Hydrogen-Based Iron Production: Nippon Steel's 1,000-Ton Test

Nippon Steel Corporation (Nippon Steel) announced on November 4 that it had successfully completed test production of direct-reduced iron using lower-grade iron ore and 100% hydrogen as the reducing agent. During more than 300 hours of continuous operation, the company produced over 1,000 tons of direct-reduced iron in total. The achievement represents an important step toward commercializing hydrogen-based direct-reduced iron production as part of efforts to establish a carbon-neutral society with virtually zero greenhouse gas emissions.

The test was conducted at the pilot reducing furnace, which uses a shaft furnace configuration, at Nippon Steel's Hasaki Research and Development Center. The facility began operations in March this year, and the trial used lower-grade iron ore, specifically blast furnace-grade pellets, as its raw material. The successful operation demonstrated the company's ability to produce direct-reduced iron using hydrogen exclusively rather than relying on conventional reducing agents.

To address the technical challenges associated with hydrogen-only reduction, Nippon Steel applied heat compensation technology designed to accommodate the endothermic characteristics of the reaction. The company also employed technology to suppress the tendency of lower-grade iron ore to become powdered during the reduction process. By combining these technologies, it achieved stable direct-reduced iron production in the test reduction furnace. Nippon Steel plans to continue testing hydrogen-based direct-reduced iron production to further develop its direct-reduction technology.

Industry Impact & Outlook

Nippon Steel's achievement demonstrates progress in addressing two important technical challenges in hydrogen-based ironmaking: managing the heat requirements of hydrogen-only reduction and maintaining the stability of lower-grade iron ore during processing. Producing more than 1,000 tons over 300 hours of continuous operation provides an important operational milestone for the company's development efforts. The successful use of blast furnace-grade pellets also demonstrates the potential to apply lower-grade iron ore to this production approach. Continued testing will be important for advancing the technology toward commercialization and supporting the development of ironmaking processes aligned with carbon-neutral manufacturing objectives.

Frequently Asked Questions

What did Nippon Steel achieve in its latest hydrogen-based iron production test?
Nippon Steel successfully produced more than 1,000 tons of direct-reduced iron using 100% hydrogen during an extended pilot-furnace test. The operation continued for more than 300 hours and used lower-grade iron ore as its raw material. This achievement represents progress toward commercializing hydrogen-based direct-reduced iron production. The technology is being developed to support a carbon-neutral society with virtually zero greenhouse gas emissions.

How much direct-reduced iron did Nippon Steel produce during the test?
Nippon Steel produced more than 1,000 tons of direct-reduced iron over more than 300 hours of continuous operation. The production was carried out using 100% hydrogen as the reducing agent, demonstrating the company's ability to maintain stable production in its pilot reducing furnace. This result marks an important milestone in its efforts to develop hydrogen-based direct-reduction technology for future commercialization.

What type of iron ore did Nippon Steel use in the hydrogen reduction test?
Nippon Steel used lower-grade iron ore in the form of blast furnace-grade pellets as the raw material for its direct-reduced iron production test. The company specifically addressed the tendency of lower-grade iron ore to become powdered during the reduction process. It applied technology designed to suppress this powdering tendency, enabling stable production in the pilot reduction furnace using hydrogen exclusively as the reducing agent.

Where did Nippon Steel conduct its 100% hydrogen reduction test?
The test was conducted at the pilot reducing furnace at Nippon Steel's Hasaki Research and Development Center. The facility uses a shaft furnace configuration and began operations in March this year. It was used to evaluate direct-reduced iron production from lower-grade iron ore with 100% hydrogen as the reducing agent. The successful trial demonstrated stable production through the application of heat compensation and powdering suppression technologies.

What technologies enabled stable hydrogen-based direct-reduced iron production?
Nippon Steel combined two technologies to achieve stable production using 100% hydrogen in its pilot reduction furnace. The first was heat compensation technology designed to match the endothermic characteristics of hydrogen-only reduction. The second suppressed the powdering tendency of lower-grade iron ore during processing. Together, these technologies addressed important operational challenges encountered when producing direct-reduced iron from lower-grade iron ore using hydrogen exclusively.

What are Nippon Steel's next steps following the successful test?
Nippon Steel plans to continue testing hydrogen-based direct-reduced iron production to further develop its direct-reduction technology. The latest achievement provides a foundation for continued development, following the production of more than 1,000 tons over more than 300 hours of continuous operation. The company's broader objective is to advance the technology toward commercialization and contribute to a carbon-neutral society through iron production with virtually zero greenhouse gas emissions.