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<p>The World Steel Association forecasts a 30% rise in global steel demand by 2050 compared to 2022, driven by economic growth, urbanization, and rising consumption. However, the steel industry emitted approximately 2.6 gigatonnes of CO<sub>2</sub> in 2019, highlighting the urgent need for environmentally friendly steel production technologies to align with the Paris Agreement targets. The direct reduction-electric furnace process, utilizing hydrogen gas as a reducing agent, offers a practical near-term solution. Additionally, Hydrogen Plasma Smelting Reduction (HPSR) presents a promising approach for sustainable steel production, enabling single-step direct steelmaking with high product quality by effectively removing impurities like phosphorus and sulfur, reducing environmental impact, and ensuring rapid processing. While previous studies focused on hematite, this study investigates HPSR for iron production from limonite (goethite) ore. Results show that extending the reduction time from 5 to 120&#xa0;s enhances the reduction degree, as evidenced by SEM–EDS analysis. Complete conversion of 5&#xa0;g of limonite ore to metallic iron was achieved within 2&#xa0;min using an Ar-80%H<sub>2</sub> gas mixture at 5 L/min. SEM–EDS analysis confirmed an average iron purity exceeding 99%. These findings validate HPSR’s efficiency and potential as a sustainable alternative to conventional steelmaking.</p> Graphical Abstract <p></p>

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Fast Iron Production from Limonite Iron Ore in a Lab-Scale Hydrogen Plasma Smelting Reduction (HPSR) Reactor

  • 期刊论文

  • 发表日期：

    2025年9月23日

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  • Baihaqi Hakim,
  • M. Akbar Rhamdhani,
  • Taufiq Hidayat,
  • Yopi Hendrawan,
  • Zulfiadi Zulhan

摘要

The World Steel Association forecasts a 30% rise in global steel demand by 2050 compared to 2022, driven by economic growth, urbanization, and rising consumption. However, the steel industry emitted approximately 2.6 gigatonnes of CO2 in 2019, highlighting the urgent need for environmentally friendly steel production technologies to align with the Paris Agreement targets. The direct reduction-electric furnace process, utilizing hydrogen gas as a reducing agent, offers a practical near-term solution. Additionally, Hydrogen Plasma Smelting Reduction (HPSR) presents a promising approach for sustainable steel production, enabling single-step direct steelmaking with high product quality by effectively removing impurities like phosphorus and sulfur, reducing environmental impact, and ensuring rapid processing. While previous studies focused on hematite, this study investigates HPSR for iron production from limonite (goethite) ore. Results show that extending the reduction time from 5 to 120 s enhances the reduction degree, as evidenced by SEM–EDS analysis. Complete conversion of 5 g of limonite ore to metallic iron was achieved within 2 min using an Ar-80%H2 gas mixture at 5 L/min. SEM–EDS analysis confirmed an average iron purity exceeding 99%. These findings validate HPSR’s efficiency and potential as a sustainable alternative to conventional steelmaking.

Graphical Abstract