- Research Article
- 10.1088/1742-6596/3195/1/012013
Hydrogen-Based Steelmaking: An Energy, Exergy and Environmental Assessment
- Mar 01, 2026
- Journal of Physics: Conference Series
- Florentin Eckl + 3 more +3
Abstract The steel industry is one of the largest industrial emitters of carbon dioxide, and new production routes are required to meet climate targets. Hydrogen-based direct reduction combined with an electric arc furnace is widely discussed as a promising pathway to significantly reduce emissions. This study investigates this production pathway with a mix of 87% scrap and 13% reduced iron. The system requires 3.40 GJ/t Steel , with hydrogen production and scrap melting as the main energy consumers. Exergy results show efficiencies of 53.6% for the electrolyzer, 74.8% for the reduction furnace, and 87.2% for the arc furnace, leading to an overall resource efficiency of 78.1%, more than twice that of the conventional blast furnace–basic oxygen furnace route. Emissions are 128 kg CO 2 e /t Steel with the Portuguese grid mix and 70 kg CO 2 e /t Steel with 100% renewables, corresponding to >94% reduction compared to conventional production. The results confirm the potential of hydrogen-based steelmaking for low-carbon steel production, while highlighting electrolyzer efficiency and renewable electricity availability as the main challenges. Further improvements through heat integration and by-product valorization could support both efficiency and sustainability
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