Hydrogen Plasma Reduction for Steelmaking and Circular Economy

Project Information

H2PlasmaRed

Grant agreement ID: 101138228

DOI

10.3030/101138228

EC signature date 4 December 2023

Start date 1 January 2024

End date 31 December 2027

Funded under

• Digital, Industry and Space

Total cost

€ 6 374 937,50

EU contribution

€ 5 997 965,00

Coordinated by

OULUN YLIOPISTO
Finland

Periodic Reporting for period 1 - H2PlasmaRed (Hydrogen Plasma Reduction for Steelmaking and Circular Economy)

Reporting period: 2024-01-01 to 2025-06-30

Summary of the context and overall objectives of the project

The main objective of H2PlasmaRed is to develop hydrogen plasma smelting reduction (HPSR) technology for the reduction of iron ores and steelmaking sidestreams to meet the targets of the European Green Deal for reducing CO2 emissions and supporting the circular economy in the steel industry across Europe. Our ambition is to introduce a near CO2-free reduction process to support the goal of the Paris Agreement - a 90% reduction in the carbon intensity of steel production by 2050. To achieve this, H2PlasmaRed will develop HPSR from TRL5 to TRL7 by demonstrating the HPSR in a pilot-HPSR reactor (hundred-kilogram-scale) that is an integrated part of a steel plant, and in a pilot-scale DC electric arc furnace (EAF, 5-ton scale) by retrofitting the existing furnace. The project's end goal is to establish a way to upscale the process from pilot-scale into industrial practice. To support this goal, the novel sensors and models developed and implemented in the project are used for HPSR process optimization from a reduction, resource, and energy efficiency standpoint.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project successfully initiated retrofitting and methodological groundwork essential for the pilot-HPSR plant demonstration trials that will be conducted until the end of 2025. The retrofitting and modification work on the 5-ton pilot DC EAF have progressed as planned, and the demonstration campaign is expected to be completed in 2026. Several supporting laboratory trials have been performed, and the optimal operation parameters have been evaluated via experimental and theoretical approaches. Iron ores and sidestream materials have been provided by project partners both for laboratory and pilot trials.

Numerous laboratory-scale HPSR trials have established procedures both for processing various iron ores and sidestreams, and how to implement in situ analysis methods, such as optical emission spectroscopy. Project’s modeling work, on the other hand, has focused on developing a first of its kind dynamic mathematical HPSR model, support for hydrogen addition into retrofitted EAF, and bridging the gap between laboratory experiments and theoretical models. The results have been reported and disseminated in projects’ public deliverables, conference presentations, and open access peer-reviewed publications.

To address the environmental footprint, process effectiveness, and competitiveness, the life cycle assessment & cost (LCA & TEA) analyses have been started, the benchmark processes have been defined, and HPSR system boundaries and critical performance factors have been identified. In addition, potential uncertainties and future scenarios have been defined. Data from H2PlasmaRed’s laboratory trials have been used as a reference, supported by thorough discussions with pilot-HPSR personnel regarding the scalability factors. Process flow diagrams of various reactors were drawn accordingly. Environmental and techno-economic indicators which will be used to communicate the results were selected. To determine the risks associated with the use of critical raw materials within the HPSR value chain, criticality analysis is being conducted.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The project’s activities have enabled the retrofitting and modifications of the pilot-HPSR reactor and the pilot-scale DC EAF, which both will provide valuable information about the scalability of HPSR and usage of existing furnaces for HPSR purposes via retrofitting. To support this work, the developed models have presented excellent agreement with experimental results, giving unprecedented insight into the HPSR process and H2 addition into an EAF. In terms of process monitoring, the optical emissions related to the reduction degree of simple hematite system have been identified together with influence of gangue elements to the plasma characteristics. H2PlasmaRed’s results are expected to reach an audience and uptake beyond only the HPSR topics, since the results will benefit the electricity-based EAF processes as a whole due to many similarities in these plasma-based processes.

H2PlasmaRed project logo

Visit to the K1 pilot-HPSR reactor during a General Assembly meeting in Austria (February 2025)

H2PlasmaRed consortium logo picture

Typical H2-plasma processing of iron ore sample in laboratory