The development of a carbon lean steel production process following the concept of direct carbon avoidance is one of the most challenging tasks the iron and steel industry must tackle in just a few decades. The necessary drastic reduction of 80% of the process’s inherent emissions by 2050 is only possible if a new process concept that uses hydrogen as the primary reductant is developed. The Hydrogen Plasma Smelting Reduction (HPSR) of ultra-fine iron ores is one of those promising concepts. The principle was already proven at a lab scale. The erection of a bench-scale facility followed this, and further scaled-ups are already planned for the upcoming years. For this scale-up, a better understanding of the fundamentals of the process is needed. In particular, knowledge of the kinetics of the process is essential for future economically feasible operations. This investigation shows the principles for evaluating and comparing the process kinetics under varying test setups by defining a representative kinetic parameter. Aside from the fundamentals for this definition, the conducted trials for the first evaluation are shown and explained. Several differences in the reduction behavior of the material at varying parameters of the process have already be shown. However, this investigation focuses on the description and definition of the method. An overall series of trials for detailed investigations will be conducted as a follow-up.

To meet the target for anthropogenic greenhouse gas (GHG) reduction, the European steel industry is obliged to reduce its emissions. A possible pathway to reach this requirement is through developments of new technologies for a GHG-free steel production. One of these processes is the hydrogen plasma smelting reduction (HPSR) developed since 1992 at the Chair of Ferrous Metallurgy at the Montanuniversitaet Leoben in Austria. Based on the already available publication of the methodology in this work, potential process parameters were investigated that influence the reduction kinetics during continuous charging to improve the process further. Preliminary tests with different charging rates and plasma gas compositions were carried out to investigate the impacts on the individual steps of the reduction process. In the main experiments, the obtained parameters were used to determine the effect of the pre-reduction degree on the kinetics and the hydrogen conversion. Finally, the preliminary and main trials were statistically evaluated using the program MODDE^® 13 Pro to identify the significant influences on reduction time, oxygen removal rate, and hydrogen conversion. High hydrogen utilization degrees could be achieved with high iron ore feeding rates and low hydrogen concentrations in the plasma gas composition. The subsequent low reduction degree and thus a high proportion of oxide melt leads to a high oxygen removal rate in the post-reduction phase and, consequently, short process times. Calculations of the reduction constant showed an average value of 1.13 × 10⁻⁵ kg oxygen/m² s Pa, which is seven times higher than the value given in literature.

Non-metallic inclusions (NMIs) in steels have been the focus of various experimental studies due to their detrimental character. While isolated processes, such as agglomeration or dissolution, have been well investigated, holistic in-situ views with high-temperature confocal scanning laser microscopy (HT-CSLM) have been rare. In this work a novel and suitable method is presented to simultaneously observe agglomeration, movement, detachment, and dissolution of non-metallic inclusions by combined the melting of steel and slag with a dual-crucible approach. Therefore, different steel/slag combinations were tested. It is shown that, with transparent that does not become tarnished by the ions stemming from the steel, the steel’s surface and non-metallic inclusions are observable. Furthermore, technological limitations are discussed, including restrictions regarding the melting point of steels and certain steel/slag combinations.

The transformation of the steel industry is inevitably linked to increased recycling rates of steel. However, end‐of‐life scrap is often contaminated with tramp elements like copper, molybdenum, and tin and while their influence on mechanical properties of steels is well described, their effect on nonmetallic inclusions remains largely unknown. Therefore, herein, two medium‐carbon steels are alloyed with up to 1 wt% of the listed tramp elements. The influence these elements have on the inclusion behavior in liquid steel is investigated using the sessile drop method in contact with alumina and zirconia as well as in steel/slag melting experiments to evaluate the formation and separation of new inclusions. Additionally, a semiempirical approach using CALPHAD to model the surface tension of steels with tramp elements is done. Copper and tin decrease the surface tension, while molybdenum increases the surface tension. It is demonstrated that most investigated alloys lead to a decrease of wetting angle as compared to the nonalloyed steels. The shown trends in the sessile drop experiments are lower contact angles with increased surface tension while a higher number of inclusions occurs with a decrease in surface tension. Thus, this study demonstrates that tramp elements affect the oxidic cleanness of steels.

Modeling is an essential tool to provide insights in the evolution of non-metallic inclusions in metallurgical processes. To provide comprehensive depictions of phase developments in laboratory experiments and the associated steel cleanness in high-speed steels, a combination of modeling approaches is employed and compared with analytical data. Macroscopic phase changes are represented using the effective equilibrium reaction zone model. This model, in conjunction with analytical and numerical approaches, also serve to describe steel cleanness modifications. The model described, together with delineated boundary conditions based on literature as well as measured data for the defined system, demonstrated a high degree of agreement with the measurements. Macroscopic changes are characterized by a mean absolute deviation between measured and calculated steel and slag component contents of 0.035 pct points with a standard deviation of 0.093 pct points and 0.92 pct points with a standard deviation of 1.61 pct points, respectively. For steel cleanness modifications, comparative analysis of inclusion compositions, mean ECDs and inclusion number densities were conducted. The mean absolute deviation of the mean ECD showed 0.02 μ m with a standard deviation of 0.03 μ m and the inclusion number density 155 inclusions per mm ² with a standard deviation of 224 inclusions per mm ² .