Development and Application of Hydrogen-Based Direct Reduction Iron Process
Abstract
:1. Introduction
2. Main Chemical Reactions in the H-DRI Process
3. Typical H-DRI Processes
3.1. Direct Reduction Process with Tank Furnace
3.2. Direct Reduction Process with Shaft Furnace
3.2.1. Midrex Process
3.2.2. Midrex-H2® Process
3.2.3. HYL-III/Energiron Process
3.2.4. HYL-ZR Process
3.2.5. BL Process
3.3. Fluidized Bed Direct Reduction Process
3.4. Characteristics Comparison of Typical H-DRI Processes
3.5. Industrial Practice and Development of Typical H-DRI Processes
4. Research on Process Optimization of H-DRI
5. Industrial Application Projects of H-DRI Process in Recent Years
6. Problems and Challenges of H-DRI Process
7. Conclusions
- The ISI is an industry with high carbon emissions, largely due to the extensive use of coal in the ironmaking process. Hydrogen metallurgy presents a promising solution to reduce carbon emissions at the source, facilitating green and low-carbon development within the ISI. Among hydrogen metallurgy processes, the H-DRI process stands out due to its significant carbon emission reduction and mature process, making it one of the most promising avenues for development. In addition, the development of the H-DRI process is also of great significance for promoting the ISI’s short process technology and energy structure optimization;
- The H-DRI process has been used in some industrial applications around the world over the past decades, but it is still in the development stage overall. The tank HYL, Midrex, Midrex-H2®, HYL-III/Energiron, HYL-ZR, BL, and Finmet processes are several typical H-DRI processes. Based on the comparison of characteristics of these different typical H-DRI processes, combined with production capacity, energy consumption, and process maturity, the Midrex and HYL-III/Energiron shaft furnace processes are currently recommended mainstream choices. Due to the high cost of pure-hydrogen reduction, it is more practical to use hydrogen-rich gas as the reducing gas in the H-DRI process. The main raw materials of reducing gas are natural gas, byproduct gas, coal gas, and external hydrogen. Different countries or regions should choose their own reducing gas raw material sources according to the characteristics of local resources;
- For H-DRI process optimization, existing studies have shown that in order to give full play to the advantage of fast hydrogen reduction rate, the temperature of the reduction reaction should be controlled above 820 °C. From the point of view of reducing energy consumption, the temperature of the reducing gas should be controlled between 900 °C and 1000 °C, and the range of H2 in the reducing gas should be controlled between 20% and 40%. Preheating of ore, recovery of top gas, and adoption of double-gas injection are all measures that contribute to enhancing the utilization rate of the reducing gas, reducing energy consumption, and improving production efficiency. In addition to the existing research results, it is necessary to continue to improve of the production performance of key equipment such as the reducing gas reforming furnace and the heating furnace and reactor, develop low-cost reducing gas preparation methods, strengthen the recovery of waste heat and energy in the overall process, and improve the overall utilization rate of energy and reducing gas;
- In the long run, if low-cost renewable energy power generation can be achieved, the generation of power with renewable energy → production of hydrogen with electrolytic water may become a mainstream hydrogen production method. In the present and future period of time, it is proposed to reduce the cost of reducing gas preparation by using byproduct gas, natural gas, and other hydrogen-rich gases, combined with the electrolysis of water to produce the reducing gas required for the H-DRI process;
- To secure stable sources of inexpensive H2, advancements in hydrogen production and storage technologies are imperative. Addressing the shortage of high-grade iron ore can be achieved through enhancements in the mineral processing of iron concentrate and the development of H-DRI processes utilizing low-grade iron ore. To diminish energy consumption and enhance the utilization rate of reducing gas, ongoing in-depth research is necessary to strike a balance between carbon emission reduction and hydrocarbon collaboration in the H-DRI process. Moreover, from the perspective of H-DRI process safety production, the corrosion and damage caused by H2 to reactors and transportation pipelines under different conditions require more testing.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Reaction Formula | |||
---|---|---|---|
−6020 | −6020 − 88.75T | ||
60,580 | 60,580 − 80.02T | ||
30,180 | 30,180 − 29.34T | ||
37,780 | 37,780 − 42.01T | ||
−47,184 | −47,184 − 46.67T | ||
19,416 | 19,416 − 37.94T | ||
−10,984 | −10,984 + 12.74T | ||
−3384 | −3384 + 0.07T |
Name of Process | Type of Process | Preparation of Reducing Gas | Composition of Reducing Gas | Characteristics |
---|---|---|---|---|
HYL-I, HYL-II | Tank type | Catalytic cracking and reforming of natural gas and water vapor. | Mainly H2 + CO, where content reaches 75%. | Non-continuous production and low efficiency (has been gradually replaced). |
Midrex | Shaft furnace | Catalytic cracking and reforming of natural gas. | H2 + CO > 90%, where H2/CO is 1.5–1.8. | Mature process with large output. The most widely used H-DRI process at present. |
Midrex-H2® | Shaft furnace | External H2. | Pure H2. | Use of pure H2 as a reducing agent without requiring reforming device; high cost. |
HYL-III/Energiron | Shaft furnace | Catalytic cracking and reforming of natural gas and water vapor. | Mainly H2 + CO, where H2/CO is 3.0–6.7. | High H2 content of reducing gas, high furnace pressure, and fast reduction speed. Equipment costs are relatively high. |
HYL-ZR | Shaft furnace | External coke oven gas. | Mixture of coke oven gas and stock gas. | Use of coke oven gas as reducing agent, without requiring reforming device. Risk of corrosion of furnace tubes due to carburization of CH4 and iron furnace tubes at high temperatures. |
BL | Shaft furnace | Physicochemical reaction between coal water slurry and oxygen. | H2 + CO > 95%. | Use of coal gas for production of hydrogen, which is suitable for areas with more coal and less gas. High cost of reducing gas production. |
Finmet | Fluidized bed | Catalytic cracking and reforming of natural gas and water vapor. | Mainly H2 + CO. | Use of iron ore powder as raw material; high reduction speed. Difficult control, low yield, and easy bonding. |
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Serial Number | Projects | Year | Source of Reducing Gas | Objectives |
---|---|---|---|---|
1 | Swedish HYBRRIT project | 2016 | Electrolytic water-generated hydrogen. | Sweden reduced CO2 emissions by 10%, and Finland reduced CO2 emissions by 7%. No fossil fuel will be used by 2045. |
2 | Korea COOLSTAR project | 2017 | Byproduct gas-generated hydrogen. | CO2 emissions will be reduced by 20% by 2030, and by 50% by 2040. Carbon neutrality will be achieved by 2050. |
3 | ArcelorMittal Project | 2019 | Natural gas-generated hydrogen + renewable energy-generated hydrogen. | CO2 emissions will be reduced by 30% by 2030, and carbon neutrality will be achieved in 2050. |
4 | German SALCOS project | 2019 | Wind power-generated hydrogen. | CO2 emissions are reduced by 95% throughout process of steel production. |
5 | Voestalpine Pratt Project | 2019 | Electrolytic water-generated hydrogen. | In the next 10–15 years, the Midrex-NG process in Texas, USA, will be changed to Midrex-H2®. The direct reduction process with a hydrogen-based fluidized bed will be developed and improved. |
6 | EU ULCORED project | 2004 | Coal-generated hydrogen, natural gas-generated hydrogen, and electrolytic water-generated hydrogen. | The CO2 emissions are reduced by more than 50%. |
7 | Zhongjin Metallurgical’s hydrogen-based shaft furnace project | 2020 | Coke oven gas. | A breakthrough is made in the use of coke oven gas to realize the key technology of hydrogen metallurgy, which promotes the low-carbon transformation in the ISI. |
8 | HBIS Group’s HBIS project | 2021 | Coke oven gas. | This is an exemplar which plays a leading role in China’s use of coke oven gas for the H-DRI process. |
9 | Baowu Steel Group’s Zhanjiang hydrogen-based shaft furnace project | 2021 | Coke oven gas, H2, and natural gas. | CO2 emissions will be reduced by 30% by 2030, and carbon neutrality will be achieved by 2050. |
10 | Northeastern University’s coal gas–hydrogen-rich shaft furnace project | Recent years | Coal gasification. | Research and development of coal gasification–hydrogen-based direct reduction shaft furnace technology to realize mature industrial application. |
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Ji, Y.; Chi, Z.; Yuan, S.; Chen, Y.; Li, Y.; Jiang, T.; Liu, X.; Zhang, W. Development and Application of Hydrogen-Based Direct Reduction Iron Process. Processes 2024, 12, 1829. https://doi.org/10.3390/pr12091829
Ji Y, Chi Z, Yuan S, Chen Y, Li Y, Jiang T, Liu X, Zhang W. Development and Application of Hydrogen-Based Direct Reduction Iron Process. Processes. 2024; 12(9):1829. https://doi.org/10.3390/pr12091829
Chicago/Turabian StyleJi, Yuzhang, Zhongyuan Chi, Shufu Yuan, Yongxu Chen, Yujie Li, Tianchi Jiang, Xin Liu, and Weijun Zhang. 2024. "Development and Application of Hydrogen-Based Direct Reduction Iron Process" Processes 12, no. 9: 1829. https://doi.org/10.3390/pr12091829