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Updated: Sep 10, 2025

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A percolating path to green iron.

Subhechchha Paul1,2, Brinthan Kanesalingam2,3, Yan Ma4,5

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|August 27, 2025
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Summary
This summary is machine-generated.

Hydrogen-based direct reduction (HyDR) offers emission-free steelmaking. This study reveals how pore structure evolution in iron oxide pellets impacts gas transport, crucial for optimizing HyDR processes.

Keywords:
hydrogenironmakingpercolationpores

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Area of Science:

  • Materials Science
  • Chemical Engineering
  • Environmental Science

Background:

  • Steel production generates significant CO2 emissions, with ironmaking being a major contributor.
  • Hydrogen-based direct reduction (HyDR) is a promising low-emission alternative for ironmaking.
  • Challenges in HyDR include altered pellet microstructures and pore networks that impede gas transport and reaction rates.

Purpose of the Study:

  • To quantify the evolution of pore structures in iron oxide pellets during HyDR.
  • To understand how nanoscale pore connectivity affects macroscale flow properties.
  • To develop a framework for optimizing HyDR reactor performance.

Main Methods:

  • Synchrotron nano X-ray computed tomography was employed to visualize pore evolution.
  • Percolation theory was applied to analyze pore connectivity.
  • Modeling connected pore structure to micro- and macroscale flow properties.

Main Results:

  • Pore evolution in iron oxide pellets was quantified across multiple scales.
  • Nanoscale pore connectivity was shown to significantly influence permeability, diffusivity, and tortuosity.
  • A link was established between pore structure and gaseous transport limitations.

Conclusions:

  • Understanding pore evolution is critical for improving HyDR efficiency.
  • The developed modeling framework connects microstructural changes to reactor performance.
  • This research provides insights to accelerate the adoption of emission-free ironmaking through HyDR.