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Results for “alternate ironmaking”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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7 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

A Novel Flash Ironmaking Process

The project goal is to develop an entirely new transformational process for alternate ironmaking based on the direct gaseous reduction of iron oxide concentrates in a flash reduction process, with the ultimate objective of significantly increasing energy productivity (by reducing energy consumption by up to 57 %) and reducing environmental emissions, especially CO 2 emissions, versus the conventional blast furnace ironmaking route.The Novel Flash Ironmaking Process uses gaseous reducing agents, such as natural gas, hydrogen, other syngas, or a combination thereof. The proposed technology is to be applied to the production of iron as a feed to the steelmaking process, eventually replacing the blast furnace and other alternate ironmaking processes. The process can also be a part of a continuous direct steelmaking process.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Energy Consumption and CO 2 Emissions in Ironmaking and Development of a Novel Flash Technology

The issues of energy consumption and CO 2 emissions of major ironmaking processes, including several new technologies, are assessed. These two issues are interconnected in that the production and use of fuels to generate energy add to the total amount of CO 2 emissions and the efforts to sequester or convert CO 2 require energy. The amounts of emissions and energy consumption in alternate ironmaking processes are compared with those for the blast furnace, currently the dominant ironmaking process. Although more than 90% of iron production is currently through the blast furnace, intense efforts are devoted to developing alternative technologies. Recent developments in alternate ironmaking processes, which are largely driven by the needs to decrease CO 2 emissions and energy consumption, are discussed in this article. This discussion will include the description of the recently developed novel flash ironmaking technology. This technology bypasses the cokemaking and pelletization/sintering steps, which are pollution prone and energy intensive, by using iron ore concentrate. This transformational technology renders large energy saving and decreased CO 2 emissions compared with the blast furnace process. Economic analysis indicated that this new technology, when operated using natural gas, would be economically feasible. As a related topic, we will also discuss different methods for computing process energy and total energy requirements in ironmaking.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A percolating path to green iron

About 1.9 gigatons of steel is produced every year, emitting 8% (3.6 gigatons) of global CO 2 in the process. More than 50% of the CO 2 emissions come from a single step of steel production, known as ironmaking. Hydrogen- based direct reduction (HyDR) of iron oxide to iron has emerged as an emission-free ironmaking alternative. However, multiple physical and chemical phenomena ranging from nanometers to meters inside HyDR reactors alter the microstructure and pore networks in iron oxide pellets, in ways that resist gaseous transport of H 2 /H 2 O, slow reaction rates, and disrupt continuous reactor operation. Using synchrotron nano X-ray computed tomography and percolation theory, we quantify the evolution of pores in iron oxide pellets and demonstrate how nanoscale pore connectivity influences micro- and macroscale flow properties such as permeability, diffusivity, and tortuosity. Our modeling framework connects disparate scales and offers opportunities to accelerate HyDR.

hydrogen↗
DOE OSTI2025

A Percolating Path to Green Iron

About 1.9 gigatonnes of steel is produced every year emitting 7% (2.7 gigatonnes) of global CO 2 in the process. More than 50% of the CO 2 emissions come from a single step of steelmaking, known as ironmaking. Hydrogen based direct reduction (HyDR) of iron oxide to iron has emerged as an emissions free ironmaking alternative. However multi-scale phenomena ranging from nanometers to meters inside HyDR reactors exhibit detrimental microstructure evolution which resists gaseous transport of H 2 /H 2 O, slows reaction rates and disrupts continuous reactor operation. To resolve the conundrum between atomic and reactor scales, we devise a percolation-theory model to reconcile nanoscale porosity with macroscopic properties relevant to reactor design models. Using synchrotron nano X-ray computed-tomography, we quantify the evolution of pores in iron oxide pellets, and demonstrate how nano-scale pore networks influence micro and macro-scale flow properties such as permeability, diffusivity and tortuosity. Our new modeling framework bridges the gap between scales and offers the criteria to accelerate HyDR by at least 5x via feedstock-reactor synergies based on percolation.

Paul, Subhechchha↗
DOE OSTI2025

Pathways to Electrochemical Ironmaking at Scale Via the Direct Reduction of Fe 2 O 3

Electrochemical ironmaking can provide an energy efficient, zero-emissions alternative to traditional methods of ironmaking, but the scalability of low-temperature electrochemical cells may be constrained by reactor throughput and the availability of acceptable feedstocks. Electrodes directly converting solid iron-oxide particles to metal circumvent traditional mass-transport limitations but are sensitive to both the particle size and nanoscale morphology of reactants. Furthermore, the effect of these properties on reactor throughput has not been systematically studied at model electrowinning surfaces. Here, we have used size-controlled, homologous α-Fe 2 O 3 particles to study how the nanoscale morphology of oxides influences the obtainable current density toward Fe metal and integrated these results in a technoeconomic model for alkaline iron electrowinning systems. Micron-scale α-Fe 2 O 3 with nanoscale porosity can be used to form Fe at current densities commensurate with industrial water electrolysis (>0.6 A cm –2 ) in the absence of external convection, providing a path to cost-competitive and scalable ironmaking using electrochemistry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Modelling of Blast Furnace with Respective Chemical Reactions in Coke and Ore Burden Layers

The ironmaking blast furnace (BF) is an efficient chemical reactor for producing liquid iron from solid iron ore, where the solids of coke and iron ore are charged in alternative layers and different chemical reactions occur in the two solid layers as they descend. Such respective reacting burden layers have not been considered explicitly in the previous BF models. In this article, a mathematical model based on multi-fluid theory is developed for describing the multiphase reacting flows considering the respective reacting burden layers. Then, this model is applied to a BF, covering the area from the burden surface at the furnace top to the liquid surface above the hearth, to describe the inner states of a BF in terms of the multiphase flows, temperature distribution and reduction process. The results show that some key important features in the layered burden with respective chemical reactions are captured, including fluctuating iso-lines in terms of gas flow and thermochemical behaviours; particularly the latter cannot be well captured in the previous BF models. The temperature difference between gas–solid phases is found to be larger near the raceway, at the cohesive zone and at the furnace top, and the thermal reserved zone can be identified near the shaft. Three chemical reserve zones of hematite, magnetite and wustite can also be observed near the stockline, in the shaft near the wall and near centre, respectively. Inside each reserve zone, the corresponding ferrous oxides stay constantly high in alternative layers; the overall performance indicators including gas utilization efficiency and reduction degree also stay stable in an alternative-layered structure. This model provides a cost-effective tool to investigate the BF in-furnace process and optimize BF operation.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Increased Use of Natural Gas in Blast Furnace Ironmaking: Mass and Energy Balance Calculations

In blast furnace ironmaking, coke can be partially replaced by injected natural gas. Tuyère injection of cold natural gas is commonly practiced in North America. In this work, limits to the tuyère injection rate have been quantified with mass and energy balances. The fundamental origin of the limits is the endothermicity of methane injection. In principle, shaft injection of preheated and partially combusted methane would obviate the endothermic effect. However, the thermal and chemical energy parameter indicates that the energy requirement in the lower part of the furnace—to melt hot metal and slag—might not be met in the case of shaft injection. Tuyère injection of preheated methane might be a feasible alternative. Calculated combustion kinetics support the feasibility of partial combustion of preheated methane (with sub-stoichiometric oxygen) before injection.

36 MATERIALS SCIENCE↗