking: How It Works

2020-07-09

Fabrice Patisson , Olivier Mirgaux

A new route for making steel from iron ore based on the use of hydrogen to reduce iron oxides is presented, detailed and analyzed. The main advantage of this steelmaking … A new route for making steel from iron ore based on the use of hydrogen to reduce iron oxides is presented, detailed and analyzed. The main advantage of this steelmaking route is the dramatic reduction (90% off) in CO2 emissions compared to those of the current standard blast-furnace route. The first process of the route is the production of hydrogen by water electrolysis using CO2-lean electricity. The challenge is to achieve massive production of H2 in acceptable economic conditions. The second process is the direct reduction of iron ore in a shaft furnace operated with hydrogen only. The third process is the melting of the carbon-free direct reduced iron in an electric arc furnace to produce steel. From mathematical modeling of the direct reduction furnace, we show that complete metallization can be achieved in a reactor smaller than the current shaft furnaces that use syngas made from natural gas. The reduction processes at the scale of the ore pellets are described and modeled using a specific structural kinetic pellet model. Finally, the differences between the reduction by hydrogen and by carbon monoxide are discussed, from the grain scale to the reactor scale. Regarding the kinetics, reduction with hydrogen is definitely faster. Several research and development and innovation projects have very recently been launched that should confirm the viability and performance of this breakthrough and environmentally friendly ironmaking process.

View PDF Chat

A General Vision for Reduction of Energy Consumption and CO2 Emissions from the Steel Industry

2020-08-19

Lauri Holappa

The 2018 IPCC (The Intergovernmental Panel on Climate Change’s) report defined the goal to limit global warming to 1.5 °C by 2050. This will require “rapid and far-reaching transitions in … The 2018 IPCC (The Intergovernmental Panel on Climate Change’s) report defined the goal to limit global warming to 1.5 °C by 2050. This will require “rapid and far-reaching transitions in land, energy, industry, buildings, transport, and cities”. The challenge falls on all sectors, especially energy production and industry. In this regard, the recent progress and future challenges of greenhouse gas emissions and energy supply are first briefly introduced. Then, the current situation of the steel industry is presented. Steel production is predicted to grow by 25–30% by 2050. The dominant iron-making route, blast furnace (BF), especially, is an energy-intensive process based on fossil fuel consumption; the steel sector is thus responsible for about 7% of all anthropogenic CO2 emissions. In order to take up the 2050 challenge, emissions should see significant cuts. Correspondingly, specific emissions (t CO2/t steel) should be radically decreased. Several large research programs in big steelmaking countries and the EU have been carried out over the last 10–15 years or are ongoing. All plausible measures to decrease CO2 emissions were explored here based on the published literature. The essential results are discussed and concluded. The specific emissions of “world steel” are currently at 1.8 t CO2/t steel. Improved energy efficiency by modernizing plants and adopting best available technologies in all process stages could decrease the emissions by 15–20%. Further reductions towards 1.0 t CO2/t steel level are achievable via novel technologies like top gas recycling in BF, oxygen BF, and maximal replacement of coke by biomass. These processes are, however, waiting for substantive industrialization. Generally, substituting hydrogen for carbon in reductants and fuels like natural gas and coke gas can decrease CO2 emissions remarkably. The same holds for direct reduction processes (DR), which have spread recently, exceeding 100 Mt annual capacity. More radical cut is possible via CO2 capture and storage (CCS). The technology is well-known in the oil industry; and potential applications in other sectors, including the steel industry, are being explored. While this might be a real solution in propitious circumstances, it is hardly universally applicable in the long run. More auspicious is the concept that aims at utilizing captured carbon in the production of chemicals, food, or fuels e.g., methanol (CCU, CCUS). The basic idea is smart, but in the early phase of its application, the high energy-consumption and costs are disincentives. The potential of hydrogen as a fuel and reductant is well-known, but it has a supporting role in iron metallurgy. In the current fight against climate warming, H2 has come into the “limelight” as a reductant, fuel, and energy storage. The hydrogen economy concept contains both production, storage, distribution, and uses. In ironmaking, several research programs have been launched for hydrogen production and reduction of iron oxides. Another global trend is the transfer from fossil fuel to electricity. “Green” electricity generation and hydrogen will be firmly linked together. The electrification of steel production is emphasized upon in this paper as the recycled scrap is estimated to grow from the 30% level to 50% by 2050. Finally, in this review, all means to reduce specific CO2 emissions have been summarized. By thorough modernization of production facilities and energy systems and by adopting new pioneering methods, “world steel” could reach the level of 0.4–0.5 t CO2/t steel and thus reduce two-thirds of current annual emissions.

View PDF Chat

The production and application of hydrogen in steel industry

2021-01-08

Wenguo Liu , Haibin Zuo , Jingsong Wang +3 more

Low-carbon production of iron and steel: Technology options, economic assessment, and policy

2021-03-10

Zhiyuan Fan , S. Julio Friedmann

Hydrogen direct reduction (H-DR) in steel industry—An overview of challenges and opportunities

2021-11-23

R.R. Wang , Youhu Zhao , Alexander Babich +2 more

Kinetics of reduction of iron oxides by H2

2007-01-21

A. Pineau , Ndue Kanari , I. Gaballah

Ironmaking and Steelmaking

2019-08-13

Zushu Li , Claire Davis

Steel is a critical material in our societies and will remain an important one for a long time into the future. In the last two decades, the world … Steel is a critical material in our societies and will remain an important one for a long time into the future. In the last two decades, the world steel industry has gone through drastic changes and this is predicted to continue in the future. The Asian countries (e.g. China, India) have been dominant in the production of steel creating global over-capacity, while the steel industry in the developed countries have made tremendous efforts to reinforce its global leadership in process technology and product development, and remain sustainable and competitive. The global steel industry is also facing various grand challenges in strict environmental regulation, new energy and materials sources, and ever-increasing customer requirements for high quality steel products, which has been addressed accordingly by the global iron and steel community. This Special Issue, “Ironmaking and Steelmaking”, released by the journal Metals, published 33 high quality articles from the international iron and steel community, covering the state-of-the-art of the ironmaking and steelmaking processes. This includes fundamental understanding, experimental investigation, pilot plant trials, industrial applications and big data utilization in the improvement and optimization of existing processes, and research and development in transformative technologies. It is hoped that the creation of this special issue as a scientific platform will help drive the iron and steel community to build a sustainable steel industry.

View PDF Chat

Decarbonizing the iron and steel industry: A systematic review of sociotechnical systems, technological innovations, and policy options

2022-03-08

Jinsoo Kim , Benjamin K. Sovacool , Morgan Bazilian +4 more

View PDF Chat

CALPHAD: Calculation of Phase Diagrams - A Comprehensive Guide

1998-01-01

Nigel J. Saunders , Peter Miodownik

Effect of high hot blast temperature on low-carbon ironmaking in large blast furnaces

2025-06-25

B. Z. Dai , Qiyuan Liu , Rukang Yan +3 more | Ironmaking & Steelmaking Processes Products and Applications

With the global challenges of environmental sustainability and the pressing demand for sustainable development, low-carbon smelting in large blast furnaces (BFs) has become a critical pathway to achieving the “dual … With the global challenges of environmental sustainability and the pressing demand for sustainable development, low-carbon smelting in large blast furnaces (BFs) has become a critical pathway to achieving the “dual carbon” goals. Based on the fundamental principles of BF ironmaking, this study employs data analysis to examine the production practices of 25 large BFs in China with capacities exceeding 4000 m³ in 2023, focusing on the relationship between hot blast temperature and fuel consumption. The study systematically summarizes effective methods to increase hot blast temperature. Additionally, taking the production practices of a large BF in a Chinese enterprise as a case study, the paper elaborates on the influence of hot blast temperature on fuel consumption and proposes specific operational protocols and raw material parameters tailored to these findings. Analysis of production practice data from BFs demonstrates that through optimization of operational systems and refined management of raw material conditions, the average hot blast temperature in large Chinese BFs can be elevated to exceed 1250°C. Furthermore, when operating within the hot blast temperature range of 1125°C to 1245°C, incremental increase of 50°C in blast temperature enables a reduction of approximately 3–4 kg/t in carbonaceous fuel consumption.

Sustainable Steel Refining by Hydrogen Plasma: Effect of Impurities on Desulfurization of Liquid Iron

2025-06-24

Ramesh Kumar , Arup Kumar Mandal | Metallurgical and Materials Transactions B

Macroeconomic and environmental impacts of two decarbonization options for the Dutch steel industry: green relocation versus green hydrogen imports

2025-06-23

Clara Caiafa , Kurt Kratena , Iñaki Arto | Energy Policy

Biochar as a sustainable alternative to conventional carbon additives in iron ore pelletization

2025-06-21

Deepak Nayak , Subhashree Nayak , Ammasi Ayyandurai +3 more | Fuel

Effects of H 2 ratio on the softening–melting behaviours of vanadium titanomagnetite pellets under simulated H 2 -rich oxygen blast furnace conditions

2025-06-20

Buxin Chen , Junyu Chen , Mao Chen +5 more | Ironmaking & Steelmaking Processes Products and Applications

The effect of H 2 ratio (0–70 vol%) on the softening–melting behaviours of vanadium titanomagnetite pellets in H 2 –CO gas mixtures has been investigated experimentally in the simulated H … The effect of H 2 ratio (0–70 vol%) on the softening–melting behaviours of vanadium titanomagnetite pellets in H 2 –CO gas mixtures has been investigated experimentally in the simulated H 2 -rich oxygen blast furnace conditions. The feasibility of vanadium titanomagnetite pellets smelted in an H 2 -rich oxygen blast furnace was discussed from gas utilisation rates, slag–iron separation performances, slag foamabilities, hot metal qualities, etc. The results indicate that although the cohesive zone range increases with the increase of H 2 ratio in gas mixtures, the permeability of the feed bed is improved greatly. The H 2 utilisation rate increases with the increase of H 2 ratio. Moreover, the formations of the slag foaming are minimised with the increase of H 2 ratio. H 2 in the reduction gases also promotes the reduction of vanadium oxides and titanium oxides, which increases the [V] content in dripping iron, and results in more TiC generations which severely deteriorates the slag–iron separation performances.

Selective Reduction of Iron from Iron–Manganese Ore of the Keregetas Deposit Using Hydrogen

2025-06-20

N. Kosdauletov , Assylbek Nurumgaliyev , Bakhyt Zhautikov +7 more | Metals

This study presents the results of the solid-state reduction of iron–manganese ore from the Keregetas deposit (Kazakhstan) using hydrogen as a reductant. The findings demonstrate that hydrogen is an effective … This study presents the results of the solid-state reduction of iron–manganese ore from the Keregetas deposit (Kazakhstan) using hydrogen as a reductant. The findings demonstrate that hydrogen is an effective and environmentally friendly reducing agent, enabling selective reduction of iron. The investigated iron–manganese ore exhibits a complex mineralogical composition comprising oxides of Fe, Mn, Si, and aluminosilicate complex phases. X-ray diffraction (XRD) analysis of the raw ore confirmed the presence of goethite, hematite, quartzite, and MnO2 as the primary mineral phases. Oxidative roasting induced the dehydration of goethite and its conversion to hematite, along with the formation of Mn2O3 and Mn3O4 phases. The detection of Mn7SiO12 indicates interaction between manganese and silica under high-temperature oxidation conditions. Reduction experiments were conducted in an RB Automazione MM 6000 laboratory furnace at temperatures ranging from 700 to 1100 °C, with a holding time of 60 min and a hydrogen flow rate of 0.5 L/min. Results revealed high selectivity of hydrogen reduction: at 700–800 °C, iron and arsenic were predominantly reduced, as evidenced by the emergence of a metallic Fe-containing phase, while oxides of Mn, Si, Ba, and Al remained in the residue. Increasing the temperature to 900–1000 °C resulted in partial reduction of manganese. At 1100 °C, a decrease in the intensity of the metallic phase was observed, likely due to sintering of ore particles and reduced gas permeability. The reduced metal and oxides were readily separable by melting. These findings provide a basis for developing processing schemes for beneficiation and hydrometallurgical treatment of iron–manganese ores from Kazakhstan.

Effect of coal-based composite binders on isothermal oxidation kinetics of vanadium–titanium magnetite pellets

2025-06-20

Yongkang Zhang , Guanghui Li , Yuanzhi Cheng +4 more | Journal of Iron and Steel Research International

Waste crayfish shell addition improves mechanical strength and reducibility of hematite briquettes

2025-06-20

Rufei Wei , Zhen Peng , Jingsong Wang +2 more | Biomass and Bioenergy

Kinetics Study of the Hydrogen Reduction of Limonite Ore Using an Unreacted Core Model for Flat-Plate Particles

2025-06-19

Jindi Huang , Yi Tao , Jing Li +3 more | Metals

The iron and steel industry is a major emitter of carbon. In the context of China’s dual-carbon goals, hydrogen-based reduction ironmaking technology has garnered unprecedented attention. It is considered a … The iron and steel industry is a major emitter of carbon. In the context of China’s dual-carbon goals, hydrogen-based reduction ironmaking technology has garnered unprecedented attention. It is considered a crucial approach to reducing carbon dioxide emissions in the steel sector and facilitating the realization of carbon neutrality. This work conducted isothermal thermogravimetric analysis on limonite ore in a N2/H2 atmosphere. The influences of reduction temperature, particle size, and hydrogen partial pressure on the hydrogen reduction reaction process of limonite were investigated. Based on the principles of isothermal thermal analysis kinetics and the unreacted core model for flat-plate particles, the mechanism function and kinetic parameters for the reduction of limonite particles were determined. The research results show that the hydrogen reduction process of limonite ore is influenced by multiple factors, including temperature, hydrogen partial pressure, and particle size. Increasing the reduction temperature and hydrogen partial pressure can significantly speed up the reduction reaction rate and enhance the degree of reduction. The kinetic parameters for the hydrogen reduction of limonite particles were obtained as follows: the reaction activation energy was 44.738 kJ·mol−1, the pre-exponential factor was 31.438 m·s−1, and the rate constant for the hydrogen reduction of limonite was k=31.438×e−44.738×1000RTm⋅s−1. In addition, contour maps were plotted to predict the reaction time and reaction temperature required for a complete reduction of limonite particles of different sizes to iron (Fe) particles under varying hydrogen partial pressures. The research findings can serve as a scientific basis for optimizing hydrogen-based reduction ironmaking technology in the iron and steel industry and achieving carbon neutrality goals.

Experimental study on the combustion and emission characteristics of thermal storage-assisted load reduction in a circulating fluidized bed

2025-06-19

Zengcai Ji , Guoliang Song , Haiyang Wang | Fuel Processing Technology

Techno-Economic Assessment of Three Different Cases for Hydrogen Production Using Carburization Looping Reforming

2025-06-19

Felipe G. Camacho , Paulo A.L. de Souza , Nader Mahinpey | Industrial & Engineering Chemistry Research

Direct reduction features of iron ore by lignocellulosic biomass and its components

2025-06-18

Antonio Fabozzi , Francesca Cerciello , Osvalda Senneca | Fuel

MEASURES TO SOLVE THE GRAIN PROBLEM IN THE KRASNOYARSK REGION IN 1953–1964

2025-06-17

Stanislav Kotsik , Ruslan V. Pavlyukevich | Socio-economic and humanitarian magazine

The purpose of the study is to identify the specifics of grain production development in the Krasnoyarsk Region in 1953–1964. In the context of industrial modernization of the region carried … The purpose of the study is to identify the specifics of grain production development in the Krasnoyarsk Region in 1953–1964. In the context of industrial modernization of the region carried out during this period, the need for a strong and productive agriculture capable of providing the local population with food increased. However, the rate of agricultural production was low, and the rural population was decreasing every year, which further created a threat of food shortage in the country. This paper analyzes a set of economic and managerial measures of the Soviet leadership in the field of agriculture and their results in the development of grain production. In 1953-1964, an attempt was made to solve a set of problems of agriculture in the country as a whole and in the Krasnoyarsk Region in particular. The extensive path of agricultural development chosen by the Soviet leadership was due to the need to obtain results in a short time, as well as a shortage of personnel and resources for the intensification of agriculture. As a result of reforms in agricultural production of the Krasnoyarsk Region, there were local improvements. The shortage of personnel became less acute, the system of training agricultural specialists expanded, agricultural technology and the state of regional seed production improved. However, N.S. Khrushchev's measures were unable to solve the main problem - grain. Crop yields remained low and even the expansion of sown areas did not lead to a significant improvement in the situation, as a result of which in the early 1960s the Soviet Union was forced to buy grain abroad. The failure of N.S. Khrushchev's reforms finally convinced the Soviet leadership of the need for widespread intensification of agriculture.

Understanding Abnormal Reduction Behavior of Partially Reduced Iron in the Blast Furnace

2025-06-17

So-Hee An , G. I. Park , Taehyeon Kim +1 more | Metallurgical and Materials Transactions B

Understanding of the Reduction Behavior in Direct Reduction of High-Phosphorus Oolitic Hematite Using a High Volatile Bituminous Coal

2025-06-16

Kexin Yu , Wenjie Zou , Jue Kou +5 more | JOM

Atmosphere Effect on the Reducing Behavior of iron ore–petcoke Briquettes

2025-06-16

Beatriz Fausta Gandra , Arthur Felipe Lino Oliveira , Maurício Covcevich Bagatini +1 more | Journal of Sustainable Metallurgy

Modern technical solutions for new and reconstructed sinter plants. Report 3. Charge the mix onto sinter machines

2025-06-16

V. Е. Kotyshev , Yu. A. Frolov , Ya. Yu. Aslamоva +2 more | Ferrous Metallurgy Bulletin of Scientific Technical and Economic Information

The technological operations and equipment for charging a sinter bed and mix onto sintering machines have been analyzed in their historical development from the mid-20th century to the present. Modern … The technological operations and equipment for charging a sinter bed and mix onto sintering machines have been analyzed in their historical development from the mid-20th century to the present. Modern requirements for the technology and components of the mix charging unit have been reviewed, refined, and expanded. It is confirmed that the system of equipment for charging concentrate-based mixes at Russian sintering plants is rational. For such mixes, installing a mix bin in front of sintering machines instead of a loading hopper into which the mix is fed from a pelletizing drum located at ground level (as at AF-5 MMK) is unacceptable. Pelletizing drums must be installed in the sintering chamber upstream of the loading hopper. For new sintering machines, a shuttle-type mix distributor perpen-dicular to the loading hopper is recommended. It is demonstrated that the use of a 10–20 mm sinter fraction bed (up to 50 mm thick) at AF-5 MMK increases the free area of the grate by 20% (gap between bars increased from 2.5 to 3.0 mm) and enables the effective use of heavy-duty grate bars. The mix charging unit should also include a mix flow stabilizer, with the drum feeder’s rotational speed maximized to the point just before mix slippage occurs. The working length of the loading chute should be ~1200 mm, with an adjustable inclination angle of 55–60°, and its lower edge positioned above the bed surface. Studies indicate that the nine-roller mix distributor installed on AF-5 MMK sintering machines achieves separation efficiency by size and carbon content comparable to a two-layer charging system, without enlarging the sintering machine’s footprint or complicating the process flow sheet. The mix bed profile on the sintering strand (and thus on the drum feeder) must ensure uniform advancement of the fuel combustion zone toward the protective bed layer across the entire width of the sintering machine.

Numerical simulation of effect of interaction between natural gas, coke oven gas and oxygen enrichment on pulverized coal combustion and raceway state of blast furnace

2025-06-14

Huan Liu , Jianliang Zhang , Li Huang +3 more | International Journal of Hydrogen Energy

How to Optimize the Blast Furnace Profiles for Maximum Energy Efficiency

2025-06-13

Junjie Li , Lulu Jiao , Shibo Kuang +3 more | Metallurgical and Materials Transactions B

Abstract While the inner profile of a blast furnace (BF) follows general standardization, its specific design remains largely experience-based. BF process modeling and optimization offer a systematic and cost-effective approach … Abstract While the inner profile of a blast furnace (BF) follows general standardization, its specific design remains largely experience-based. BF process modeling and optimization offer a systematic and cost-effective approach to studying the effects of key variables, including material properties, BF geometry, and operational conditions, providing valuable insights for BF design and control. In this work, a 3D BF process model was employed to investigate the design rules for BF geometry in the 1000 to 5000 m 3 volume range. First, under fixed operating conditions, the optimal BF geometry for each volume was identified by minimizing total energy consumption. The results show that the method employed in this study can quantitatively replicate well-established industrial trends related to BF volume. Secondly, an analysis of transport phenomena within a furnace provided a rationale for these geometric trends. Lastly, it is shown that the optimum BF profile is also affected by the preset geometric constraints, even under the same operating conditions. Therefore, customized BF design may be required to better align with varying production needs.

The Effect Of Boiler Type, Unit Capacity, And Coal Calorific Value On Co? Emission Factors In Coal-Fired Power Plants: A Multi-Method Calculation Approach

2025-06-13

Bayu Sukma , Gabriel Andari Kristanto | Journal Of World Science

This study analyzed the carbon dioxide (CO?) emission factors of 27 coal-fired power plants in Indonesia using three different calculation approaches sourced from the scientific literature. This study aims to … This study analyzed the carbon dioxide (CO?) emission factors of 27 coal-fired power plants in Indonesia using three different calculation approaches sourced from the scientific literature. This study aims to evaluate the accuracy and sensitivity of each method and examine the influence of the technical variables of the plant, namely boiler type and specification, unit capacity, and type of coal calories, on the value of specific CO? emission factors. Data were obtained from accredited emission verification institutions and analyzed in a quantitative descriptive manner with ANOVA statistical tests and correlation. The results showed that the energy output-based method (t CO?/MWh) was more representative of the actual generation conditions, with an average emission value of 1.18 t CO?/MWh. Units with supercritical technology and a capacity of >300 MW tended to have lower emission factors. In contrast, the use of low-calorie coal produces significantly higher emissions. This study provides important recommendations for direct calculation-based emission calculations, selection of low-emission technologies, and the formulation of low-carbon energy policies to support the achievement of Indonesia's NDC.

Application of effective drying methods and storage characteristics of iron ore briquettes

2025-06-12

Rishi Sharma , Devidas S. Nimaje | Mineral Processing and Extractive Metallurgy Transactions of the Institutions of Mining and Metallurgy

In the iron ore agglomeration industry, extensive research has been conducted on various drying techniques. Drying iron ore briquettes is essential to provide the initial strength needed for freshly prepared … In the iron ore agglomeration industry, extensive research has been conducted on various drying techniques. Drying iron ore briquettes is essential to provide the initial strength needed for freshly prepared briquettes. Briquettes with the composition of iron ore fines (16.5%), (Linz-Donawitz) sludge (47.2%), flue dust (28.3%), bentonite (2%), and cement (6%) were dried using hot air oven drying, microwave drying and infra-red drying under controlled heating conditions. After drying the briquette samples were stored under ambient atmospheric conditions for 7 days. The open air drying of the briquettes is the cheapest method available for the curing of briquettes, but it mainly depends on sunlight. It adversely affects the continuous supply of iron ore briquettes for the steel industry in the winter and rainy seasons. This work aims to determine the most efficient drying technique with low carbon emission as compared to high temperature drying using conventional drying techniques. The briquettes should have some initial strength so they do not break while being transported from one place to another for steel production. These briquettes should be strong enough so that they do not disintegrate before the start of the reduction process in the blast furnace. Infra-red drying at 120°C produced the highest strength of 4.195 N/mm 2 (MPa), surpassing the strength (3.680 N/mm 2 ) achieved by hot air drying. This method of low temperature drying not only facilitates the production of high-quality dried products but also contributes to the creation of eco-friendly briquettes with reduced carbon emission. Here this study employs low temperature drying as a sustainable drying practice.

Reduction kinetics of pure and industrial hematite samples with hydrogen in a small fixed bed system

2025-06-01

Antonio D’Angelo , Emiliano Salucci , Vincenzo Russo +2 more | Chemical Engineering Journal

Impact of random packing on residence time distribution of particles in bubbling fluidized beds: Part 2 - Counter-current flow reactors

2025-06-01

Nasrin Nemati , Tobias Mattisson , David Pallarès +2 more | Powder Technology

Insight into the migration pathways of titanium and iron in Titanomagnetite through on-site observation using HT-CLSM during roasting and reduction processes

2025-06-01

Sheng Dou , Shiteng Qin , Shijie Ma +3 more | Journal of environmental chemical engineering