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Electrometallurgy Today, 2026, №03

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2026 №03 (03) 2026 №03 (05)

Electrometallurgy Today 2026 №03


"Suchasna Elektrometallurgiya" (Electrometallurgy Today), 2026, #3, 24-31 pages

Prospects for the application of plasma technologies in hydrogen-based iron reduction

V.O. Shapovalov1, D.M. Zhyrov1, V.G. Mogylatenko1,2, F.K. Biktagirov1, V.R. Burnashev1

1E.O. Paton Electric Welding Institute of the NAS of Ukraine 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: vmogilatenko@gmail.com
2National Technical University of Ukraine «Igor Sikorsky Kyiv Polytechnic Institute» 37 Prospect Beresteiskyi, 03056, Kyiv, Ukraine

Abstract
This paper examines the prospects of applying plasma technologies to hydrogen-based iron reduction in the context of ferrous metallurgy decarbonization. The thermodynamic and kinetic features of hydrogen reduction of iron oxides are analyzed based on Fe–O–H phase diagrams and temperature dependences of Gibbs free energy. It is shown that the stage of reduction from wüstite to metallic iron is the most energetically and kinetically unfavorable under conventional solid-state reduction conditions. The advantages of hydrogen plasma application are substantiated, which owing to formation of activated hydrogen species significantly intensifies the reduction reactions and reduces diffusion limitations. Liquid-phase hydrogen plasma reduction processes and the challenges associated with their industrial scale-up, including electrode erosion, refractory degradation, and electric arc stability, are considered. A hybrid technological route combining solid-state hydrogen reduction with plasma-assisted final reduction is proposed as the most energy-efficient and technologically feasible pathway for implementing hydrogen metallurgy on an industrial scale.30 Ref., 3 Fig.
Keywords: iron, steel industry decarbonization, hydrogen reduction, hydrogen plasma reduction, iron oxides, hybrid technological routes, Fe–O–H thermodynamics, iron reduction kinetics

Received: 11.05.2026
Received in revised form: 17.06.2026
Accepted: 14.07.2026
Posted online: 24.07.2026

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Suggested Citation

V.O. Shapovalov, D.M. Zhyrov, V.G. Mogylatenko, F.K. Biktagirov, V.R. Burnashev (2026) Prospects for the application of plasma technologies in hydrogen-based iron reduction. Electrometallurgy Today, 03, 24-31.