Advanced physical model of hydrothermic reduction of iron ore pellets by dissociated 2H+ ionic gas in the shaft furnace

Abstract

ABSTRACT Development of various alternative routes for the direct reduction of iron-ore (DRI) and production of sponge irons becomes a necessity today to reduce carbon dioxide (CO2) gas emissions in industrial iron & steel (I&S) making processes. Therefore, the main objective of this work is focused to reduce the carbon footprint in DRI production by eliminating fossil fuel consumption. The reduced iron could be used to melt in the electric arc furnace (EAF) to produce liquid steel by minimising direct scrap addition. Indeed, this paper shows an advanced physical model of a hydrogen fuel shaft furnace for the direct reduced iron-making process by fundamental development of technology with essential modifications in its working principle. This processing technology is hypothetically designed with knowledge of theoretical literature inputs and wisdom of iron and steel-making experience. In this model of a shaft furnace, a scientific approach is designed based on the dissociation of molecular-hydrogen gas (H2+) obtained by water electrolysis and ionisation of the hydrogen gas (2H+) and is incorporated for a high degree of gas adsorption and metallisation during chemical reduction of iron ore (Fe2O3) pellets. The steps involved in the working principle of the new design shaft furnace are simulated and modelled suitably for the existing Midrex furnace operation, which is generally used for DRI production. This approach could be tried using 100% dissociated hydrogen ionic gas (2H+, H+) for future direct reduced iron making by water electrolysis and hydrogen ionisation. Moreover, the reformed reducing gases (CH4–H2–CO) used in the Midrex process can be replaced by the ionised hydrogen gases as an advancement.