The large-scale storage of hydrogen plays a fundamental role in a potential future hydrogen economy. Although the storage of gaseous hydrogen in salt caverns already is used on a full industrial scale, the approach is not applicable in all regions due to varying geological conditions. Therefore, other storage methods are necessary. In this article, options for the large-scale storage of hydrogen are reviewed and compared based on fundamental thermodynamic and engineering aspects. The application of certain storage technologies, such as liquid hydrogen, methanol, ammonia, and dibenzyltoluene, is found to be advantageous in terms of storage density, cost of storage, and safety. The variable costs for these high-density storage technologies are largely associated with a high electricity demand for the storage process or with a high heat demand for the hydrogen release process. If hydrogen is produced via electrolysis and stored during times of low electricity prices in an industrial setting, these variable costs may be tolerable.

Steelmaking is responsible for around 7% of the global emissions of carbon dioxide and new steelmaking processes are necessary to reach international climate targets. As a response to this, steelmaking processes based on the direct reduction of iron ore by hydrogen produced via water electrolysis powered by renewable electricity have been suggested. Here we present a novel variant of hydrogen-based steelmaking incorporating methanol as a hydrogen and carbon carrier together with high-temperature co-electrolysis of water and carbon dioxide and biomass oxy-fuel combustion. The energy and mass balances of the process are analyzed. It is found that this methanol-based direct reduction process may potentially offer a number of process-related advantages over a process based on pure hydrogen, featuring several process integration options. Notably, the electricity and total energy use of the steelmaking process could be reduced by up to 25% and 8% compared to a reference pure-hydrogen process, respectively. The amount of high-temperature (>200 °C) heat that must be supplied to the process could also be reduced by up to approximately 34%, although the demand for medium-temperature heat is substantially increased. Furthermore, the suggested process could allow for the production of high-quality direct reduced iron with appropriate carburization to alleviate downstream processing in an electric arc furnace, which is not the case for a process based on pure hydrogen.

This study investigates the integration of water electrolysis technologies in fossil-free steelmaking via the direct reduction of iron ore followed by processing in an electric arc furnace (EAF). Hydrogen (H2) production via low or high temperature electrolysis (LTE and HTE) is considered for the production of carbon-free direct reduced iron (DRI). The introduction of carbon into the DRI reduces the electricity demand of the EAF. Such carburization can be achieved by introducing carbon monoxide (CO) into the direct reduction process. Therefore, the production of mixtures of H2 and CO using either a combination of LTE coupled with a reverse water-gas shift reactor (rWGS-LTE) or high-temperature co-electrolysis (HTCE) was also investigated. The results show that HTE has the potential to reduce the specific electricity consumption (SEC) of liquid steel (LS) production by 21% compared to the LTE case. Nevertheless, due to the high investment cost of HTE units, both routes reach similar LS production costs of approximately 400 €/tonne LS. However, if future investment cost targets for HTE units are reached, a production cost of 301 €/tonne LS is attainable under the conditions given in this study. For the production of DRI containing carbon, a higher SEC is calculated for the LTE-rWGS system compared to HTCE (4.80 vs. 3.07 MWh/tonne LS). Although the use of HTCE or LTE-rWGS leads to similar LS production costs, future cost reduction of HTCE could result in a 10% reduction in LS production cost (418 vs. 375 €/tonne LS). We show that the use of HTE, either for the production of pure H2 or H2 and CO mixtures, may be advantageous compared to the use of LTE in H2-based steelmaking, although results are sensitive to electrolyzer investment costs, efficiencies, and electricity prices.

Steelmaking is responsible for approximately one third of total industrial carbon dioxide (CO2) emissions. Hydrogen (H2) direct reduction (H-DR) may be a feasible route towards the decarbonization of primary steelmaking if H2 is produced via electrolysis using fossil-free electricity. However, electrolysis is an electricity-intensive process. Therefore, it is preferable that H2 is predominantly produced during times of low electricity prices, which is enabled by the storage of H2. This work compares the integration of H2 storage in four liquid carriers, methanol (MeOH), formic acid (FA), ammonia (NH3) and perhydro-dibenzyltoluene (H18-DBT), in H-DR processes. In contrast to conventional H2 storage methods, these carriers allow for H2 storage in liquid form at moderate overpressures, reducing the storage capacity cost. The main downside to liquid H2 carriers is that thermochemical processes are necessary for both the storage and release processes, often with significant investment and operational costs. The carriers are compared using thermodynamic and economic data to estimate operational and capital costs in the H-DR context considering process integration options. It is concluded that the use of MeOH is promising compared to the other considered carriers. For large storage volumes, MeOH-based H2 storage may also be an attractive option to the underground storage of compressed H2. The other considered liquid H2 carriers suffer from large thermodynamic barriers for hydrogenation (FA) or dehydrogenation (NH3, H18-DBT) and higher investment costs. However, for the use of MeOH in an H-DR process to be practically feasible, questions regarding process flexibility and the optimal sourcing of CO2 and heat must be answered

Hydrogen direct reduction has been proposed as a means to decarbonize primary steelmaking. Preferably, the hydrogen necessary for this process is produced via water electrolysis. A downside to electrolysis is the large electricity demand. The electricity cost of water electrolysis may be reduced by using a hydrogen storage to exploit variations in electricity price, i.e., producing more hydrogen when the electricity price is low and vice versa. In this paper we compare two kinds of hydrogen storages in the context of a hydrogen direct reduction process via simulations based on historic Swedish electricity prices: the storage of gaseous hydrogen in an underground lined rock cavern and the storage of hydrogen chemically bound in methanol. We find the methanol-based storages to be economically advantageous to lined rock caverns in several scenarios. The main advantages of methanol-based storage are the low investment cost of storage capacity and the possibility to decouple storage capacity from rate capacity. Nevertheless, no storage option is found to be profitable for historic Swedish electricity prices. For the storages to be profitable, electricity prices must be volatile with relatively frequent high peaks, which has happened rarely in Sweden in recent years. However, such scenarios may become more common with the expected increase of intermittent renewable power in the Swedish electricity system.

Steelmaking is responsible for 7% of the global net emissions of carbon dioxide and heavily reducing emissions from currently dominating steelmaking processes is difficult and costly. Recently, new steelmaking processes based on the reduction of iron ore with hydrogen (H2) produced via water electrolysis have been suggested. If the electricity input to such processes is fossil-free, near-zero carbon dioxide emissions steelmaking is achievable. However, the high electricity demand of electrolysis is a significant implementation barrier. A H2 storage may alleviate this via allowing a larger share of H2 to be produced at low electricity prices. However, accurately forecasting the dynamics of electricity markets is challenging. This increases the risk of investment in a H2 storage. Here we evaluate a novel methanol-based H2 storage concept for a H2-based steelmaking process that also allows for the co-production of methanol. During electricity price peaks, the methanol can be reformed to produce H2 for the steelmaking process. During prolonged periods of low electricity prices, excess methanol can be produced and sold off, thus improving the prospects of storage profitability. We use historical electricity prices and a process model to evaluate methanol-fossil-free steel co-production schemes. Methanol co-production has the potential to improve the economics of H2 supply to a fossil-free steelmaking process by up to an average of 0.40 €/kg H2 across considered scenarios, equivalent to a reduction in H2 production electricity costs of 25.0%.