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DOE OSTI2021

The Future of Nuclear Energy: Electrochemical Reprocessing of Fuel Takes Center Stage

Nuclear power plants use energy-dense fuel and provide dependable baseload energy without generating greenhouse gas emissions. Despite these advantages, the long-term management of used nuclear fuel (UNF) remains a key challenge due to its lifetime (hundreds of thousands of years) and radiotoxicity. The components of UNF that contribute the most to this challenge are the actinide elements. A potential solution to this issue is to separate these radioisotopes from the bulk of the UNF and recycle them as fuel in advanced nuclear reactors. These separations can be achieved using electrochemical reprocessing, which employs electrochemical conversion and electrodeposition in a high-temperature molten salt electrolyte medium to separate the actinides from UNF. In this work, we review the current status, fundamental challenges, and future prospects of electrochemical reprocessing as they relate to UNF recycling.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Assembly of MiniFuel Targets for Irradiation of U-Mo Fuel Specimens in the High Flux Isotope Reactor

To support the development of advanced low-enriched uranium for use in nuclear reactors, irradiation testing of U-Mo disk specimens was performed at the Oak Ridge National Laboratory (ORNL) High Flux Isotope Reactor (HFIR) to collect experimental irradiation data on this type of fuel at pressurized water reactor–relevant temperatures. U-Mo is a uranium alloy that has superior dimensional stability relative to alpha-phase uranium metal and has a substantially higher uranium density compared to UO 2 . U-Mo disks specimens were fabricated at Idaho National Laboratory and inserted into MiniFuel targets for HFIR irradiation. Three MiniFuel targets were successfully assembled, welded, tested, and delivered to HFIR, along with their quality assurance documentation. The targets were inserted into HFIR’s inner vertical experiment facility within the permanent beryllium reflector. Each target contains six disk specimens and will be irradiated in HFIR for three, four, and eight cycles, with target temperatures between 250 and 500°C. This report summarizes the experiment design, test matrix, pre-characterization of specimens, and experiment assembly.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Chalcogenide Glass-Capped Fiber-Optic Sensor for Real-Time Temperature Monitoring in Extreme Environments

We demonstrate a novel chalcogenide glass (ChG)-capped optical fiber temperature sensor capable of operating within harsh environment. The sensor architecture utilizes the heat-induced phase change (amorphous-to-crystalline) property of ChGs, which rapidly (80–100 ns) changes the optical properties of the material. The sensor response to temperature variation around the phase change of the ChG cap at the tip of the fiber provides abrupt changes in the reflected power intensity. This temperature is indicative of the temperature at the sensing node. We present the sensing performance of six different compositions of ChGs and a method to interpret the temperature profile between 440 °C and 600 °C in real-time using an array structure. The unique radiation-hardness property of ChGs makes the devices compatible with high-temperature and high-radiation environments, such as monitoring the cladding temperature of Light Water (LWR) or Sodium-cooled Fast (SFR) reactors.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

The Essential Role of Nuclear Energy in Achieving Economy-wide Net-Zero Solutions

Governments and private industry around the world have established aggressive goals to achieve net-zero emissions for the power, industrial, and transportation sectors by 2050. These aggressive goals demand immediate action if we are to be successful, and they require us to think more holistically about our clean energy options. Programs within the U.S. Department of Energy (DOE) are addressing these holistic solutions. Traditionally, electricity generation and management and meeting energy demands for industry and transportation are considered independently. As we seek to achieve net-zero, we need to reassess energy demands. When we consider overall energy use, only one-third is in the form of electricity. Additional energy demands are in the form of heat or steam for industrial processes, as well as transportation. These sectors are much harder to abate, and electrification may not be the best option. Reducing environmental emissions at an affordable cost, while maintaining grid reliability and resilience, will require us to use all of the clean energy resources that we have available. That means coordinating the use of nuclear, renewables, and fossil fuels with carbon capture to meet growing demands for electricity, industrial applications, and mobility. The DOE Office of Nuclear Energy (DOE-NE) program on Integrated Energy Systems (IES) is led by researchers at Idaho National Laboratory (INL) and work is conducted in partnership with an array of other DOE laboratories, industry, and academia. The primary focus of IES research is to assess the technical and economic potential of IES to enhance the flexibility and utilization of nuclear reactors working alongside renewable generators to meet an array of energy demands—thereby maximizing the utilization of clean energy resources across all energy sectors. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and chemicals. The DOE-NE program additionally partners with the Hydrogen and Fuel Cell Technologies Office under the DOE Office of Energy Efficiency and Renewable Energy to jointly fund the development of analysis tools, technologies, and nuclear-integrated hydrogen demonstration projects. This presentation highlights the wide array of R&D being conducted across multiple DOE-funded programs to develop and deploy nuclear-based IES that will be key to achieving our net-zero goals. By working with key collaborators in the nuclear industry, analytical studies are now becoming a reality in demonstration projects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Advancing Nuclear Energy to Support Economy-wide Net-zero Solutions: Challenges and Opportunities

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Development of a Radiation-Tolerant Front End Digitizer

High-radiation and high-temperature environments represent notoriously detrimental conditions for electronics. Yet sensors and instrumentation are critically important for the safe operation of nuclear reactors and for the validity of the scientific experiments conducted within them. Traditionally, sensors in such extreme environments operate with few active components, resulting in small signals (mV–V, nA–µA range) that must be transmitted through long cable runs before digitization by sensitive data acquisition systems located in clean, less-harsh environments. Long cables are prone to picking up noise through electromagnetic interference and distortion caused by their parasitic impedances, resulting in signal degradation. The Front End Digitizer (FREND) system described and demonstrated herein seeks to address these issues by enabling the placement of a radiation-resistant analog front end within reactor containment, or other high-radiation environments. FREND will enable early signal pre-amplification, digitization, and optical encoding within the high-radiation field to transmit sensor signals over an optical fiber to the non-nuclear environment of an instrument room. Early signal pre-amplification and digitization maintain signal integrity, whereas optical transmission renders the system blind to induced electromagnetic noise over the long cable runs. This report describes the FREND initial prototype, which can multiplex and optically encode data from up to four sensor inputs, though, in principle, this can be extended to any number of sensor inputs. The end result is an extremely flexible, high-fidelity system.

42 ENGINEERING↗

DOE OSTI2024

Simulation, Structural, Thermal and Mechanical Properties of the FeTiTaVW High Entropy Alloy

Developing new materials to be applied in extreme environments is an opportunity and a challenge for the future. High entropy alloys are new materials that seem promising approaches to work in nuclear fusion reactors. In this work, FeTaTiVW high entropy alloys were developed and characterized with Molecular Dynamic and Hybrid Molecular Dynamic Monte Carlo simulations. The simulation results show that phase separation originates a lower potential energy per atom and a high level of segregation compared to those of a uniform solid solution. Moreover, the experimental diffractogram of the milled powder shows the formation of a body-centred cubic-type structure and the presence of TiO2. In addition, the microstructure of the consolidated material evidenced three phases: W-rich, Ti-rich, and a phase with all the elements. This phase separation observed in the microstructure agrees with the Hybrid Molecular Dynamic Monte Carlo simulation. Moreover, the consolidated material’s thermal conductivity and specific heat are almost constant from 25 °C to 1000 °C, and linear expansion increases with increasing temperature. On the other hand, specific heat and thermal expansion values are in between CuCrZr and W values (materials chosen for the reactor walls). The FeTaTiVW high entropy alloy evidences a ductile behaviour at 1000 °C. Therefore, the promising thermal properties of this system can be attributed to the multiple phases and systems with different compositions of the same elements, which is exciting for future developments.

Martins, Ricardo (ORCID:0000000177685704)↗

DOE OSTI2025

Design of a System Interface for Flexible Thermal Power Extraction from Two Advanced Reactors

This report presents the design of system interfaces enabling flexible thermal power extraction from two advanced nuclear reactor concepts: a sodium-cooled fast reactor (SFR) operating on a Rankine cycle, and a gas-cooled reactor (GCR) utilizing a Brayton cycle. The study addresses the dual challenge of ensuring reliable base-load electricity generation while meeting the variable high-temperature steam demands of industrial processes (IPs).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

CsPbI 3 Nanocrystals Go with the Flow: From Formation Mechanism to Continuous Nanomanufacturing

Despite the groundbreaking advancements in the synthesis of inorganic lead halide perovskite (LHP) nanocrystals (NCs), stimulated from their intriguing size-, composition-, and morphology-dependent optical and optoelectronic properties, their formation mechanism through the hot-injection (HI) synthetic route is not well-understood. Here in this work, for the first time, in-flow HI synthesis of cesium lead iodide (CsPbI 3 ) NCs is introduced and a comprehensive understanding of the interdependent competing reaction parameters controlling the NC morphology (nanocube vs nanoplatelet) and properties is provided. Utilizing the developed flow synthesis strategy, a change in the CsPbI 3 NC formation mechanism at temperatures higher than 150 °C, resulting in different CsPbI 3 morphologies is revealed. Through comparison of the flow- versus flask-based synthesis, deficiencies of batch reactors in reproducible and scalable synthesis of CsPbI 3 NCs with fast formation kinetics are demonstrated. The developed modular flow chemistry route provides a new frontier for high-temperature studies of solution-processed LHP NCs and enables their consistent and reliable continuous nanomanufacturing for next-generation energy technologies.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Turbulence suppression at extreme plasma densities on DIII-D and EAST

Recent high-poloidal-beta (high-βP) experiments on DIII-D and EAST have made coordinated breakthroughs for high confinement quality at high density near the Greenwald limit. Density gradient amplification of turbulence suppression at high βP can explain both of these achievements. Experiments on DIII-D have achieved Greenwald fraction (fGr = line-averaged density/Greenwald density) above 1 simultaneously with normalized energy confinement (H98y2) around 1.5, as required in fusion reactor designs but never before verified in tokamak experiments with the divertor configuration. A synergy between increased H98y2 and fGr is observed with strong gas puffing, due to the build-up of an internal transport barrier at large radius in the temperature and density channels. Transport simulations reveal that the favorable trend of reduced turbulent energy transport at higher density is only expected when increasing the density gradient at high local safety factor and high β, thus at high βP to ensure strong α-stabilization. These conditions are crucial to many conceptual designs for steady-state reactors. New experiments on EAST have nearly doubled the ion temperature at fGr ∼ 0.9, consistent with predict-first modeling results based on the same physics revealed from the DIII-D analysis. All previous EAST long-pulse H-modes have Ti ≪ Te near plasma axis. Transport modeling indicates that the profiles are limited by ion-temperature-gradient modes at mid-radius. The modeling also suggested potential solutions, including reducing magnetic shear, enhancing density gradients, and higher impurity concentration. Following this guidance, EAST experiments directly show a strong enhancement of Ti achieved with a combination of a second plasma current ramp-up, a density gradient increase, and a Zeff perturbation by a short pulse (100 ms) of impurity injection, as predicted by the earlier modeling.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Accelerated Fuel Qualification of Fast Modular Reactor Fuel in a Thermal Reactor: Modeling and Simulation Paired with Irradiation Testing

The accelerated fuel qualification (AFQ) methodology is applied by simulating accelerated fuel tests of the General Atomics Electromagnetic Systems’ fuel system for its 44-MW(electric) gas-cooled, fast-spectrum fast modular reactor (FMR). This fuel is comprised of UO 2 pellets in SiGA® cladding, a silicon carbide ceramic matrix composite. Fast reactors, like the FMR, offer many benefits, including high fuel utilization and flexibility, but may require a lengthy material design process if tests are performed using fast neutron irradiation alone. A thermal neutron irradiation can instead be used to rapidly test how well key components of the current material models extend to high burnup. Thermal neutrons produce a different radial power distribution within the pin than fast neutrons. However, the temperature and burnup values for the two neutron types are comparable, and the differences between the simulated fuel responses are relatively small, demonstrating the weak sensitivity of the physics-based fuel model calculations on the neutron type and the irradiation rate. Furthermore, the deformation of the SiGA cladding saturates after about 1 displacement per atom for both neutron spectra. In an accelerated fuel test, the irradiation time required to reach the target fuel burnup can be reduced by a factor of 3 by using a small rodlet with a 45% smaller pellet diameter while maintaining the same linear power. Therefore, the time for data collection up to high burnup can be significantly reduced while maintaining the same temperature profile, which largely determines the material response. Tests of fuel rodlets of standard and compact size will be carried out in the Idaho National Laboratory’s Advanced Test Reactor (ATR), including full size and compact rodlets with varying gap sizes. By applying physics-based mechanistic modeling and simulation in accordance with the AFQ methodology, this type of compact rodlet testing in a thermal test reactor captures the necessary phenomena to test fuel material models up to high burnup and to simulate the expected impact of fast neutron radiation on the fuel in FMR operations. Finally, this approach to testing fast reactor fuels in existing thermal test reactors, paired with advanced physics-based mechanistic modeling and simulation, is expected to be applicable to a range of advanced fuels and will decrease the overall fuel qualification timeframe from decades to years.

Advanced test reactor (ATR)↗

DOE OSTI2025

Investigation of radiated-power for low aspect ratio fusion plasmas

Investigating radiated power in fusion plasmas is of utmost importance to understand the effect of undesired impurities, such as metals, in present devices, or also desired impurities, such as noble gasses, to purposefully radiate a large fraction of power in future devices. These studies are especially important for high Z impurities which will play a crucial role in future generation fusion pilot plants. In this work, we have developed a power radiation analysis module, which is used to investigate 2D distributions of impurity densities and radiated power asymmetries caused due to both plasma rotation and the cooling rate dependence on temperature profile for the cases of experimental NSTX plasmas and designed scenarios for the spherical tokamak advanced reactor (STAR), both being low aspect ratio tokamaks. Two different atomic databases have been tested during this work to study their impact on the radiated power distribution, especially for high Z impurities. Also in PRAM, self-consistent calculations of two-dimensional electron, main ion, and impurity ion densities are carried out using one-dimensional input density, temperature, and rotation profiles. In the case of NSTX, discharges with high rotation of ∼ 170 km s, measured with charge exchange recombination spectroscopy, have been investigated. Rotation-induced charge separation, leading to an electrostatic potential, is calculated iteratively to a self-consistent solution while testing high Z impurities to observe any 2D asymmetry in the core radiated power due to centrifugal forces. The STAR design, being much larger (R = 4 m), is projected to have a much lower rotation, and is shown to have low rotation-induced asymmetries, on the order of ten percent or less, between the low field and high field sides. However, another effect not due to rotation but to the dependence of impurity cooling rates on temperature can lead to radiation peaking off-axis, near the plasma edge. This effect is noticeable for argon in NSTX, for example, but can also be enhanced for certain impurities at much higher temperatures projected for STAR (T e0 ~ 32 keV), for example for undesired tungsten or possibly desired xenon.

NSTX↗

DOE OSTI2024

Intensified biogas to liquid (IBGTL) Process: Experimental validation and modeling analysis

The Intensified Biogas to Liquid (IBGTL) process aims to overcome traditional economy-of-scale barriers in biogas-to-liquid fuel production by integrating bi-reforming and Fischer-Tropsch synthesis (FTS) in a single IBGTL reactor. This reactor operates at uniform pressure with different optimized temperatures across two zones for efficient conversion, utilizing multifunctional bi-reforming catalysts and high-temperature FTS catalysts. Bench scale experiments were carried out using landfill gas (LFG) in a single pass process, and the yield data from these experiments were fed into process scale-up design and techno-economic analysis (TEA) across four scenarios: (1) a single pass process, (2) a process with material recycling, (3) a process with liquefied petroleum gas (LPG) co-product recovery, and (4) a process with electricity generation from the fuel gas produced. TEA identified Scenario 2 as the most cost-effective, achieving a Minimum Fuel Selling Price (MFSP) of $\$4.59$ per gallon, competitive with the current national diesel price of $\$4.7$ per gallon. However, comparison with the conventional two-reactor system highlights the need for catalyst performance improvements. Sensitivity analysis emphasized the importance of manufacturing cost, liquid fuel yield, and biogas flow rate. Further analysis determined that the IBGTL process must achieve a diesel mass yield beyond 11.7% to surpass the economic viability of the conventional TriFTS (Tri-reforming followed by Fischer-Tropsch Synthesis) process. If the IBGTL process attains the TriFTS yield of up to 17%, the resulting MFSP could be approximately 31% lower than the current TriFTS MFSP. Furthermore, renewable energy credits and carbon credits can further enhance the economic viability of BGTL processes.

09 BIOMASS FUELS↗

DOE OSTI2021

Technological aspects in blanket design: Effects of micro-alloying and thermo-mechanical treatments of EUROFER97 type steels after neutron irradiation

Presently available data on neutron irradiation damage raise doubts on the feasibility of using EUROFER97 steel for a water-cooled starter blanket in a DEMO reactor, since the ductile-to-brittle transition temperature (DBTT) increases significantly for irradiation temperatures below 350°C. The additional DBTT shift caused by H and He transmutation can only be estimated based on very few results with isotopically tailored EUROFER97 steel. Conservative calculations show that the DBTT of EUROFER97 steel could exceed the operating temperature in water-cooled starter blankets within a relatively short time period. This paper presents results from a EUROfusion funded irradiation campaign that was performed in the High Flux Isotope Reactor at Oak Ridge National Laboratory. The paper compares ten newly developed reduced activation ferritic-martensitic (RAFM) steels irradiated to a nominal dose of 2.5 dpa at 300°C. The post-irradiation experiments using Small Specimen Test Technology included hardness, tensile, and fracture mechanics tests combined with fractography and microstructure analysis are presented. Results show that micro-alloying EUROFER97-type steels influenced the mechanical properties but a dominating impact on irradiation damage resistance could not be identified. In contrast, specific thermo-mechanical treatments lead to better DBTT behavior. Discussion about irradiation response to heat treatment conditions is also given. Here, despite requiring data also at high dpa values, the results indicate that with these modified materials an increased lifetime and potentially also an increased operating temperature window can be achieved compared to EUROFER97.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

High-performance ECRH at W7-X: experience and perspectives

The second operation phase of W7-X (OP1.2) showed the potential of exclusively electron cyclotron resonance heating (ECRH)-sustained plasma operations in stellarators. Employing multi-pass ECRH scenario in the second harmonic O-mode (O2-ECRH), stationary densities of up to 1.4 × 10 20 m -3 could be achieved. This scenario also made stationary divertor detachment possible, which is a reactor-relevant scenario for power and particle exhaust. At high densities and with sufficiently high density gradients for an improved ion confinement, the coupling between the electrons and ions was strong enough to bring the ion temperature to values above 3 keV and to the neoclassical limit for some magnetic configurations, thus enabling to test the W7-X neoclassical optimization. The planned enhancement of the ECRH performance will enable to advance towards reactor-relevant beta values and to investigate their stability and confinement of fast particles, which is a priority goal of W7-X.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Improving Proton Conductivity by Navigating Proton Trapping in High Scandium-Doped Barium Zirconate Electrolytes

Proton-conducting oxides are used in intermediate-temperature (300 °C < T < 700 °C) applications of fuel cells, electrolyzers, membrane reactors, hydrogen pumps, and sensors. The proton conductivity of doped ABO 3 perovskites is partly dependent on the proton concentration and hence on the level of material hydration. However, how the material hydration ability is affected by differences in doping is not fully understood. Here, we show the prospect of proton trapping and detrapping that influences material hydration and dehydration. The proton-trapping influence is significant for Sc-doped BaZrO 3 compared to Y-doped BaZrO 3 . Here, our work offers a perspective to understand how defect interaction/associations influence the hydration ability of proton-conducting oxides. Furthermore, positron annihilation lifetime spectroscopy was revealed to be a valuable technique for studying the proton-trapping phenomena and the defect chemistry of dense proton conductors. Density functional theory calculations also showed that a high hydration level in Sc-doped BaZrO 3 boosts proton migration. In contrast, the effect of boosting the proton migration due to increased hydration is limited for Y-doped BaZrO 3 . This effect, in turn, might explain the trend of conductivity with dopant concentration in doped BaZrO 3 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Feasibility and strategic implications of deploying nuclear power reactors in Africa

This report assesses the feasibility and strategic implications of deploying nuclear power reactors, including large-scale plants, advanced small modular reactors (SMRs), and microreactors, in African countries. Case studies focus on South Africa, Egypt, Kenya, Ghana, and Nigeria, examining nuclear energy’s role in Africa’s rapidly evolving energy landscape, marked by fast-growing demand, significant electricity access gaps, increasing renewable penetration, and strong policy commitments to industrialization and energy security. Several U.S. reactor technologies and designs are considered based on their development status and readiness for deployment. The analysis finds that nuclear power can provide reliable, clean baseload and flexible generation, as well as high-temperature process heat for desalination, hydrogen production, and industrial applications. However, suitability is highly country-specific, depending on grid size and stability, transmission capacity, cooling water availability, regulatory readiness, and fuel supply chains. Near-term deployment opportunities are strongest for light-water reactors (such as NuScale, BWRX-300, AP300, and SMR-300) that use low-enriched uranium and build on proven technology. More advanced concepts, including gas-cooled, sodium-cooled, molten-salt cooled reactors, and microreactors, will likely be relevant for African deployment in the 2030s or later, contingent on demonstration projects, high-assay low-enriched uranium (HALEU) fuel availability, and mature international licensing frameworks. Economic analysis shows that SMRs are capital-intensive, with projected overnight costs for 300 MWe units in 2025 ranging from approximately 1.4 to 2.6 billion USD per module. The levelized cost of electricity (LCOE) is highly sensitive to the weighted average cost of capital (WACC). Given typically higher financing costs and utility balance-sheet weaknesses in many African countries, bankable project structures will require sovereign guarantees, robust offtake arrangements, and layered financing from export credit agencies, development finance institutions, and vendor nations. Comparisons with recent large nuclear projects in the United Arab Emirates (UAE) and Egypt underscore the central role of state-backed loans, long tenors, and concessional terms. Country case studies illustrate a spectrum of readiness and opportunity. South Africa operates two 920 MWe pressurized light water reactors (totaling 1,840 MWe) at Koeberg and has the most mature regulatory and industrial base, positioning it as a prime candidate for both large reactors and SMRs to replace coal, support desalination, and anchor industrial hubs. Egypt is constructing four VVER-1200 units at El Dabaa with strong state leadership and could later complement this fleet with SMRs for coastal and industrial applications. Kenya and Ghana are advancing through IAEA Milestones with growing institutional capacity and clear interest in SMRs that match their smaller grids and industrialization plans. Nigeria has the largest demand potential but faces acute constraints in grid reliability, project bankability, and regulatory capacity; targeted deployments of large reactors and SMRs near coastal or industrial sites could have high impact if accompanied by major grid upgrades and institutional reforms. The report identifies cross-cutting challenges such as financing, political continuity, public acceptance, nonproliferation and security, waste and back-end management, regulatory capacity, grid adequacy, and long deployment timelines for first-of-a-kind designs, and ANL/NSE-26/3 ii proposes broad directions for resolution. These include stronger multifaceted financing for nuclear, long-term national energy strategies that transcend electoral cycles, proactive stakeholder engagement, strengthened regional and national regulators, and systematic workforce development through centers of excellence and expanded training. The United States should develop partnerships with African countries and offer end-to-end nuclear package similar to those used effectively by competitors: coordinated project development, state-backed financing, long-term fuel services, and durable in-country support through regional offices and sustained workforce/regulatory training. With timely planning, sustained political commitment, and appropriate financing and institutional support, nuclear energy, both large reactors and advanced SMRs, can become a meaningful, though not dominant, pillar of Africa’s future power mix, enhancing energy security, enabling industrial growth, and supporting climate goals.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Iron Oxide Reduction Rate Affects Iron Product Morphology

Magnetite concentrates from different parts of the Mesabi Range, exhibiting varying tendencies to encapsulate, were reduced using thermogravimetric analysis (TGA) and a high-temperature confocal scanning laser microscope (CSLM). Gas-phase mass-transfer conditions were intentionally varied by employing two reactors with different geometries: the TGA produced significantly slower reduction, whereas the CSLM setup yielded reduction rates up to 20 times faster under mass-transfer-controlled conditions. A preliminary mechanism is proposed to explain the transition from a porous iron product to a dense encapsulating layer. Encapsulation is interpreted as the outcome of competition between pore creation, driven by the reduction rate, and pore elimination, driven by surface diffusion. When pore formation is insufficient to counteract pore coarsening, a dense iron layer develops and restricts further reduction.

encapsulation↗