Periodic Reporting for period 2 - MaxH2DR (Maximise H2 Enrichment in Direct Reduction Shaft Furnaces)
Reporting period: 2023-12-01 to 2025-05-31
In standard Direct Reduction (DR) shafts, the H2 content in the reduction gas is approximately 60 Vol-% or lower and no industrial or demonstration-scale results were published yet for DR with strong H2 enrichment (H2>80 Vol-%), the so-called “H2-enriched DR”. Although H2-enriched DR is technologically validated, the lack of industrial experience leaves a significant maturity gap and significant knowledge gaps which hinder fast and effective industrial roll out needed to reach EU climate policy targets. Knowledge gaps exist on the effects of higher H2-enrichment on the thermal and chemical processes, but even more on the pellet/Direct Reduced Iron (DRI) properties and on the overall DR process operation at industrial scale. With the clear long-term target of (almost) pure H2 usage, considering the major knowledge and maturity gaps of pure H2-DR, it is of utmost importance for scale-up and industrial application to apply a flexible stepwise approach with fast implementation of gradually H2-enriched DR along with technical progress and availability of clean H2.
The overall goal of MaxH2DR is to fill the gap between available knowledge about H2-enriched DR from lab-scale and upcoming demonstration projects and the knowledge required to scale-up and operate industrial H2 -enriched DR furnaces. To this aim, MaxH2DR aims at achieving the following set of measurable and verifiable general objectives:
1. create new knowledge combining several ground-breaking novel approaches on the physical and chemical processes that dominate H2-enriched DR;
2. exploit new knowledge and data and implement this into digital toolkits for the DR furnace and its process integration to enable reliable prognoses;
3. provide the digital basis for the planned Carbon Direct Avoidance demonstrator with >80% CO2 mitigation within the Clean Steel Partnership;
4. support sustainable industrial implementation of DR with maximum H2 enrichment;
5. raise the maturity of the relevant toolkits from TRL5 to TRL8.
The overall goal of MaxH2DR is to fill the gap between available knowledge about H2-enriched DR from lab-scale and upcoming demonstration projects and the knowledge required to scale-up and operate industrial H2 -enriched DR furnaces. To this aim, MaxH2DR aims at achieving the following set of measurable and verifiable general objectives:
1. create new knowledge combining several ground-breaking novel approaches on the physical and chemical processes that dominate H2-enriched DR;
2. exploit new knowledge and data and implement this into digital toolkits for the DR furnace and its process integration to enable reliable prognoses;
3. provide the digital basis for the planned Carbon Direct Avoidance demonstrator with >80% CO2 mitigation within the Clean Steel Partnership;
4. support sustainable industrial implementation of DR with maximum H2 enrichment;
5. raise the maturity of the relevant toolkits from TRL5 to TRL8.
Investigations of reduction kinetics continued to build a high-quality kinetic database for H2-based DR for calibration of models and tools under development. Two complementary kinetic sub-models were developed and tested, in particular a Single Pellet Kinetic Model (SPKM). Improvements and updates were carried out to refine models capabilities and results.
Metallurgical tests were carried out in the DR Simulator testing facility under high H2 enrichment to evaluate the reduction behaviour of considered pellets. Additional tests showed different pellet degradation behaviours at different elevated temperatures and fines generation in post-reduction mechanical degradation tests. It was observed that increased pellet reduction reaction during tests leads to developing progressively deeper cracks.
The rotational shear test device for measuring adhesive forces of pellet bulks in a H2-rich atmosphere at high temperature and shear was constructed. Its operability was validated, and tests were carried out to verify its usability and functioning: some modifications compared to the initial design were necessary. A testing protocol was implemented, and different samples were investigated.
A DEM-based tool was developed to simulate mechanical interactions between the particles and simulations were conducted. The updated SPKM was implemented via Finite Element Method (FEM), Discrete Element Method/Computational Fluid Dynamics (DEM/CFD) and Finite Volume Method (FVM) simulation. Dedicated simulations demonstrate the successful integration.
Tests were carried out to determine the gas permeability of different materials. Firstly, a tubular device was used, then experiments were done in the Midrex-based demonstrator. It was also used to determine pressure drop and particle movements for the DR furnaces models, e.g the DEM/CFD model simulating the interaction between fluid and bulk solids. The simulation generally matches experimental data with some deviations on pressure drops. The DEM-CFD model for granular particle movement and gas flow was validated. The FEM model was updated by further calibrating the rheology model based on the apparent viscosity to optimise the simulation of solid flow. Finally, the results of models and trials were compared to complete the validation work to provide the “hybrid demonstrator” for DR shaft furnace scale-up and optimisation.
Several modelling and IT work was carried out to revise the multipurpose simulation toolkit to simulate the overall-production chain during transition scenarios: gas and energy network. Some AML models, and IT procedures to manage data exchange, convergences, demands, scenarios, etc. were updated. New models of new process units for transition scenarios were developed: Models were developed in Aspen Plus representing both Midrex+H2 and Energiron Zero Reformer processes in all stages, and in AML language. An EAF model was developed in IRMA. Discussion was done with an advisory board member to obtain data to update one of the DRI process models. The AML system optimization model was used in exemplar analyses to illustrate model applications and to evaluate test cases; together with first LCA analyses it highlights the high influence of grid electricity costs and emission intensities to allow the transition to hydrogen-based steelmaking. A list of scenarios to be simulated with the IRMA-Aspen Plus combined tool was elaborated.
An intensive dissemination work was carried out by the consortium through participation to international scientific events and publications of scientific papers. Connections with other related EU-funded projects were established. The consortium applied for the Net-zero industries Award 2024 and was awarded as a national winner for Germany.
Metallurgical tests were carried out in the DR Simulator testing facility under high H2 enrichment to evaluate the reduction behaviour of considered pellets. Additional tests showed different pellet degradation behaviours at different elevated temperatures and fines generation in post-reduction mechanical degradation tests. It was observed that increased pellet reduction reaction during tests leads to developing progressively deeper cracks.
The rotational shear test device for measuring adhesive forces of pellet bulks in a H2-rich atmosphere at high temperature and shear was constructed. Its operability was validated, and tests were carried out to verify its usability and functioning: some modifications compared to the initial design were necessary. A testing protocol was implemented, and different samples were investigated.
A DEM-based tool was developed to simulate mechanical interactions between the particles and simulations were conducted. The updated SPKM was implemented via Finite Element Method (FEM), Discrete Element Method/Computational Fluid Dynamics (DEM/CFD) and Finite Volume Method (FVM) simulation. Dedicated simulations demonstrate the successful integration.
Tests were carried out to determine the gas permeability of different materials. Firstly, a tubular device was used, then experiments were done in the Midrex-based demonstrator. It was also used to determine pressure drop and particle movements for the DR furnaces models, e.g the DEM/CFD model simulating the interaction between fluid and bulk solids. The simulation generally matches experimental data with some deviations on pressure drops. The DEM-CFD model for granular particle movement and gas flow was validated. The FEM model was updated by further calibrating the rheology model based on the apparent viscosity to optimise the simulation of solid flow. Finally, the results of models and trials were compared to complete the validation work to provide the “hybrid demonstrator” for DR shaft furnace scale-up and optimisation.
Several modelling and IT work was carried out to revise the multipurpose simulation toolkit to simulate the overall-production chain during transition scenarios: gas and energy network. Some AML models, and IT procedures to manage data exchange, convergences, demands, scenarios, etc. were updated. New models of new process units for transition scenarios were developed: Models were developed in Aspen Plus representing both Midrex+H2 and Energiron Zero Reformer processes in all stages, and in AML language. An EAF model was developed in IRMA. Discussion was done with an advisory board member to obtain data to update one of the DRI process models. The AML system optimization model was used in exemplar analyses to illustrate model applications and to evaluate test cases; together with first LCA analyses it highlights the high influence of grid electricity costs and emission intensities to allow the transition to hydrogen-based steelmaking. A list of scenarios to be simulated with the IRMA-Aspen Plus combined tool was elaborated.
An intensive dissemination work was carried out by the consortium through participation to international scientific events and publications of scientific papers. Connections with other related EU-funded projects were established. The consortium applied for the Net-zero industries Award 2024 and was awarded as a national winner for Germany.
MaxH2DR will provide the following overall results, which go far beyond the state of the art in the concerned field:
1. new fundamental knowledge and data on reduction kinetics and physical properties of (partly) reduced pellets exploited in new chemical and physical sub-models (e.g. kinetics, cohesion);
2. a unique test rig to quantify physical pellet bulk properties in industrial H2-enriched DR conditions;
3. a new demonstrator to investigate the linked solid and gas flow in DR shaft furnaces
4. a world-first complete DR process model fully implemented as innovative DEM/CFD simulation;
5. a new strategy combining DEM/CFD simulation with physical demonstration of material and gas flow and its exploitation into a fast flexible FEM DR process model (hybrid demonstrator);
6. a process chain simulation toolkit covering metallurgical aspects, material, gas and energy flows and their optimal integration.
1. new fundamental knowledge and data on reduction kinetics and physical properties of (partly) reduced pellets exploited in new chemical and physical sub-models (e.g. kinetics, cohesion);
2. a unique test rig to quantify physical pellet bulk properties in industrial H2-enriched DR conditions;
3. a new demonstrator to investigate the linked solid and gas flow in DR shaft furnaces
4. a world-first complete DR process model fully implemented as innovative DEM/CFD simulation;
5. a new strategy combining DEM/CFD simulation with physical demonstration of material and gas flow and its exploitation into a fast flexible FEM DR process model (hybrid demonstrator);
6. a process chain simulation toolkit covering metallurgical aspects, material, gas and energy flows and their optimal integration.