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This article describes the development of a novel ironmaking technology based on flash reduction. The development started with the proof of the kinetic feasibility, considering that a typical flash reactor provides only a few seconds of residence time. This was followed by tests in a laboratory flash reactor and finally a pilot plant operation. The rate equations formulated in this work were developed considering the optimum combination of temperature, residence time, and reducing gas partial pressure to achieve &gt; 95% reduction degree. Experiments in the intermediate-scale laboratory flash reactor indicated that more than 90% reduction degree could be obtained in a few second residence time at temperature as low as 1175 °C. A pilot reactor operating at 1200–1550 °C was installed and run to collect data necessary for scaling up the process. The tests in this large reactor validated the design concept in terms of heat supply and residence time, and identified technical hurdles. This investigation proved the technical feasibility of the flash ironmaking technology. The results of this work will facilitate the design for the industrial flash ironmaking reactor. The novel technology is expected to decrease the energy consumption in ironmaking by up to 44% compared with the average blast furnace process, and will reduce CO 2  emissions by up to 51%. When hydrogen is used, the proposed process would use up to 60% less energy with little carbon dioxide emissions. However, it is noted that the energy requirements and CO 2  emissions during the production of natural gas, hydrogen or coal must be added for a comprehensive comparison.

Development of the Flash Ironmaking Technology (FIT) for Green Ironmaking with Low Energy Consumption