The effect of hydrogen pre-reduction on the carbon-reducibility of pelletised UG2 chromite

• South African UG2 ore was pre-reduced in a H 2 atmosphere. • H 2 pre-reduction metalized approximately 64 % of Fe-oxides. • H 2 pre-reduction reduced C dependency by 16 %. • Fe was stripped from the ore using hot-acid leaching. • The Fe-stripped UG2 was reduced using solid C to yield a high Cr content phase. This study investigated the incorporation of hydrogen (H 2 ) as a partial replacement of carbon (C) during ferrochrome (FeCr) production. Chromite was subjected to H 2 -reduction to metallise its iron (Fe) −oxide content, followed by the removal of the metallised Fe by acid leaching. Hereafter, the chromium (Cr) −oxide rich ore was subjected to C-reduction. During H 2 -reduction, 64.3 % ± 6.1 % of Fe-oxides could be metallise, whereas C-reduction metallised the remaining Fe-oxides, as well as the Cr-oxide constituency. The C-reduction at 1300 °C resulted in near-complete metallisation of both the Fe- and Cr-oxide constituencies. By following this route, C emissions were reduced by approximately 16 %. It was further determined the process followed a shrinking core model. This model was confirmed by sub-surface microscopy, which highlighted the formation of a metallic layer at the chromite particle surface. This layer formation was evident during both H 2 - and C-reduction. It was also found that during the implemented Fe removal process that decrepitation of the H 2 -treated ore occurred. Mineralogical analysis of the H 2 -reduced and leached chromite suggests the formation of an eskolaite-type phase. Subsequent removal of the metallised Cr resulted in a MgAl 2 O 4 spinel-type phase, which suggests that the majority of Fe and Cr were removed. These findings provide comprehensive insights into the chemical, physical, and mineralogical transformations of chromite during reduction and leaching, offering valuable implications for the decarburisation of FeCr production.