DULUTH, Minn. – The U.S. Department of Energy (US DOE) announced last week the awarding of four grants totaling over $8 million to the University of Minnesota’s Natural Resources Research Institute (NRRI) to support the research and development of transformational technologies essential for reducing energy demand and improving American industrial competitiveness, beginning on Minnesota’s Iron Range.
These federal funds are matched with University, state and industry funding, and reflect a growing partnership between NRRI and national laboratories.
1. Pre-FEED (Front-End Engineering Design) for green iron plant
Funding: $1.34M (Hydrogen and Fuel Cells Technology Office, HFTO)
Partners: Barr Engineering, Big Rock Exploration, U. S. Steel, NREL
Summary:
NRRI and partners will examine the feasibility of constructing a hydrogen-based direct reduced iron (DRI) plant in Minnesota. The proposed facility would use hydrogen instead of coal or natural gas, with onsite integration of hydrogen generation by electrolysis, renewable electricity generation, and storage for hydrogen and energy. The proposed project would address technical and operational risks associated with integrating renewable energy and hydrogen production for continuous iron making at an industrial scale, while defining the economically viable scale for producing renewable hydrogen-based direct reduced iron. If successful, it would represent a path toward a low-carbon, secure domestic supply of iron for the U.S. steel industry, and its findings could be applied to other carbon-intensive industries. The University of Minnesota has identified this project as a priority and has requested state funding for Green Energy-Green Iron research as part of its Biennial Budget Request to the Legislature.
2. Graphite Core Induction Smelting Technology for Production of CO2-free Carburized Pig Iron
Funding: $3M (Industrial Efficiency and Decarbonization Office, IEDO) + NRRI matching funds
Partners: Metcovery II, LLC and NREL
Summary:
This research will scale and demonstrate a flow-through induction melting furnace. The furnace uses a novel graphite susceptor core concept, targeted explicitly toward pre-processing low-grade DRI into a carburized pig iron product. By displacing a significant amount of pig iron used in domestic electric arc steel furnaces with a lower carbon intensity will significantly reduce emissions while maintaining high productivity and economically competitive steel production.
3. Transformative Taconite Beneficiation Flowsheet of the Future
Funding: $3.1M (IEDO) + NRRI and Industry matching funds
Partner: U. S. Steel, NREL
Summary:
This research will focus on developing a transformational production flowsheet to upgrade Minnesota taconite ores to “direct reduction” (DR) grade. It aims to reduce the overall energy demand of DR grade pellet production by 25 percent, increase iron recovery efficiency by 3-5 percent and improve pellet quality. This effort will increase the supply of DR grade ores to meet increased demand while reducing the energy footprint.
4. Circular and Intensified Recovery of Iron Oxide from Abundant Oxidized Tailings for Sustainable Direct Reduced Iron Technologies (i.e., Circular Iron)
Funding: $3M (IEDO), Cornell University - Project Lead
Partner: NREL
Summary:
NRRI is a sub-awardee for $800,000 to provide iron ore processing and scale-up demonstration expertise. The project will focus on recovering high grade iron oxide of less than 68 percent iron from mine tailings and metallurgical slag using a novel electrochemical process. It will enable deployment of direct reduction (DR) technology in ironmaking by expanding production of high-grade iron feedstocks while reducing carbon emissions.
The Natural Resources Research Institute is a state-chartered, University of Minnesota System research unit with three sites in Northern Minnesota, fulfilling a mission to deliver integrated research solutions that value our resources, environment and economy for a sustainable and resilient future.
PHOTO TOP: NRRI campus in Coleraine, Minn.