Periodic Reporting for period 1 - HELIOS (The adoption of hydrogen metallurgy in the climate-neutral production of steel)
Okres sprawozdawczy: 2023-10-01 do 2025-09-30
Steel is the core of a modern, sustainable society – it is irreplaceable in green-energy technologies like wind, wave and solar, in the mobility sector and in constructions. Steel is also the backbone of sustainable growth, representing 95% of all the metal we produce.
Europe is a major steelmaker, larger than both the US and Russia (incl. other CIS). It has about 500 producers in 23 EU countries, representing 330000 direct jobs, and 2.7 million direct, indirect and induced jobs.
Steel is also the most recycled metal in the world. The beauty of steel is that it can be infinitely recycled, without loss of quality, and the residues and waste energy from its production are valuable resources for a circular EU economy.
The current steel production is however responsible for 2.6-3.0 billion tonnes total annual emissions of CO2, accounting for 7-9% of the global CO2 emissions. As global average, around 1.85-1.92 tonnes of CO2 per tonne of crude steel is produced. 75% of the steel’s energy mix is coal-based, in particular in the BF-BOF route, where carbon is also used as a reductant in the BF process. Next to carbon capture, the direct avoidance of CO2 emissions through the hydrogen-based DRI production is an emerging technology for climate-neutral steel production. By replacing carbon with green hydrogen as a reducing agent, most CO2 emissions from the ironmaking process can be eliminated. In combination with renewable energy, it is the cornerstone for the future decarbonization strategy of the steel sector.
The HELIOS Doctoral Network trains 10 motivated and talented Doctoral Candidates (DCs) in breakthrough technologies for the hydrogen-based production of green steel, including both carbon steel and stainless steel. The combination of state- of-the-art doctoral research projects, intersectoral secondments and supervision by leading companies and universities are the foundations of HELIOS’s success.
The research objectives in HELIOS are:
(1) Engineer processes and develop models to leverage the H-DR route to the same state-of-the art level as the BF-BOF route in Europe with respect to process, energy and resource efficiency as well as product quality;
(2) Develop first-of-a-kind hydrogen plasma-based reduction processes for stainless-steel producers and their raw-material producers;
(3) Develop metal-recovery processes for residues from steel production based on hydrogen and/or hydrogen plasma-based reduction;
(4) Develop measuring and analysis tools and models to support the application of hydrogen-based processes in the carbon and stainless-steel production routes.
Europe is a major steelmaker, larger than both the US and Russia (incl. other CIS). It has about 500 producers in 23 EU countries, representing 330000 direct jobs, and 2.7 million direct, indirect and induced jobs.
Steel is also the most recycled metal in the world. The beauty of steel is that it can be infinitely recycled, without loss of quality, and the residues and waste energy from its production are valuable resources for a circular EU economy.
The current steel production is however responsible for 2.6-3.0 billion tonnes total annual emissions of CO2, accounting for 7-9% of the global CO2 emissions. As global average, around 1.85-1.92 tonnes of CO2 per tonne of crude steel is produced. 75% of the steel’s energy mix is coal-based, in particular in the BF-BOF route, where carbon is also used as a reductant in the BF process. Next to carbon capture, the direct avoidance of CO2 emissions through the hydrogen-based DRI production is an emerging technology for climate-neutral steel production. By replacing carbon with green hydrogen as a reducing agent, most CO2 emissions from the ironmaking process can be eliminated. In combination with renewable energy, it is the cornerstone for the future decarbonization strategy of the steel sector.
The HELIOS Doctoral Network trains 10 motivated and talented Doctoral Candidates (DCs) in breakthrough technologies for the hydrogen-based production of green steel, including both carbon steel and stainless steel. The combination of state- of-the-art doctoral research projects, intersectoral secondments and supervision by leading companies and universities are the foundations of HELIOS’s success.
The research objectives in HELIOS are:
(1) Engineer processes and develop models to leverage the H-DR route to the same state-of-the art level as the BF-BOF route in Europe with respect to process, energy and resource efficiency as well as product quality;
(2) Develop first-of-a-kind hydrogen plasma-based reduction processes for stainless-steel producers and their raw-material producers;
(3) Develop metal-recovery processes for residues from steel production based on hydrogen and/or hydrogen plasma-based reduction;
(4) Develop measuring and analysis tools and models to support the application of hydrogen-based processes in the carbon and stainless-steel production routes.
A comprehensive literature on H2-based DRI reduction and degradation has been completed by DC1.
In situ carburization in the furnace’s cooling zone is being explored by DC2 to enhance DRI compatibility with current steelmaking practices—improving energy balance, slag foaming, and melting efficiency. Thermodynamic analyses have suggested optimal conditions for carburization based on gas composition, temperature, and pellet grade. Experimental validation using single pellets is underway.
The melting behavior of H-DRI has been studied by DC3 through lab-scale melting experiments and thermal property measurements. A model that predicts the thermal properties of HDRI from the composition over a wide range of HDRI samples has been developed, with regression and machine learning components trained. The predictions show good agreement with thermodynamic results and differential scanning calorimetry (DSC) data.
The influence of carbon content on P and N removal in the primary steelmaking process step has been assessed by DC4 via thermodynamic simulations, considering temperature, slag composition, and pO2. These insights guide the design of high-temperature experiments and the development of a predictive model.
Lab-scale experiments by DC5 and DC6 have explored the hydrogen plasma smelting reduction of pure Cr2O₃ and Cr-containing mixtures, assessing the influence of process parameters and oxide compositions. DC5 and DC6 have tailored their system compositions to reflect chromite ores and AOD slags, respectively. Initial results confirm the feasibility of Cr2O₃ reduction, though further optimization is needed to achieve higher reduction degrees. Thermodynamic calculations are used to support the experimental design and interpretation.
Industrial dust from stainless steel production has been thoroughly characterized by DC7 to identify phase composition and elemental distribution. Based on these insights, two flowsheets have been developed to recover Fe, Cu, Ni, Cr, and Mo: one using solid-state hydrogen reduction with selective leaching, and the other combining molten-state hydrogen reduction with hydrogen plasma smelting. Both flowsheets are currently under investigation to evaluate their recovery efficiency for the targeted elements.
DC8 is evaluating technologies for continuous hydrogen content and temperature monitoring during EAF and HPSR operations. Several options have been identified, and both lab- and pilot-scale tests are underway to assess their performance.
DC9 applied Optical Emission Spectroscopy (OES) for in-situ plasma monitoring during the hydrogen plasma smelting reduction (HPSR) of ilmenite, pure and fluxed chromium oxides Cr2O₃ reduction. Data analysis revealed the temporal evolution of plasma elements and enabled plasma temperature estimation, offering real-time insights into the reduction process. The analysis of chromium oxide trials is ongoing and will provide valuable information for the process conditions during HPSR.
For sustainability assessment, DC10 selected NG-DRI-EAF as the benchmark and compiled relevant literature data. This serves as a reference for comparing the hydrogen-based processes developed by other DCs. Life cycle costing is being studied, and economic data are being gathered. A consequential life cycle assessment will be conducted to evaluate potential market shifts due to hydrogen-based steelmaking.
In situ carburization in the furnace’s cooling zone is being explored by DC2 to enhance DRI compatibility with current steelmaking practices—improving energy balance, slag foaming, and melting efficiency. Thermodynamic analyses have suggested optimal conditions for carburization based on gas composition, temperature, and pellet grade. Experimental validation using single pellets is underway.
The melting behavior of H-DRI has been studied by DC3 through lab-scale melting experiments and thermal property measurements. A model that predicts the thermal properties of HDRI from the composition over a wide range of HDRI samples has been developed, with regression and machine learning components trained. The predictions show good agreement with thermodynamic results and differential scanning calorimetry (DSC) data.
The influence of carbon content on P and N removal in the primary steelmaking process step has been assessed by DC4 via thermodynamic simulations, considering temperature, slag composition, and pO2. These insights guide the design of high-temperature experiments and the development of a predictive model.
Lab-scale experiments by DC5 and DC6 have explored the hydrogen plasma smelting reduction of pure Cr2O₃ and Cr-containing mixtures, assessing the influence of process parameters and oxide compositions. DC5 and DC6 have tailored their system compositions to reflect chromite ores and AOD slags, respectively. Initial results confirm the feasibility of Cr2O₃ reduction, though further optimization is needed to achieve higher reduction degrees. Thermodynamic calculations are used to support the experimental design and interpretation.
Industrial dust from stainless steel production has been thoroughly characterized by DC7 to identify phase composition and elemental distribution. Based on these insights, two flowsheets have been developed to recover Fe, Cu, Ni, Cr, and Mo: one using solid-state hydrogen reduction with selective leaching, and the other combining molten-state hydrogen reduction with hydrogen plasma smelting. Both flowsheets are currently under investigation to evaluate their recovery efficiency for the targeted elements.
DC8 is evaluating technologies for continuous hydrogen content and temperature monitoring during EAF and HPSR operations. Several options have been identified, and both lab- and pilot-scale tests are underway to assess their performance.
DC9 applied Optical Emission Spectroscopy (OES) for in-situ plasma monitoring during the hydrogen plasma smelting reduction (HPSR) of ilmenite, pure and fluxed chromium oxides Cr2O₃ reduction. Data analysis revealed the temporal evolution of plasma elements and enabled plasma temperature estimation, offering real-time insights into the reduction process. The analysis of chromium oxide trials is ongoing and will provide valuable information for the process conditions during HPSR.
For sustainability assessment, DC10 selected NG-DRI-EAF as the benchmark and compiled relevant literature data. This serves as a reference for comparing the hydrogen-based processes developed by other DCs. Life cycle costing is being studied, and economic data are being gathered. A consequential life cycle assessment will be conducted to evaluate potential market shifts due to hydrogen-based steelmaking.
It is early at this stage of the project implementation.