Work

Reactive MP-PIC simulation of hydrogen-based iron oxide reduction in a fluidized bed reactor

Year: 2026

Type: article

Abstract: Hydrogen-based direct reduction of iron has the potential to drastically reduce the carbon dioxide emissions of steelmaking. However, widespread adoption of fluidized bed reactors is limited due to operational instabilities. This study presents a numerical model simulating iron-oxide reduction within fluidized bed reactors, with validation against literature confirming the model’s accuracy in predicting pressure drops and hydrodynamic trends. Further, we explore how varying process conditions, such as temperature and reduction degree, influence reactor performance and stability in real-world conditions. Key findings demonstrate that elevated process temperatures and higher reduction degrees correlated with increased particle bed instabilities and a greater risk of channelling. Another notable observation is that the potential for reoxidation reaches its maximum at mid-reduction, likely contributing to the decline in reaction rate. These insights enhance our understanding of the complex reduction process, offering potential productivity improvements for hydrogen-gas-based fluidized bed reactors.

Source: International Journal of Hydrogen Energy

DOI: 10.1016/j.ijhydene.2026.154911

Authors: Jan Z. Wadowski, Geoffrey A. Brooks, Jamal Naser

Institutions: Swinburne University of Technology, Commonwealth Scientific and Industrial Research Organisation

Language: English

Topic: Iron and Steelmaking Processes

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Affordable and clean energy

Open Access status: hybrid

Estimated APC paid: $3,730