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Authors = Olivier Mirgaux

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19 pages, 2806 KiB  
Article
Operating Solutions to Improve the Direct Reduction of Iron Ore by Hydrogen in a Shaft Furnace
by Antoine Marsigny, Olivier Mirgaux and Fabrice Patisson
Metals 2025, 15(8), 862; https://doi.org/10.3390/met15080862 - 1 Aug 2025
Viewed by 275
Abstract
The production of iron and steel plays a significant role in the anthropogenic carbon footprint, accounting for 7% of global GHG emissions. In the context of CO2 mitigation, the steelmaking industry is looking to potentially replace traditional carbon-based ironmaking processes with hydrogen-based [...] Read more.
The production of iron and steel plays a significant role in the anthropogenic carbon footprint, accounting for 7% of global GHG emissions. In the context of CO2 mitigation, the steelmaking industry is looking to potentially replace traditional carbon-based ironmaking processes with hydrogen-based direct reduction of iron ore in shaft furnaces. Before industrialization, detailed modeling and parametric studies were needed to determine the proper operating parameters of this promising technology. The modeling approach selected here was to complement REDUCTOR, a detailed finite-volume model of the shaft furnace, which can simulate the gas and solid flows, heat transfers and reaction kinetics throughout the reactor, with an extension that describes the whole gas circuit of the direct reduction plant, including the top gas recycling set up and the fresh hydrogen production. Innovative strategies (such as the redirection of part of the bustle gas to a cooling inlet, the use of high nitrogen content in the gas, and the introduction of a hot solid burden) were investigated, and their effects on furnace operation (gas utilization degree and total energy consumption) were studied with a constant metallization target of 94%. It has also been demonstrated that complete metallization can be achieved at little expense. These strategies can improve the thermochemical state of the furnace and lead to different energy requirements. Full article
(This article belongs to the Special Issue Recent Developments and Research on Ironmaking and Steelmaking)
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14 pages, 2153 KiB  
Article
Environmental Performances of Various CCU Options in the Framework of an Integrated Chemical Plant
by Olivier Mirgaux, Hélène Anselmi and Fabrice Patisson
Membranes 2021, 11(11), 815; https://doi.org/10.3390/membranes11110815 - 26 Oct 2021
Cited by 5 | Viewed by 2505
Abstract
Several carbon capture processes are investigated to separate a part of the CO2 contained in the flue gas of a coal-fired power plant located in a chemical integrated plant, with the objective of using it as a raw material in a production [...] Read more.
Several carbon capture processes are investigated to separate a part of the CO2 contained in the flue gas of a coal-fired power plant located in a chemical integrated plant, with the objective of using it as a raw material in a production process. The expected results are to reduce the impact on global warming potential (GWP) and to increase the productivity of the plant. The study is based on the modelling of the combination of systems in the plant using a process simulation software and using life cycle assessment to evaluate both technical feasibility and environmental aspects. Models for the power plant, the production processes, amine chemical absorption, membrane separation and adsorption on activated coal are developed and validated against industrial and literature data. The life cycle inventory is obtained from the mass and energy balances given by the systems model. A first set of calculations is launched with a high purity requirement for the CO2 stream (95%) recycled into the process. Those calculations show a 12% increase in productivity for the chemical process considered, but result in no significant gain in terms of GWP. Conversely, scenarios with a lower CO2 purity (40%) show a drop around 9% of the impacts on GWP using membrane separation and activated coal adsorption, while keeping the other impacts at about the same level. Full article
(This article belongs to the Special Issue Carbon Dioxide Capture Based on Polymeric Membrane)
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15 pages, 7148 KiB  
Article
Hydrogen Ironmaking: How It Works
by Fabrice Patisson and Olivier Mirgaux
Metals 2020, 10(7), 922; https://doi.org/10.3390/met10070922 - 9 Jul 2020
Cited by 199 | Viewed by 45628
Abstract
A new route for making steel from iron ore based on the use of hydrogen to reduce iron oxides is presented, detailed and analyzed. The main advantage of this steelmaking route is the dramatic reduction (90% off) in CO2 emissions compared to [...] Read more.
A new route for making steel from iron ore based on the use of hydrogen to reduce iron oxides is presented, detailed and analyzed. The main advantage of this steelmaking route is the dramatic reduction (90% off) in CO2 emissions compared to those of the current standard blast-furnace route. The first process of the route is the production of hydrogen by water electrolysis using CO2-lean electricity. The challenge is to achieve massive production of H2 in acceptable economic conditions. The second process is the direct reduction of iron ore in a shaft furnace operated with hydrogen only. The third process is the melting of the carbon-free direct reduced iron in an electric arc furnace to produce steel. From mathematical modeling of the direct reduction furnace, we show that complete metallization can be achieved in a reactor smaller than the current shaft furnaces that use syngas made from natural gas. The reduction processes at the scale of the ore pellets are described and modeled using a specific structural kinetic pellet model. Finally, the differences between the reduction by hydrogen and by carbon monoxide are discussed, from the grain scale to the reactor scale. Regarding the kinetics, reduction with hydrogen is definitely faster. Several research and development and innovation projects have very recently been launched that should confirm the viability and performance of this breakthrough and environmentally friendly ironmaking process. Full article
(This article belongs to the Special Issue Challenges and Prospects of Steelmaking Towards the Year 2050)
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12 pages, 3158 KiB  
Article
Carbon Impact Mitigation of the Iron Ore Direct Reduction Process through Computer-Aided Optimization and Design Changes
by Rami Béchara, Hamzeh Hamadeh, Olivier Mirgaux and Fabrice Patisson
Metals 2020, 10(3), 367; https://doi.org/10.3390/met10030367 - 12 Mar 2020
Cited by 24 | Viewed by 10926
Abstract
The steel industry is known to have one of the highest environmental impacts on the industrial sector, especially in terms of CO2 emissions. The so-called direct reduction route, which makes use of reformed natural gas along with top gas recycling to reduce [...] Read more.
The steel industry is known to have one of the highest environmental impacts on the industrial sector, especially in terms of CO2 emissions. The so-called direct reduction route, which makes use of reformed natural gas along with top gas recycling to reduce iron oxide pellets with H2 and CO, is responsible for lower CO2 emissions than the classic blast furnace route and is currently under development. The present article focuses on the direct reduction process and discusses means to further decrease the CO2 emission rate. A set of 10 operating parameters were simultaneously changed according to computer-aided optimization. The results provide about 15% improvement over original emissions for comparable output values. Full article
(This article belongs to the Special Issue Mathematical Modeling and Simulation in Ironmaking and Steelmaking)
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16 pages, 4076 KiB  
Article
Detailed Modeling of the Direct Reduction of Iron Ore in a Shaft Furnace
by Hamzeh Hamadeh, Olivier Mirgaux and Fabrice Patisson
Materials 2018, 11(10), 1865; https://doi.org/10.3390/ma11101865 - 1 Oct 2018
Cited by 101 | Viewed by 15545
Abstract
This paper addresses the modeling of the iron ore direct reduction process, a process likely to reduce CO2 emissions from the steel industry. The shaft furnace is divided into three sections (reduction, transition, and cooling), and the model is two-dimensional (cylindrical geometry [...] Read more.
This paper addresses the modeling of the iron ore direct reduction process, a process likely to reduce CO2 emissions from the steel industry. The shaft furnace is divided into three sections (reduction, transition, and cooling), and the model is two-dimensional (cylindrical geometry for the upper sections and conical geometry for the lower one), to correctly describe the lateral gas feed and cooling gas outlet. This model relies on a detailed description of the main physical–chemical and thermal phenomena, using a multi-scale approach. The moving bed is assumed to be comprised of pellets of grains and crystallites. We also take into account eight heterogeneous and two homogeneous chemical reactions. The local mass, energy, and momentum balances are numerically solved, using the finite volume method. This model was successfully validated by simulating the shaft furnaces of two direct reduction plants of different capacities. The calculated results reveal the detailed interior behavior of the shaft furnace operation. Eight different zones can be distinguished, according to their predominant thermal and reaction characteristics. An important finding is the presence of a central zone of lesser temperature and conversion. Full article
(This article belongs to the Special Issue Design of Alloy Metals for Low-Mass Structures)
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18 pages, 5517 KiB  
Article
Optimization of the Iron Ore Direct Reduction Process through Multiscale Process Modeling
by Rami Béchara, Hamzeh Hamadeh, Olivier Mirgaux and Fabrice Patisson
Materials 2018, 11(7), 1094; https://doi.org/10.3390/ma11071094 - 27 Jun 2018
Cited by 77 | Viewed by 12769
Abstract
Iron ore direct reduction is an attractive alternative steelmaking process in the context of greenhouse gas mitigation. To simulate the process and explore possible optimization, we developed a systemic, multiscale process model. The reduction of the iron ore pellets is described using a [...] Read more.
Iron ore direct reduction is an attractive alternative steelmaking process in the context of greenhouse gas mitigation. To simulate the process and explore possible optimization, we developed a systemic, multiscale process model. The reduction of the iron ore pellets is described using a specific grain model, reflecting the transformations from hematite to iron. The shaft furnace is modeled as a set of interconnected one-dimensional zones into which the principal chemical reactions (3-step reduction, methane reforming, Boudouard and water gas shift) are accounted for with their kinetics. The previous models are finally integrated in a global, plant-scale, model using the Aspen Plus software. The reformer, scrubber, and heat exchanger are included. Results at the shaft furnace scale enlighten the role of the different zones according to the physico-chemical phenomena occurring. At the plant scale, we demonstrate the capabilities of the model to investigate new operating conditions leading to lower CO2 emissions. Full article
(This article belongs to the Special Issue Design of Alloy Metals for Low-Mass Structures)
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