B.

Tech SEMINAR ON
ASSESMENT OF HYDROGEN DIRECT REDUCTION ON FOSSIL
FREE STEELMAKING
B.Tech Mechanical Engineering
Presented by:

MUHAMMED MUBASHIR T
REG. NO: AWH 19 ME 022

Under Guidance of
Mr. Safeer . M (Asst.Professor)

MECHANICAL ENGINEERING DEPARTMENT

AWH ENGINEERING COLLEGE
CALICUT - 673008
DECEMBER 2022
INTRODUCTION
• Steel and cement industries are the largest contributors of global
industrial CO2 emissions.
• Usually steel is produced using blast furnace-basic oxygen
steelmaking(BF-BOS).
• It is reliant upon coke as a reducing agent.
• Produces 1.8 tons of CO2 is released per ton of steel produced.
• The option of electrification and the use of hydrogen has gained attention.

• European steelmakers like GrInHy , H2FUTURE initiated projects focusing on

electrolyser development, and HYBRIT aiming to develop an entire fossil free

primary steel production.

• Basic concept is to use a hydrogen direct reduction(H-DR) process to produce

direct reduced iron(DRI),then converted into steel in an electric arc furnace(EAF)

 What is steel?
• An alloy of iron and carbon.
• Content of carbon ranges up to 2%.
• To improve strength and fracture resistance.
 Steps of steel production

• Step 1 - Iron making process

• Step 2 - Primary steel making
• Step 3 - Secondary steel making
• Step 4 - Casting
• Step 5 - First forming
• Step 6 – Finishing process
 How traditionally steel is produced?
 DESIGN FOR H-DR PROCESS
• Electrolyser :- For splitting hydrogen from
water.
• Shaft furnace :- For direct reduction of iron
ore.
• Condenser :- Used to convert gaseous water
vapour into liquid water.
• H2 storage :- A tank to store the hydrogen.
CHEMICAL REACTIONS
• 
TRADITIONAL VS H-DR PROCESS
RESULTS AND DISCUSSIONS
• For continuous operation on 100% HBI requires 1504 kg of iron ore pellets per
ton of steel production.

• Without considering hydrogen losses, 51kg of hydrogen is needed per ton of steel
output.

• If EAF is charged with equal amounts of HBI and scrap, 738 kg of pellets, 536 kg
of scrap and 25 kg of hydrogen are needed per ton of steel production.
 ENERGY ANALYSIS
• A specific energy consumption (SEC) of
3.48 MWh/t of liquid steel was calculated
for the process , whereas a BOS
consumes 3.68 MWh/t.
• Electrolyser consumes two third of
energy.
• EAF and ore heating consumes energy
lesser than electrolyser.

Fig:-Specific energy consumption(SEC) of H-DR process as a function of

the scrap charged into the EAF[MWh/tLS]
• SEC is sensitive to the amount of scrap added to the EAF.

• The reason is that less iron ore is needed per output.

• Other factors affecting SEC :-

i. Low HBI metallization

ii. How much excess H2 is supplied to shaft

iii. Chance for heat loss between the shaft and EAF
 CO2 EMISSION
• The process is entirely electrified, the
emission depend on power grid emission
intensity (GEI).
• To compare the performance, a break-even
GEI is calculated.
• At pure HBI operation, the GEI is 532
kgCO2/MWh.
• At 25% scrap charge, GEI reaches 661
kgCO2/MWh.

Fig :- Break-even grid emission intensity (GEI) as a function of scrap

charged into the EAF
• CO2 is emitted during the extraction of iron ore and limestone , lime calcination
and through the addition of carbon as an essential component of steel.

• Even these emissions taken into account, it will be equal to only 2.8% of emissions
from BOS route.

• Avoiding emission from lime calcination require CCUS or substitution of lime

with any alternative.

• To replace carbon addition, bio-methane or other sources of biogenic carbon can

be used.
 ECONOMICS
• Capital expenditures (CAPEX) and operational expenses (OPEX) were calculated.
• Production costs are derived from these results.
• Assessment is based on 2030 technology.
• Electrolyser CAPEX is expected to decrease , while shaft and EAF costs are
assumed fixed.
 Fig :- Production cost of steel vs electricity cost(scrap Fig :- Production cost of steel vs electricity cost (scrap
charge 0%) charge 50%)

• Production costs for steel are calculated for pure HBI operation and 50% scrap
charge respectively.
• Production costs are highly sensitive to electricity price.
• This sensitivity is reduced when more scrap is charged.
• 50:50 charge of HBI and scrap reduces overall production cost.
 CONCLUSION
• The total energy requirement is similar to traditional BOS.
• Instead of coal and coke, project runs on electricity.
• The total production costs for liquid steel from HBI depends on price of electricity
and amount of scrap used.
• Production cost ranges from 361 to 640 EUR per ton for electricity costs of 20-
100 EUR/MWh.
REFERENCES

• Assessment of hydrogen direct reduction for fossil-free steelmaking ;

Valentin Vogl , Max Åhman, Lars J. Nilsson (2018)

• Energy system requirements of fossil-free steelmaking using hydrogen direct

reduction ; Andrew J. Pimm , Tim T. Cockerill , William F. Gale (2021)

THANK YOU