COMPARISON OF ENERGY CONSUMPTION IN STEEL PRODUCTION BY OUTDATED SINTER-BLAST FURNACE AND OPEN-HEARTH PROCESSES WITH MIDREX H2 MODERN TECHNOLOGY OF DIRECT IRON REDUCTION AND SMELTING IN AN ARC FURNACE

Abstract

Based on the assertion that metallurgy is one of the most crucial industries needing to transition to more environmentally friendly production methods, the importance of moving from outdated steel production technologies used in Ukraine (particularly at “Zaporizhstal”) to more modern ones is highlighted. It has been found that the implementation of modern technologies, such as direct reduction using Midrex H2 followed by pellet smelting in electric arc furnaces (EAF), will be an important step towards reducing emissions and improving the energy efficiency of steel production technologies. The study compares the energy consumption of different steel production methods, including a sintering plant with an aspiration system, an open-hearth furnace, Midrex H2 technology, and EAF. It was found that the energy BSFC consumption of the sintering plant is approximately 33 kWh/t, the blast furnace – 3,3 kWh/t, the open-hearth furnace – 4 kWh/t, Midrex H2 – 85 kWh/t, and EAF – 340 kWh/t. Although Midrex H2 technology has higher energy consumption compared to traditional methods, it offers significant environmental benefits due to lower CO2 emissions. EAF provides flexibility and efficiency in recycling steel scrap, despite the highest energy consumption. The evaluation of different production types also considers maintenance costs, infrastructure investments, and environmental impact. Comparing these technologies allows for identifying the most efficient and economically viable steel production methods for modern conditions. The research methodology included on-site measurements, data processing and analysis, as well as a comparative analysis. The results show that the sinter-blast furnace process combined with the open-hearth furnace generates significant CO2 emissions compared to the Midrex H2 + EAF technology. The sintering process is one of the most energy-intensive, while the blast furnace requires less energy. The open-hearth furnace consumes relatively little energy, but its inefficiency makes it less attractive. Midrex H2 demonstrates high energy efficiency and environmental cleanliness. EAF, despite high energy costs, is flexible in using secondary raw materials. The study’s conclusions emphasize the varying energy efficiency of different technologies. The research underscores the importance of developing and implementing modern technologies for the future of the industry.