Process and system for steel and hydrogen production using recycled ferrous scrap and natural gas

A reactor to produce steel and hydrogen, the reactor comprising:

• an enclosed volume;
• a first inlet to feed a metal composition into the enclosed volume;
• a second inlet to feed a hydrocarbon reactant into the enclosed volume;
• a heat source to melt the metal composition into a first molten metal composition and to decompose the hydrocarbon reactant into at least one fluid product and carbon, wherein the first molten metal composition comprises iron and a metal, wherein the metal comprises at least one of:
• iron, nickel, manganese, cobalt, scandium, or lanthanum, wherein a metal alloy is formed from a mixture of the carbon and the first molten metal composition, and wherein a homogenous second molten composition is separated from the metal alloy;
• a second enclosed volume, wherein the second inlet is coupled to the second enclosed volume;
• a plurality of nozzles coupled to a bottom of the enclosed volume, wherein the first molten metal composition is dispersed into the second enclosed volume with the hydrocarbon reactant, wherein the first molten metal composition is dispersed at a range of 0.2 to 20,000 square centimeters of a surface area of the first molten metal composition per cubic centimeter of a volume of the second enclosed volume;
• and
• a second heat source to heat the second enclosed volume and to maintain a temperature between 500 degrees Celsius (° C.) to 1500° C.