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 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.