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Numerical Study on the Effect of Material Parameters and Process Conditions on the Melting Time of Hydrogen-Direct Reduced Iron
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Process. SSAB AB, Grp Res & Innovat, Klarabergsviadukten 70, D6Box 70, S-10121 Stockholm, Sweden; KTH Royal Inst Technol, Unit Proc, Brinellvagen 23, Stockholm, Sweden.ORCID iD: 0000-0002-8313-8667
SSAB AB, Grp Res & Innovat, Klarabergsviadukten 70, D6Box 70, S-10121 Stockholm, Sweden; Hybrit Dev AB, Grp Res & Innovat, Klarabergsviadukten 70, E6, S-10121 Stockholm, Sweden.
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering, Process.ORCID iD: 0000-0003-4384-7984
2025 (English)In: Metallurgical and materials transactions. B, process metallurgy and materials processing science, ISSN 1073-5615, E-ISSN 1543-1916Article in journal (Refereed) Published
Abstract [en]

The melting time of hydrogen direct reduced iron pellets (H-DRI) is a limiting factor for productivity in electric arc furnace steelmaking for fossil-free steel. The effect of material and process parameters on melting time was evaluated under laminar conditions using computational fluid dynamics. The study found that the melting time of H-DRI is primarily determined by the properties of the slag bath and its movement, with H-DRI properties being secondary. The shortest melting time was achieved by combining high temperature (> 1950 K), high viscosity foam (> 0.1 Pa s), and high thermal conductivity (> 0.9 W m(-1) K-1) of the slag. With optimal conditions a melting time of 4.56 seconds was observed for a 10 mm diameter H-DRI, although thicker slag with lower terminal velocity was shown to have greater potential for complete melting of the pellet within the slag. Decreasing H-DRI porosity from 65 to 50 pct with maintained mass increases melting time by 4 pct and increasing initial temperature from 300 K to 1100 K decreases melting time by 20 pct. Furthermore, an increased bath temperature from 1850 K to 1950 K results in approximately 55 pct reduction in melting time due to increased superheat. Forced convection in the system was also found to significantly reduce the melting time for H-DRI.

Place, publisher, year, edition, pages
Springer Nature , 2025.
National Category
Metallurgy and Metallic Materials
Identifiers
URN: urn:nbn:se:kth:diva-362963DOI: 10.1007/s11663-025-03504-zISI: 001457901900001Scopus ID: 2-s2.0-105001737023OAI: oai:DiVA.org:kth-362963DiVA, id: diva2:1956138
Note

QC 20250505

Available from: 2025-05-05 Created: 2025-05-05 Last updated: 2025-05-05Bibliographically approved

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Svantesson, JonasErsson, Mikael

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