The ironmaking process involves the removal of oxygen atoms from the iron oxides to produce iron. Currently, the coal/coke-based blast furnace process dominates the industry with a 71% share of global steel production, making it responsible for 25% of total global industrial CO2 emissions. Several processes have been commercialized to reduce these CO2 emissions such as the direct reduction process which utilizes natural gas for energy and reducing agent. In the last few decades, H2 has been identified as an alternative reducing agent in place of coal and reformed natural gas for decarbonizing the ironmaking process.To commercialize the H2 direct reduction (H2DR) process, it is necessary to study this process on a laboratory, pilot, and industrial scale to identify and address the roadblocks in the path of commercialization. Based on the literature review performed in this dissertation, four knowledge gaps were identified, and hypotheses were formulated to address the same. First, a numerical model was developed for a single iron ore pellet reduction process with a dynamic porosity function, and it was validated using experiments. Second, the equation of the radius of pellet was derived as a function of the degree of reduction using experimental data to account for the shrinking and swelling. Third, a numerical model was developed for a pilot scale H2DR reactor and was validated for average metallization of the pellets at the reactor outlet and the internal temperature profile in the reduction zone. Fourth, the numerical model for the pilot scale H2DR reactor showed a gradient of metallization at the outlet boundary which was validated by experimental metallization analysis of 31 randomly selected pellet samples one by one. At the end of the dissertation, the pilot scale model of the H2DR reactor was scaled up to an industrial scale with a DRI production capacity of 2.38 million tons/year approximately. The mass balance obtained from the industrial scale model was used to perform the techno-economic analysis to determine the economic implications of shifting from a 100% natural gas operation to a 100% H2 operation on an industrial scale.

The characterization of interface properties in molten slag is crucial for understanding the interface phenomenon and the reactions between slag and metal. This study focuses on examining the influence of Cr2O3, an important surface active oxide, on the wettability and surface tension of slag. Industrial Electric Arc Furnace (EAF) slag with two different Cr2O3 contents (1 wt% and 3 wt%) was investigated using the sessile drop measurement technique at a high temperature of 1650°C. For the preparation of 3 wt% Cr2O3-doped slags, the following crucibles were used: Al2O3, Mo, and MgO. The behavior of crucibles, the dissolution process as well as its effect on the slag thermophysical properties were studied. For the evaluation of surface tension, Mo and MgO substrates were used. The contact angle was measured using the sessile drop method, and the surface tension was calculated using the Young-Laplace-based software. The interaction and wettability behavior between the slag and different substrates was studied. The effects of Cr2O3 content, in correlation with Al2O3, Mo, and MgO, as well as temperature, on the surface tension, and phase formation were analyzed using FactSage 8.2. The results indicate an increase in the formation of solid phases with Al2O3 and Mo dissolution into the slag. The composition of the MoO3 is confirmed with the XRF and EDS analysis. Furthermore, an increase in the formation of the spinel phase was observed with the addition of chromium, which is confirmed via XRD. The increase in the CaCrMo-oxide-based spinel led to a decrease in the surface tension of the slag. The surface tension of the slag pre-melted in a Mo, decreases as the Cr2O3 content increases. The effects of the amounts of Cr2O3 in correlation with Al2O3, MgO, and MoO3 on the slag foaming index were determined using the existing models in the literature.