Skip to main content
To KTH's start page

Direct reduction of alloy metals 2

DRAM2

Today, most metal alloys are made in two stages. Both stages are highly energy- and carbon-intensive. The first stage produces precursors, such as iron, and simple mixtures of metals. The second stage melts metals together at high temperatures to produce alloys. To eliminate these energy- and carbon dioxide-intensive stages, we propose a disruptive approach of mixing oxide powders and reducing them in hydrogen to form the alloy in a single, low temperature step. This saves energy and eliminates carbon-based reduction. Our approach has been demonstrated on a lab scale for iron-nickel and copper-nickel alloys. The novelty in this proposal is to show that the process can be applied to many more alloys and at larger scales. The outcomes will be a basis to radically reduce greenhouse gas emissions during production of alloys.We shall also develop a flexible tool to quantify energy and greenhouse gas savings, for use in optimising other processes that are also vital to Sweden.

Funding agency

Swedish Energy Agency

Beginning and end dates

5 February 2024 to 31 July 2026

Contact

Christopher Hulme
Christopher Hulme associate professor chrihs@kth.se +4687908459 Profile
Page responsible:webmaster@mse.kth.se
Belongs to: Materials Science and Engineering
Last changed: Feb 11, 2026
Optimization of the ingot casting process by minimising macrosegregation and porosity
Avoiding cracking during casting of a duplex stainless steel
Electrically Heated 3D-Printed Catalysts for CO₂-to-Solid Carbon Conversion via a Two-Step Thermochemical Process
Highly efficient technologies for increased yields in steelmaking processes and reduced environmental impact
Valorization of wet biomass residues for sustainable steel production with efficient nutrient recycling
Direct reduction of alloy metals 2
Synthesis, structure and application of bio-binders for electrodes and refractories in the metallurgical process industries
Efficient Integration and Utilization of Biogenic H₂-rich Syngas for Sustainable Steel Production
Substitution of fossil-based carbon with lignin in furnace electrodes for the metallurgical industry
Metallic Elements Dissipation Avoided by Life cycle design for Steel
Application of Microwave Plasma Generator for the Production of Solar Grade Silicon
Substitution of fossil Combination in Industrial high-Temperature processes by Advanced Electrical and plasma heating technologies
P purification of MeOH sludge to produce synthetic fluorspar and to recover phosphorus
Refractory materials in steel production: mechanisms of lining wear
Validation of Simulation Models for Steel Production
3D Bio-Graphene from Biochar via Catalytic Graphitization for Li–S Batteries
Fossil free Graphite production with Molten iron graphitization of biomass
Upgrading of biobased pyrolysis oil in existing refinery infrastructure
Biomaterials for carbon anode in aluminium production
Innovative Integrated Tools and Technologies to Protect and Treat Drinking Water from Disinfection Byproducts (DBPs)
Catalytic reduction of CO2 gas to solid carbon - towards emission-free steelmaking
Resource Efficient Materials for Additive Manufacturing
Refractory Life Extension and Fluorspar Elimination in the AOD Process
Sustainable slag fluxing in the AOD converter