A Containerized Open Arc Smelter Using Hydrogen as the Reductant: A Design and Modelling Approach

Abstract

Abstract Hydrogen plasma smelting reduction (HPSR) offers a promising alternative ironmaking pathway that significantly reduces carbon emissions by replacing carbon-based reductants with hydrogen. This paper presents the design and modelling of a containerized, 100 kVA bench-scale HPSR test unit, developed to support continuous smelting operations at a feed rate of 18–20 kg/h. The furnace is engineered for batch tapping of 60–80 kg and designed to simulate industrial conditions more closely than traditional laboratory-scale setups. A dynamic simulation model was developed to perform mass and energy balance calculations, incorporating time-dependent heat loss estimations based on furnace geometry and operating parameters. This model informed key design decisions and enables real-time assessment of furnace performance under varying process conditions. The paper also integrates insights from ongoing experimental work to refine the mechanical and process design, including considerations for slag chemistry, feed strategies, and arc stability. The proposed test unit serves as a critical step toward increasing the technology readiness level of HPSR, enabling systematic evaluation of process variables and supporting the transition to low-carbon steelmaking technologies.