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Decarbonizing steel manufacturing: a comparative study of technological innovations in BF-BOF, DRI-EAF, and Scrap-EAF production routes

Student name: Mr Kunal Rathi
Guide: Dr Shruti Sharma Rana
Year of completion: 2025
Host Organisation: Jindal Stainless Limited
Supervisor (Host Organisation): Mr Sameer Singh
Abstract:

The steel industry is one of the most carbon-intensive sectors globally, accounting for approximately 7–9% of global CO₂ emissions. As countries commit to net-zero targets, decarbonizing steel production has emerged as a critical challenge and opportunity. This study compares three primary steel production routes—Blast Furnace–Basic Oxygen Furnace (BF–BOF), Direct Reduced Iron–Electric Arc Furnace (DRI–EAF), and Scrap-based Electric Arc Furnace (Scrap–EAF)—to evaluate the effectiveness of emerging technological innovations aimed at reducing carbon emissions. Through a detailed review of industrial practices, policy frameworks, and techno-economic analyses, the dissertation assesses innovations such as hydrogen-based DRI, carbon capture and utilization (CCUS), electrification, and integration of renewable energy. The study explores technological advancements such as hydrogen-based reduction, renewable electricity integration, carbon capture utilization and storage (CCUS), and circular economy strategies like scrap recycling. Using data from global benchmarks, industry case studies, and policy frameworks, a techno-economic and environmental comparison is developed across the three routes. Emission intensity (kg CO₂/ton), energy consumption (GJ/ton), capital and operating costs, and scalability are assessed. Key findings indicate that Scrap–EAF is the most carbon- efficient route but faces limitations due to scrap availability and quality. DRI– EAF, particularly hydrogen-based, offers significant decarbonization potential but entails high energy demands and investment requirements. BF–BOF, while currently dominant, must undergo transformative upgrades such as CCUS and hydrogen injection to remain viable in a low-carbon future.

Keywords: Steel decarbonization, BF–BOF, DRI–EAF, Scrap–EAF, green hydrogen, CCUS.