Reduction kinetics of hematite powder using argon/hydrogen plasma with prospects for near net shaping of sustainable iron

Kannan, Rangasayee; Stevens, Adam G.; Fancher, Christopher; Rahman, Obaidullah; Miller, Roger; Ward, Jack; Ziabari, Amir Koushyar; Babu, Sudarsanam Suresh; Nandwana, Peeyush

doi:10.1016/j.susmat.2024.e00879

Title: Reduction kinetics of hematite powder using argon/hydrogen plasma with prospects for near net shaping of sustainable iron

Journal Article · 05 March 2024 · Sustainable Materials and Technologies

DOI: https://doi.org/10.1016/j.susmat.2024.e00879 · OSTI ID:2326310

Kannan, Rangasayee ^[1]; Stevens, Adam G. ^[1]; Fancher, Christopher ^[1]; Rahman, Obaidullah ^[1]; Miller, Roger ^[1]; Ward, Jack ^[1]; Ziabari, Amir Koushyar ^[1]; Babu, Sudarsanam Suresh ^[2]; Nandwana, Peeyush ^[1]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)

Direct reduction of iron ore using hydrogen plasma is being explored as a potential solution to decarbonize the iron and steel sector. The current state-of-the-art demonstrated reduction of hematite pellets via hydrogen plasma using Ar + 10% H₂ but had slow reduction kinetics, requiring 30 minutes of plasma exposure for complete reduction. Here we show that using hematite in a powder form, easily obtainable from beneficiated ore, results in 10× faster kinetics using plasma generated from Ar + 2% H₂ shielding gas compared to the current state-of-the art. Additionally, the increased kinetics using powders and a dilute hydrogen concentration can enable the use of advanced manufacturing techniques like blown powder directed energy deposition using a plasma tungsten arc welding torch to manufacture near net shape components directly from the ore concentrates. This ore to part approach will also reduce the emissions associated with downstream processes like rolling, forging, and machining, thereby further aiding in the sectorial decarbonization efforts.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2326310

Alternate ID(s):: OSTI ID: 2369991

Journal Information:: Sustainable Materials and Technologies, Vol. 40; ISSN 2214-9937

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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