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Abrar Taimullah, Izzul Islam, Dale Tandersen, Ulil Amri Nizhamul, Taufiq Hidayat, Yerbolat Makhambetov, Yopi Hendrawan, and Zulfiadi Zulhan, Direct and sustainable stainless steelmaking from nickel and chromite ores by hydrogen plasma smelting reduction, Int. J. Miner. Metall. Mater., (2025). https://doi.org/10.1007/s12613-024-3068-4
Abrar Taimullah, Izzul Islam, Dale Tandersen, Ulil Amri Nizhamul, Taufiq Hidayat, Yerbolat Makhambetov, Yopi Hendrawan, and Zulfiadi Zulhan, Direct and sustainable stainless steelmaking from nickel and chromite ores by hydrogen plasma smelting reduction, Int. J. Miner. Metall. Mater., (2025). https://doi.org/10.1007/s12613-024-3068-4
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基于氢等离子体熔炼还原技术直接利用镍矿和铬铁矿生产不锈钢

摘要: 不锈钢因其优异的性能和广泛的应用而闻名,但传统生产工艺通常需要多个阶段,并且使用化石基碳质还原剂,导致大量二氧化碳排放。本研究提出了一种新颖、可持续且高效的方法——氢等离子熔融还原技术,可直接利用红土镍矿和铬铁矿生产不锈钢。研究旨在探讨矿石配比对AISI 300系列不锈钢生产的影响,并通过热力学计算和实验研究评估还原过程随时间的变化规律。研究结果表明,随着炉料中铬铁矿比例的增加,金属中铬含量升高而镍含量降低,同时氧化物中Cr2O3 和 Al2O3的含量也随之增加。当炉料由30%铬铁矿和70%煅烧镍矿组成时,可获得较优的AISI 300不锈钢成分。在氢等离子体处理180秒后,所得金属中Fe、Cr、Ni和Si的质量分数分别为62.95%、19.37%、11.83%和0.72%。在熔融还原过程中,几乎所有的NiO化合物在60秒内被还原为金属Ni,而FeO化合物则在120秒内几乎完全还原为金属Fe。经过120秒的还原处理,即可成功制备出AISI 300系列不锈钢,其Fe、Cr、Ni和Si质量分数分别达到64.36%、21.92%、10.08%和0.61%。然而,由于渣中Cr₂O₃含量仍较高(15.52%),工艺优化仍有较大潜力。这种超快速、直接的生产方法具有显著的优势,有望通过减少环境影响和提高工艺效率,彻底改变不锈钢生产方式。特别是,该方法可完全省去传统不锈钢冶炼中所需的氩氧脱碳炉(AOD)和真空氧脱碳炉(VOD)设备。

 

Direct and sustainable stainless steelmaking from nickel and chromite ores by hydrogen plasma smelting reduction

Abstract: Stainless steel, known for its exceptional properties and diverse applications, conventionally requires a multistage process that generates considerable CO2 emissions by using fossil-based carbon reductants. This study investigated hydrogen plasma smelting reduction as a novel, sustainable, and efficient method for producing stainless steel directly from lateritic nickel and chromite ores. The research aimed to examine the effect of ore proportion on AISI 300 series stainless steel production and assess the reduction process over time through thermochemical calculations and experimental studies. Results showed that increasing the proportion of chromite ore in the feed raises Cr content and reduces Ni content in metals while increasing Cr2O3 and Al2O3 content in oxides. A briquette comprising 30wt% chromite ore and 70wt% calcined nickel ore yields better results for AISI 300 stainless steel, with Fe, Cr, Ni, and Si content of 62.95wt%, 19.37wt%, 11.83wt%, and 0.72wt%, respectively, after 180 s of hydrogen plasma exposure. Nearly all NiO compounds are converted into Ni after 60 s of smelting reduction, whereas FeO compounds are almost fully converted into Fe after 120 s of smelting reduction. AISI 300 series stainless steel is successfully produced after 120 s of reduction, achieving Fe, Cr, Ni, and Si content of 64.36wt%, 21.92wt%, 10.08wt%, and 0.61wt%, respectively. Process optimization remains promising because the Cr2O3 content in the slag is still relatively high at 15.52wt%. This ultrafast and direct production method holds considerable potential to transform stainless steel production by reducing environmental impact and enhancing process efficiency. Specifically, the method eliminates the use of an argon oxygen decarburization converter and vacuum oxygen decarburization in stainless steelmaking.

 

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