Hydrogen Plasma Smelting Reduction of Fe 2 O 3
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I.
INTRODUCTION
DURING the year 2017, 1691.2 million tons of crude steel were produced in the world.[1] The major production routes are (i) blast furnace-basic oxygen furnace (BF-BOF), (ii) direct reduced iron-electric arc furnace (DRI-EAF), and (iii) smelting reduction-basic oxygen furnace/electric arc furnace (SR-BOF/EAF); the decrease in quantity of production through these routes follow the same order. All these routes involve carbon in some form which has limitations of (future) supply and environmental pollution. Carbon dioxide (CO2) is the main greenhouse gas emitted from the steel industry; BF alone emits 1.4 tons of CO2 for every ton of hot metal produced which constitutes 65 pct of plant emissions.[2]
P.R. BEHERA is with the Centre for Sustainable Materials Research and Technology (SMaRT@UNSW), School of Materials Science and Engineering, University of New South Wales (UNSW), Room 402/13, Building E10, Sydney, NSW 2052, Australia and also with the Advanced Materials Technology Department, Institute of Minerals and Materials Technology, Council of Scientific and Industrial Research (CSIR-IMMT), Bhubaneswar, Odisha 751013, India. Contact e-mail: [email protected] B. BHOI and P.S. MUKHERJEE are with the Advanced Materials Technology Department, Institute of Minerals and Materials Technology, Council of Scientific and Industrial Research (CSIR-IMMT). R.K. PARAMGURU is with the School of Mechanical Engineering, and Students Research Center, KIIT Deemed to be University, Bhubaneswar 751024, India. B.K. MISHRA is with the Indian Institute of Technology, Goa 403401, India and with the Institute of Minerals and Materials Technology, Council of Scientific and Industrial Research (CSIR-IMMT), Bhubaneswar, Odisha 751013, India. Manuscript submitted December 14, 2017. Article published online December 3, 2018. 262—VOLUME 50B, FEBRUARY 2019
Even though the above-mentioned process technologies are efficient, economical, and ever-evolving, for the sake of green gas concerns a lot of attempts are being made worldwide to look for alternate process routes where green gas emissions are either eliminated altogether or drastically reduced. Some such efforts include the ultra low CO2 steelmaking (ULCOS) programs running in European Union (EU) since 2004 covering areas of research in (a) top gas recycling blast furnace (TGR-BF or ULCOS-BF) incorporating carbon dioxide capture and storage (CCS)[2]; (b) HIsarna, a technology based on bath smelting which combines three reactors, the first one for preheating and partial pyrolysis of coal, the second one is a melting cyclone for ore melting followed by the smelter vessel for final ore reduction and metal production (the special aspects include reduced CO2 emission which is almost CCS ready and a process flexible to substitute coal with either biomass, natural gas or hydrogen)[3]; (c) ULCORED, a solid DRI making process using natural gas followed by melting in EAF[4]; (d) ULCOWIN, a direct electro-winning process operating slightly above 100 C in an aqueous (slurry of) alkaline s
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