The use of magnetite-based iron ore fines by means of fluidized bed technology has become a promising route to produce direct reduced iron. The significant influence of a prior oxidation treatment, which occurs in the preheating stage, on the subsequent fluidization and reduction behavior was observed in our previous study. As a result, it is important to investigate the oxidation of magnetite-based iron ore fines for an optimization of the proposed route. Three magnetite-based iron ore brands were analyzed. The oxidation characteristics are investigated based on thermogravimetric analysis. The surface morphology, structural evolution, and phase transformation were studied with a scanning electron microscope, an optical light microscope, and a high-temperature-X-ray diffraction (HT-XRD), respectively. The three samples showed different oxidation capacity indexes (OCIs) but similar TG-DTG curves. The oxidation rate peaks at around 330 °C and 550 °C indicated the formation of γ-Fe₂O₃ and α-Fe₂O₃. The hematite phase shows a particular growth habit. The oxidation first occurs at the surface, forming gridlike hematite structures, and then extends to the inside, resulting in hematite needles. The specific surface area and pore volume decrease significantly due to the sintering effect during oxidation.

This paper studies the integration of direct reduced iron (DRI) and hot briquetted iron (HBI) into the steelmaking process via an electric arc furnace (EAF). Considering a variety of DRI production techniques distinguished by different reactor types, this paper provides a comparative overview of the current state. It delves into significant challenges, such as the susceptibility of DRI to reoxidation and the necessity of thorough handling to maintain its quality. The effectiveness of several reoxidation mitigation strategies, including the application of thin oxide layers, briquetting, various coatings, and nitride formation in ammonia-based reduction processes, is evaluated. Most existing studies have primarily focused on the reoxidation of DRI rather than on HBI, despite the fact that HBI may undergo reoxidation. The importance of DRI/HBI in offering an alternative to the integrated steelmaking route is highlighted, focusing on how it changes the EAF process compared to those for melting scrap. This paper also identifies several research prospects for further DRI/HBI applications in steel production.

The imperative to achieve a climate-neutral industry necessitates CO₂-free alternatives for H₂ production. Recent developments suggest that plasma technology holds promise in this regard. This study investigates H₂ production by methane pyrolysis using a lab-scale plasma furnace, with the primary objective of achieving a high H₂ yield through continuous production. The plasma furnace features a DC-transferred thermal plasma arc system. The plasma gas comprises Ar and CH₄, introduced into the reaction zone through the graphite hollow cathode. The off-gas is channeled for further analysis, while the plasma arc is recorded by a camera installed on the top lid. Results showcase a high H₂ yield in the range of up to 100%. A stable process is facilitated by a higher power and lower CH₄ input, contributing to a higher H₂ yield in the end. Conversely, an increased gas flow results in a shorter gas residence time, reducing H₂ yield. The images of the plasma arc zone vividly depict the formation and growth of carbon, leading to disruptive interruptions in the arc, hence declining efficiency. The produced solid carbon exhibits high purity with a fluffy and fine structure. This paper concludes that further optimization and development of the process are essential to achieve stable continuous operation with a high utilization degree.

The reduction of magnetite-based iron ore fines in a hydrogen-induced fluidized bed becomes an attractive fossil-free ironmaking route. Our previous study showed that a prior oxidation treatment of magnetite was helpful to improve its fluidization and reduction behavior. However, the underlying oxidation mechanisms of magnetite ore fines remained unclear and required further investigations. In this study, two magnetite ore brands were analyzed viain situ high-temperature X-ray diffraction (HT-XRD) during oxidation, to investigate the thermal transformation of Fe₃O₄ to α-Fe₂O₃ at crystal scale. The lattice constants and crystallite sizes of both phases and oxidation degree were evaluated at different temperatures based on the HT-XRD patterns. The lattice constants of Fe₃O₄ and α-Fe₂O₃ increased with an increase in temperature due to the thermal expansion and can be successfully fitted with temperature by second-order polynomials. With Fe₃O₄ being oxidized into Fe₂O₃, the Fe₂O₃ crystallite grew and showed a certain growth habit. The Fe₂O₃ crystallite grew faster along the a/b axis than the c axis. The oxidation kinetics followed the parabolic law as shown by the sigmoid-shaped oxidation degree curve, suggesting that the solid diffusion of ions was the rate-limiting step.

Hydrogen-based direct reduced iron (HyDRI) produced by fluidized bed has great potential for achieving the target of net-zero carbon in steelmaking. However, when magnetite ores were used as feedstock, several process parameters showed influences on its fluidization and reduction behaviors. To confirm the dominant influencing factors and its optimum process condition, the orthogonal experimental method was conducted in the present study. The result shows that the primary and secondary influencing factors are oxidation temperature, oxidation content, MgO addition amount, and gas velocity. The optimum condition is that the magnetite iron ore is deeply oxidized at 800 °C, mixed with 1.5 wt.% of MgO powder, and reduced in the fluidized bed at a gas velocity of 0.45 m/s.