Effective Equilibrium Reaction Zone Modeling of Hydrogen Plasma Smelting Reduction: A Scenario Analysis

Abstract

This work develops a dynamic model for hydrogen plasma smelting reduction (HPSR) in direct current arc furnaces, implemented with a zonal approach to simulate industrial operations. The model couples thermodynamic principles with grouped mass‐transfer parameters to predict the time evolution of mass, temperature, and composition in the metal, slag, and off‐gas across furnace zones. Calibration is performed against published experimental data to accurately capture key mass‐transfer dynamics. Industrial scenarios, including variations in ore pre‐reduction, off‐gas recycling, and feed arrangements, are analyzed, with simulations quantifying specific energy requirements (SER) and evaluating impacts on hydrogen utilization and degree of reduction. Results indicate that off‐gas recycling yields the lowest SER. Sensitivity analysis identifies feed distribution and ore pre‐reduction as dominant variables influencing hydrogen utilization and SER. The findings provide operational insights to guide experimental planning and help optimize conditions for energy efficiency and sustainability in HPSR. The model serves as a tool to evaluate new process scenarios and benchmark performance. Recommendations include refining mass‐transfer coefficients and hydrogen lance effects to further improve efficiency. The planned 100 kVA test unit by Metix will enable empirical validation and iterative tuning of the modeling framework, supporting the development of sustainable metallurgical practices across the industry.