Prevention of sticking in H2 fluidised bed DRI production

R&D Focus Areas:
Industrial heat processes

Lead Organisation:
University of Newcastle

Status:
Active

Start date:
October 2023

Completion date:
September 2026

Key contacts:
Lead Investigator: Associate Professor Tom Honeyands (University of Newcastle):  tom.a.honeyands@newcastle.edu.au

Funding:
Heavy Industry Low-Carbon Transition CRC

Total project cost:
AUD$2,762,162 (cash and in-kind contributions)

Project summary description:
The steel industry needs to de-carbonise, with a likely low carbon route being the production of steel from hydrogen DRI using existing or emerging fluidised bed processes (CIRCORED, HYFOR, HYREX), followed by melting in an electric furnace.

At present Australian iron ores are utilised in the traditional blast furnace ironmaking process, with no current supply to DRI processes. The suitability of Australian ore fines and magnetite concentrates as mined/after beneficiation needs to be assessed in fluidised bed processes with particular emphasis on maximising operating temperature while preventing sticking. However, the reduction kinetics of Australian ore fines in a fluidised bed reactor are relatively unexplored.

The aims of the project are to:

• Investigate the fluidised bed production of DRI from South Australian and Pilbara hematite-goethite fine iron ores over a range of low temperature operating conditions and anti-sticking measures including the use of anti-sticking additives (e.g. MgO, CaO, lime kiln dust) as well as varying fluidising gas composition (i.e. inert gases to increase gas density) and/or fluidisation velocity (i.e. fluidisation regime)
• To experimentally investigate the reducibility behaviour of Australian ores using hydrogen gas atmosphere in the Thermogravimetric Analyser (TGA)
• To extract kinetics during low-temperature operation of fluidised bed reduction experiments
• Gain a fundamental understanding about the mechanism underpinning the sticking phenomenon in fluidised beds and assess the role anti-sticking additives such as MgO in alleviating its impact
• Measure the wall friction and internal angles of friction for DRI produced with anti-sticking additives to inform materials handling system design

Related publications and key links:
To be advised.

Higher degree studies supported:
To be advised.

 

Reviewed: July 2024