The Paton Welding Journal, 2025, №09

2025 №09 (05)

DOI of Article 10.37434/tpwj2025.09.06

2025 №09 (01)

---

The Paton Welding Journal, 2025, #9, 46-50 pages

Industrial technologies of direct reduction of iron from ore raw materials and prospects for the use of hydrogen in reduction processes

V.O. Shapovalov¹, V.G. Mogilatenko², D.M. Zhyrov¹, V.R. Burnashev¹

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

Abstract
A significant reduction in carbon dioxide emissions in metallurgy can be achieved by using a mixture of carbon monoxide and hydrogen for iron reduction. Industrial technologies of direct reduction of iron from ore raw materials are considered. Reactions in reduction processes are analyzed. It is shown that at temperatures above 800 °C, hydrogen is a more effective reducing agent than carbon monoxide. Ways of improving the energy efficiency of existing technologies are demonstrated. It is shown that today the main technology of iron reduction from ore is reduction in shaft furnaces using a mixture of carbon monoxide and hydrogen. A generalized scheme of direct reduced iron production is presented. It is shown that in the production of direct reduced iron, the use of hydrogen makes it possible to halve carbon dioxide emissions compared to the use of natural gas, provided that electricity is generated from renewable sources or at nuclear power plants. It is concluded that a promising way to eliminate carbon emissions during the reduction of iron from ore or pellets is the use of plasma technologies.
Keywords: direct reduced iron, hydrogen, shaft furnace, carbon dioxide emissions

Received: 26.05.2025
Received in revised form: 05.08.2025
Accepted: 17.09.2025

References

1. Isnaldi, R. Souza Filho, Hauke Springer et al. (2022) Green steel at its crossroads: hybrid hydrogen-based reduction of iron ores. https://arxiv.org/ftp/arxiv/papers/2201/2201.13356.pdf
2. Giovannini, S. (2020) 50 shades of (grey and blue and green) hydrogen puzzled by all the colours and argon? This article is for you. Energy Cities. https://energy-cities.eu
3. Kolisnichenko, V. (2023) Global production of cast iron grew by 1.1 % in 2023. https://gmk.center/ua/news/globalne-virobnictvo-chavunu-u-2023-roci-zroslo-na-1-1-r-r/
4. (2023) World Direct Reduction Statistics. https://www.midrex.com/wp-content/uploads/MidrexSTATSBook2023.pdf
5. The MIDREX Process — The world’s most reliable and productive Direct Reduction Technology. https://www.midrex.com/wp-content/uploads/MIdrex_Process_Brochure_4-12-18.pdf
6. Pauluzzi, D., Giraldo, A.H., Zugliano, A. et al. (2021) CFD Study of an Energiron Reactor Fed With Different Concentrations of Hydrogen. AISTech Iron & Steel Technology. https://www.energiron.com/wp-content/uploads/2021/09/MARCH-2021_AIST-IRON-STEEL-TECHNOLOGY.pdf
7. Pauluzzi, D., Martinis, A. Sustainable decrease of CO2 Emissions in the Steelmaking Industry by Means of the Fine Ore Direct Reduction Circored Energiron Direct Reduction Technology. https://www.researchgate.net/publication/329059091_SUSTAINABLE _DECREA SE_OF_CO2_EM ISSIONS_IN_THE_STEELMA KING_INDUSTRY_BY_MEANS_OF_THE_ENERGIRON_DIRECT_REDUCTION_TECHNOLOGY
8. https://www.metso.com/globalassets/pdfs-and-other-downloads/circored---fine-ore-direct-reduction.pdf
9. Pochtariov, O.V. (2024) Improvement of technological means of quality control of iron ore raw materials in underground mining: Syn. of Thesis for PhD. Kryvorizh. Nats. Un-t. Kryvyi Rig.
10. Bondarenko, B.I., Shapovalov, V.A., Garmash, N.I. (2003) Theory and technology of coke-free metallurgy. Kyiv, Naukova Dumka
11. Gubin, G.V., Piven, V.O. (2010) Modern commercial methods of iron coke-free metallurgy. Kryvyi Rig.
12. Hotlink System. Benefits of Charging Hot Dri (HDRI). https://www.midrex.com/wp-content/uploads/Hot_Transport_-_HOTLINK.pdf
13. Zhyrov, D.M. (2011) Peculiarities of the plasma-arc liquid- phase reduction of iron with gases: Syn. of Thesis for Cand. of Tech. Sci. Degree. Kyiv, PWI.
14. Mogylatenko, V.G., Shapovalov, V.O., Biktagirov, F.K., Kozin, R.V. (2023) Thermal decomposition of hematite pellets during plasma-arc smelting in argon atmosphere. In: Proc. of XVth Inter. Sci.-Tech. Conf. on New Materials and Technologies in Mechanical Engineering, 27–28 April 2023. Kyiv, KPI, 23–29.
15. https://foundry.kpi.ua/wp-content/uploads/2023/06/conferenziya_ 2023.pdf

---

Suggested Citation

V.O. Shapovalov, V.G. Mogilatenko, D.M. Zhyrov, V.R. Burnashev (2025) Industrial technologies of direct reduction of iron from ore raw materials and prospects for the use of hydrogen in reduction processes. The Paton Welding J., 09, 46-50.

---