Towards Zero CO2 Continuous Steelmaking Directly from Ore

Abstract

In-line continuous processing of high-grade hematite ore (crushed ore or fines) with a pure hydrogen reductant is assessed. An appraisal is made of the rate controlling mechanisms involved in the reduction of a pure layer of molten wustite being transported by floating on a molten carrier iron carbon-free medium at temperatures just in excess of the iron melting point. Published research clearly indicates that under these conditions the kinetics are principally controlled by molecular gaseous diffusion. Thus, the rate is essentially not influenced by total gas pressure above 1 atmosphere. Accordingly, on safety grounds it is recommended that high pressure should not be used for hydrogen steelmaking in the future, but the operation should be conducted close to atmospheric pressure with low pressure steam encapsulation of the plant items involved. Using hydrogen as the reductant means that sub-surface nucleation of CO bubbles cannot disrupt continuous processing. The operation is then no different to processing a normal liquid phase. The off-gases from the reduction zone of a melt circulation loop are super-clean and only contaminated with iron vapor. Accordingly, the best available technology becomes available for energy conservation without risk of non-fusible solids deposition. The net result is that the energy requirements are expected to be superior to other potential processes.