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Zheng X, Paul S, Moghimi L, Wang Y, Vilá RA, Zhang F, Gao X, Deng J, Jiang Y, Xiao X, Wu C, Greenburg LC, Yang Y, Cui Y, Vailionis A, Kuzmenko I, llavsky J, Yin Y, Cui Y, Dresselhaus-Marais L. Correlating chemistry and mass transport in sustainable iron production. Proc Natl Acad Sci U S A 2023; 120:e2305097120. [PMID: 37847734 PMCID: PMC10614607 DOI: 10.1073/pnas.2305097120] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/29/2023] [Accepted: 09/01/2023] [Indexed: 10/19/2023] Open
Abstract
Steelmaking contributes 8% to the total CO2 emissions globally, primarily due to coal-based iron ore reduction. Clean hydrogen-based ironmaking has variable performance because the dominant gas-solid reduction mechanism is set by the defects and pores inside the mm- to nm-sized oxide particles that change significantly as the reaction progresses. While these governing dynamics are essential to establish continuous flow of iron and its ores through reactors, the direct link between agglomeration and chemistry is still contested due to missing measurements. In this work, we directly measure the connection between chemistry and agglomeration in the smallest iron oxides relevant to magnetite ores. Using synthesized spherical 10-nm magnetite particles reacting in H2, we resolve the formation and consumption of wüstite (Fe1-xO)-the step most commonly attributed to whiskering. Using X-ray diffraction, we resolve crystallographic anisotropy in the rate of the initial reaction. Complementary imaging demonstrated how the particles self-assemble, subsequently react, and grow into elongated "whisker" structures. Our insights into how morphologically uniform iron oxide particles react and agglomerate in H2 reduction enable future size-dependent models to effectively describe the multiscale aspects of iron ore reduction.
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Affiliation(s)
- Xueli Zheng
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
- Stanford Institute for Materials and Energy Sciences, SLAC National Accelerator Laboratory, Menlo Park, CA94025
| | - Subhechchha Paul
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
- PULSE Institute, SLAC National Accelerator Laboratory, Menlo Park, CA94025
| | - Lauren Moghimi
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
- PULSE Institute, SLAC National Accelerator Laboratory, Menlo Park, CA94025
| | - Yifan Wang
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
- PULSE Institute, SLAC National Accelerator Laboratory, Menlo Park, CA94025
| | - Rafael A. Vilá
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
| | - Fan Zhang
- Materials Measurement Science Division, National Institute of Standards and Technology, Gaithersburg, MD20899
| | - Xin Gao
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
| | - Junjing Deng
- X-ray Science Division, Advanced Photon Source, Argonne National Laboratory, Lemont, IL60439
| | - Yi Jiang
- X-ray Science Division, Advanced Photon Source, Argonne National Laboratory, Lemont, IL60439
| | - Xin Xiao
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
| | - Chaolumen Wu
- Department of Chemistry, University of California, Riverside, CA92521
| | - Louisa C. Greenburg
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
| | - Yufei Yang
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
| | - Yi Cui
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
| | - Arturas Vailionis
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
| | - Ivan Kuzmenko
- X-ray Science Division, Advanced Photon Source, Argonne National Laboratory, Lemont, IL60439
| | - Jan llavsky
- X-ray Science Division, Advanced Photon Source, Argonne National Laboratory, Lemont, IL60439
| | - Yadong Yin
- Department of Chemistry, University of California, Riverside, CA92521
| | - Yi Cui
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
- Stanford Institute for Materials and Energy Sciences, SLAC National Accelerator Laboratory, Menlo Park, CA94025
| | - Leora Dresselhaus-Marais
- Department of Materials Science and Engineering, Stanford University, Stanford, CA94305
- Stanford Institute for Materials and Energy Sciences, SLAC National Accelerator Laboratory, Menlo Park, CA94025
- PULSE Institute, SLAC National Accelerator Laboratory, Menlo Park, CA94025
- Department of Photon Science, SLAC National Accelerator Laboratory, Menlo Park, CA94025
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