A Review on the Hydrogen-Based Molten Reduction of Iron Oxides

In the context of global carbon neutrality goals, substituting hydrogen for carbon as a reductant represents a critical pathway for mitigating emissions in the iron and steel industry. Hydrogen-based molten reduction technology, characterized by its rapid reaction kinetics and high feedstock flexibility, has emerged as a pivotal direction for the industry’s low-carbon transition. This article systematically reviews research progress on the hydrogen-based reduction of molten iron oxides. The thermodynamic behavior of molten systems is discussed, confirming the feasibility of reducing molten FeO with hydrogen at elevated temperatures. Furthermore, discrepancies and nonlinear characteristics within current mainstream thermodynamic databases regarding the high-temperature molten region are identified. Kinetic studies demonstrate that reduction rates in the molten state significantly exceed those in the solid state. The rate-limiting step is shown to vary with reaction conditions, primarily shifting between interfacial chemical reaction and liquid-phase mass transfer control. Additionally, the influence mechanisms of key parameters—including temperature, reaction time, gas flow rate, gas composition, and slag composition—on the reduction process are comprehensively reviewed. By synthesizing existing methodologies and theoretical advancements, this review aims to provide a theoretical reference for optimizing hydrogen-based molten reduction processes for iron oxides.