A research team led by Prof. ZHAO Peng from the Hefei Institutes of Physical Science the Chinese Academy of Sciences has completed a long-duration test of a 5 MW single plasma torch designed for industrial metallurgical applications. The system, developed in collaboration with Baowu Equipment Intelligent Technology Co., Ltd. and Baowu Heavy Industries Co., Ltd., operated continuously for 172 hours on the offline experimental platform at Xinjiang Bayi Iron & Steel Co., Ltd.

During the trial, the researchers performed optical and electrical diagnostics on a MW-level plasma torch for the first time worldwide. Additionally, the test established a new benchmark for the highest power reached by a single plasma torch.

Currently the largest single-unit plasma torch, the 5 MW plasma torch is ready for industrial use. According to the team, all performance targets were met or exceeded, including operational stability, reliability, and safety under high-load and complex working conditions. Temperature imaging and other diagnostic tools were used to evaluate the characteristics of the plasma throughout the test.

With temperatures reaching tens of thousands of degrees Celsius, the torch can deliver a stable source of heat to metallurgical furnaces. When integrated into iron-making processes, it is expected to partially replace fossil fuel combustion, offering a cleaner and more controllable thermal environment. Its high plasma activity may also enhance the reduction-reaction depth and efficiency.

Prof ZHAO's team contributed plasma physics expertise accumulated through major scientific facilities such as the Experimental Advanced Superconducting Tokamak. This expertise helped address technical challenges in extending the lifetime of the torch and achieving stable operation at high power. Baowu Equipment Intelligent Technology Co., Ltd. and Baowu Heavy Industries Co., Ltd. contributed to the design and operation of the long-lifetime torch and supported the engineering implementation on site.

"If powered by renewable electricity, plasma torches could provide a route toward lower-carbon smelting," said Prof. ZHAO. The 5 MW torch test is an initial step in verifying the technical feasibility of such applications in the steel industry.

5 MW plasma torch running during the 172-hour test. (Image by SU Yi)

Temperature distribution imaging of 5 MW plasma torch physical diagnostics (Image by SU Yi)