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Iron- and steelmaking cause ~7% of the global CO2 emissions, due to the use of carbon for the reduction of iron ores. Replacing carbon by hydrogen as the reductant offers a pathway to reduce emissions. However, production of hydrogen using…

With 1.85 billion tons produced per year, steel is the most important material class in terms of volume and environmental impact. While steel is a sustainability enabler, for instance through lightweight design, magnetic devices, and…

In an effort to develop breakthrough technologies that enable drastic reduction in CO2 emissions from steel industry (ULCOS project), the reduction of iron ore by pure hydrogen in a direct reduction shaft furnace was investigated. After…

Materials Science · Physics 2014-02-10 Andrea Ranzani Da Costa , D. Wagner , Fabrice Patisson

To reduce the emission of greenhouse gases by the steel industry, particularly for ironmaking, the production of DRI (Direct Reduced Iron) using hydrogen as the reducing gas instead of carbon monoxide is being considered. In this context,…

Materials Science · Physics 2008-12-18 D. Wagner , O. Devisme , F. Patisson , D. Ablitzer

Steelmaking contributes 8% to the total CO2 emissions globally, primarily due to coal-based iron ore reduction. Clean hydrogen-based ironmaking has variable performance because the dominant gas-solid reduction mechanism is set by the…

Direct reduction of iron using hydrogen-rich gas is rapidly emerging as a key strategy for green steel production. This process involves complex, multiscale phenomena, encompassing solid-state phase transformations and gas transport through…

Materials Science · Physics 2025-08-05 Ömer K. Büyükuslu , Fabrice Yang , Dierk Raabe , Moritz to Baben , Anna L. Ravensburg

Gas-solid reactions are cornerstones of many catalytic and redox processes that will underpin the energy and sustainability transition. The specific case of hydrogen-based iron oxide reduction is the foundation to render the global steel…

Materials Science · Physics 2023-01-18 Ayman A. El-Zoka , Leigh T. Stephenson , Se-Ho Kim , Baptiste Gault , Dierk Raabe

Fossil-free ironmaking is indispensable for reducing massive anthropogenic CO2 emissions in the steel industry. Hydrogen-based direct reduction (HyDR) is among the most attractive solutions for green ironmaking, with high technology…

The reduction of ferromanganese ores into metallic feedstock is an energy-intensive process with substantial carbon emissions, necessitating sustainable alternatives. Hydrogen-based pre-reduction of manganese-rich ores offers a low-emission…

Materials Science · Physics 2025-07-15 Anurag Bajpai , Barak Ratzker , Shiv Shankar , Dierk Raabe , Yan Ma

Kinetic understanding of hydrogen co-reduction of multinary and multi-phase oxides is of interest for enhancing sustainability of alloy production and transition to a hydrogen-based economy. Benefits include decrease in energy consumption,…

Materials Science · Physics 2026-03-17 Emmanuel Uwayezu , Shaolou Wei , Yujiao Li , Johannes D. Bartl , Dierk Raabe , Alfred Ludwig

Hydrogen-based direct reduction offers a sustainable pathway to decarbonize the metal production industry. However, stable metal oxides, like Cr$_2$O$_3$, are notoriously difficult to reduce, requiring extremely high temperatures (above…

The effect of silica-promotion on the reduction of iron oxides in hydrogen was investigated using in situ X-ray diffraction and aberration-corrected transmission electron microscopy to understand the mechanism of reduction and the identity…

Materials Science · Physics 2021-05-13 M. J. Coombes , E. J. Olivier , E. Prestat , S. J. Haigh , E. du Plessis , J. H. Neethling

In this paper, we propose a concept to utilise Carbon-dioxide for Steel-Making and would like to name it after the first author as OSRAM-CO$_2$-SM process. We found in our lab experiments that the carbon content in high-carbon ferro-chrome…

Materials Science · Physics 2015-07-15 O. Seetha Ramayya , O. S. K. S. Sastri

The co-reduction of metal oxide mixtures using hydrogen as a reductant in conjunction with compaction and sintering of the evolving metallic blends offers a promising alternative toward sustainable alloy production through a single,…

Materials Science · Physics 2026-01-21 Shiv Shankar , Barak Ratzker , Yan Ma , Dierk Raabe

Iron disproportionation reactions in mantle silicates can produce metallic iron that drives Earth's deep mantle toward metal saturation under reduced conditions. Subducting slabs transport hydrated silicates to these depths, where…

Geophysics · Physics 2026-05-13 Junjie Dong , Lars P Stixrude , Paul D Asimow , Jie Li

The hydrogen-based route could be a valuable way to produce steel considering its low carbon dioxide emissions. In ULCOS, it is regarded as a long-term option, largely dependent on the emergence of a hydrogen economy. To anticipate its…

Materials Science · Physics 2009-11-26 Andrea Ranzani Da Costa , D. Wagner , F. Patisson , D. Ablitzer

Co-reduction of multicomponent oxides with hydrogen provides a carbon-neutral approach toward sustainable alloy design. Herein, we investigate the hydrogen-based direct reduction, using in-situ high-energy X-ray diffraction of two precursor…

Materials Science · Physics 2025-10-09 Shiv Shankar , Barak Ratzker , Claudio Pistidda , Dierk Raabe , Yan Ma

As a result of the 2021 United Nations Climate Change Conference (COP26), several countries committed to phasing down coal electricity as soon as possible, deactivating hundreds of power plants in the near future. CO$_2$-free electricity…

Recycled aluminum alloys are pivotal for sustainable manufacturing, offering strength, durability, and environmental advantages. However, the presence of iron (Fe) impurities poses a major challenge, undermining their properties and…

Materials Science · Physics 2023-10-11 Lu Jiang , Ross. K. W. Marceau , Thomas Dorin

Storing electrical energy for long periods and transporting it over long distances is an essential task of the necessary transition to a CO$_2$-free energy economy. An oxidation-reduction cycle based on iron and its oxides represents a very…

Systems and Control · Electrical Eng. & Systems 2023-03-28 Johannes Janicka , Paulo Debiagi , Arne Scholtissek , Andreas Dreizler , Bernd Epple , Reiner Pawellek , Alexander Maltsev , Christian Hasse
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