Reduction kinetics of hematite powder using argon/hydrogen plasma with prospects for near net shaping of sustainable iron

Direct reduction of iron ore using hydrogen plasma is being explored as a potential solution to decarbonize the iron and steel sector. The current state-of-the-art utilized hydrogen plasma from Ar + 10% H2 shielding gas but had slow reduction kinetics. Here we show that using hematite in a powder form, easily obtainable from beneficiated ore, results in 10× faster kinetics using Ar + 2%H2 shielding gas compared to the current state-of-the art. The increased kinetics using powders and a dilute hydrogen concentration can enable the use of advanced manufacturing techniques like blown powder directed energy deposition using plasma tungsten arc welding torch to manufacture near net shape components directly from the ore concentrates, thereby reducing the downstream processes like rolling, forging, and machining and further aid in the sectorial decarbonization efforts.