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Steelmaking contributes 8% to the total CO2 emissions globally, primarily dueto coal-based iron ore reduction. Clean hydrogen-based ironmaking has variableperformance because the dominant gas-solid reduction mechanism is set by thedefects and pores inside the mm-nm sized oxide particles that changesignificantly as the reaction progresses. While these governing dynamics areessential to establish continuous flow of iron and its ores through reactors,the direct link between agglomeration and chemistry is still contested due tomissing measurements. In this work, we directly measure the connection betweenchemistry and agglomeration in the smallest iron oxides relevant to magnetiteores. Using synthesized spherical 10-nm magnetite particles reacting in H2, weresolve the formation and consumption of w\"ustite (FeO) - the step mostcommonly attributed to agglomeration. Using X-ray scattering and microscopy, weresolve crystallographic anisotropy in the rate of the initial reaction, whichbecomes isotropic as the material sinters. Complementing with imaging, wedemonstrate how the particles self-assemble, subsequently react and sinter into~100x oblong grains. Our insights into how morphologically uniform iron oxideparticles react and agglomerate H2 reduction enable future size-dependentmodels to effectively describe the multiscale iron ore reduction.

Correlating Chemical Reaction and Mass Transport in Hydrogen-based Direct Reduction of Iron Oxide