Development of ‘Green’-Metallurgy Technologies

SAVELIEV S.G., YAROSH T.P., KONDRATENKO M.M., BABAIEVSKA O.V., BABOSHKO D.Yu., and PLOTNIKOV V.V.

Kryvyi Rih National University, 11 Vitaliy Matusevych Str., UA-50027 Kryvyi Rih, Ukraine

Received 17.02.2025, Final version 06.05.2025 Download PDF logo PDF

Abstract
The article is concerned with the urgent problem of decarbonisation of metallurgy, which produces 8% of global CO2 emissions into the atmosphere. Solving this problem will help us protect ourselves from the effects of climate change caused by rising temperatures on the Earth’s surface. Metallurgical production, which does not emit CO2 into the atmosphere and consumes raw materials and energy obtained without the use of fossil fuels, is called ‘green’ metallurgy. The transformation of ferrous metallurgy into ‘green’ one occurs mainly by replacing the traditional steelmaking scheme ‘blast furnace–oxygen converter’ with a new one ‘direct reduced iron–electric arc furnace’. The article identifies the most promising methods for producing ‘green’ steel: Midrex, Energiron ZR, YBRIT, in which direct reduced iron is obtained in shaft furnaces using a gaseous reducing agent. The Energiron ZR technology is implemented at the plant of the American company Nucor Steel Louisiana. The Midrex and HYBRIT technologies will be implemented at the plants under construction in the Swedish cities of Boden and Gällivare. The article also draws attention to the new energy-efficient HIsarna cast iron production technology, which allows capturing up to 80% of CO2, as well as reducing emissions of dust, NOx, SOx, and CO by 60–80%.

Keywords: metallurgical process, gas, steel, hydrogen, emission, iron.

DOI: https://doi.org/10.15407/ufm.26.02.***

Citation: S.G. Saveliev, T.P. Yarosh, M.M. Kondratenko, O.V. Babaievska, D.Yu. Baboshko, and V.V. Plotnikov, Development of ‘Green’-Metallurgy Technologies, Progress in Physics of Metals, 26, No. 2: ***–*** (2025)


References  
  1. M.S. Trushin, The role of green parties in the modern EU policy, Bulletin of the Volga Region Institute of Administration, 22, No. 4: 17 (2022) (in Russian); https://doi.org/10.22394/1682-2358-2022-4-17-26
  2. G.V. Gubіn and V.O. Pіven’, Suchasnі Promyslovі Sposoby Bezkoksovoi Metalurgіyi Zalіza [Modern Industrial Methods of Coke-Less Iron Metallurgy] (Kryvyi Rih: 2010) (in Ukrainian).
  3. L. Chai, Yu. Wang, Z. Sun, M. Si, Y. Liang, and X. Min, Innovative Development Strategy of Green Metallurgy, Strategic Study of CAE, 24, No. 2: 10 (2022); https://doi.org/10.15302/J-SSCAE-2022.02.004
  4. K. Levchuk, Shvedskaya SSAB Postavila Volvo Pervuyu Partiyu ‘Zelenoy’ Stali [Swedish SSAB supplied Volvo with the first batch of ‘green’ steel] (GMK Center: 1598/19/2021); https://gmk.center/news/shvedskaya-ssab-postavila-volvo-pervuju-partiju-zelenoj-stali
  5. HYBRIT Fossil-free steel 2024; https://www-hybritdevelopment-se
  6. E. Prystavka, Sozdana pervaia ‘zelenaya’ stal bez iskopaemoho topliva [The First ‘Green’ System Created without Fossil Fuels] (KhAITEK, Nauka: 2021); https://hightech.fm/2021/08/19/first-fossil-free
  7. S. Liamets, Chem evropeiskaya ‘zelenaya metallurgiya’ otlichayetsya ot ukrayinskoi [How does European ‘green metallurgy’ differ from Ukrainian] (Blohy Chytachiv: 13/08/2020); https://blogs.korrespondent.net/blog/business/4262819
  8. Pro vnesennya zmin do deyakykh zakoniv Ukrayiny shchodo udoskonalennya umov pidtrymky vyrobnytstva ehlektrychnoyi energii z alternatyvnykh dzherel [On the introduction of amendments to some laws of Ukraine regarding the improvement of the conditions for supporting the production of electricity from alternative sources] (Verkhovna Rada Ukrainy. Zakonodavstvo Ukrainy); https://zakon.rada.gov.ua/laws/show/810-20#Text
  9. Ekolohichna transformatsiya: yak rozvyvayetsya zelena metalurhiya v Ukrayini [Environmental transformation: how green metallurgy is developing in Ukraine] (New Voice: 1092/12/08/2023) https://biz.nv.ua/ukr/markets/vidnovlennya-promislovosti-a-ukrajini-v-yakomu-stani-zelena-metalurgiya-perspektivi-50346472.html
  10. Indiya vydelyayet $1,74 mlrd na podderzhku proizvodstva «zelenoi» stali [India allocates $1.74 billion to support green steel production] (METALLPLACE: 17/01/2025); https://metallplace.ru/news170125_8
  11. C. Ramakgala and G. Danha, A review of ironmaking by direct reduction processes: Quality requirements and sustainability, Procedia Manufacturing, 35: 242 (2019) (in Russian); https://doi.org/10.1016/j.promfg.2019.05.034
  12. E.P. Bolshyna, Ekologiya Metallurgicheskogo Proizvodstva: Kurs lektsyi [Ecology of Metallurgical Production: Course of lectures] (Novotroitsk: NF NITU ‘MISiS’ 2012) (in Russian); https://z-lib.io/book/16653255
  13. Mirovoye proizvodstvo zheleza pryamogo vosstanovleniya v fevrale 2024 goda [World production of direct reduced iron in February 2024] (METALLPLACE: 25/03/2024); https://metallplace.ru/news250324_18
  14. Tata Steel testiruyet ispolzovaniye vodoroda dlya raboty domennykh pechei [Tata Steel is testing the use of hydrogen to operate blast furnaces] (YYS Metallosnabzhenie: 2023); https://www.metalinfo.ru/ru/news/148287
  15. L. Guo, F. Liu, and Z. Guo, Development process of iron and steel metallurgy technology and the low-carbon development path in the new era, Chemical Industry and Engineering Progress, 43, No. 7: 3567 (2024); https://doi.org/10.16085/j.issn.1000-6613.2024-0104
  16. M. Hosseinzadeh, N. Kasiri, and M. Rezaei, A comprehensive multiscale review of shaft furnace and reformer in direct reduction of iron oxide, Minerals Engineering, 222: 109123 (2025); https://doi.org/10.1016/j.mineng.2024.109123
  17. S. Peng, R. Binglang, W. Jingsong, W. Guang, Z. Haibin, and X. Qingguo, Current situation and development prospects of metallurgical by-product gas utilization in China’s steel industry, International Journal of Hydrogen Energy. 48, No. 74: 28945 (2023); https://doi.org/10.1016/j.ijhydene.2023.04.050
  18. A. Bisen, Industrial project report on metallurgical review: Production of direct reduced iron (DRI HBI). Tech. Rep. INT-Tech/01/2021, Researchgate, (Technical Core Group (TCG): HBI Dept.) (2022) (in Indian); https://doi.org/10.13140/RG.2.2.19272.12804/1
  19. V. Kolisnichenko, Global DRI production up 6.5% y/y in 2023 — Midrex (GMK Center: 952/04/09/2024); https://gmk.center/en/news/global-dri-production-up-6-5-y-y-in-2023-midrex
  20. Midrex: Producing 76 million tons of direct reduction iron in the world in 2023 (Arab Iron and Steel Union: 03/07/2024) https://aisusteel.org/en/27936/
  21. G. Wallwork, The MIDREX® plant is extremely flexible and can accommodate the initial transitions from a carbon to a hydrogen economy (MIDREX: 2024) https://aisusteel.org/en/27936
  22. H. Yermolenko, Thyssenkrupp chose Midrex Flex technology for the new DRI plant (GMK Centre: 1731/15/03/2023); https://gmk.center/en/news/thyssenkrupp-chose-midrex-flex-technology-for-the-new-dri-plant
  23. H. Yermolenko, H2 Green Steel: a startup shaping the future of green steel industry (GMK Centre: 6989/03/10/2023); https://gmk.center/en/posts/h2-green-steel-a-startup-shaping-the-future-of-green-steel-industry
  24. Energiron Direct Reduction Technology (MFG Robot: 2024) (in Russian); https://ru.mfgrobots.com/mfg/mpm/1010021345.html
  25. ENERGIRON enables Nucor to achieve a World Production Record (Tenova: 06/11/2024); https://tenova.com
  26. P. Duarte, J. Becerra, C. Lizcano, and A. Martinis, ENERGIRON Direct Reduction Technology — Economical, Flexible, Environmentally Friendly (Tenova: 2007); https://tenova.com
  27. A. Mukhopadhyay and M. Ometto, 302-312 Energy saving and CO2 reduction in Energiron DRI production, 6th International Congress on Science and Technology of Ironmaking 2012 (ICSTI): Associao Brasileira de Metalurgia (Rio de Janeiro, Brazil: Curran); https://abmproceedings.com.br/en/article/energy-saving-and-co2-reduction-in-energirondri-production-3
  28. Energiron (Tenova); https://tenova.com/technologies/energiron
  29. A. Martinis, Salzgitter Flachstahl selects Energiron DR technology (Danielі. NEWS & EVENTS: 24/05/2023); https://www.danieli.com/en/news-media/news/salzgitter-flachstahl-selects-energiron-dr-technology_37_814.htm
  30. H. Yermolenko, LKAB selects Energiron technology for DRI plant in Sweden (GMK Center: 3692/13/02/2024); https://gmk.center/en/news/lkab-selects-energiron-technology-for-dri-plant-in-sweden
  31. Tata Steel receives DR technology from Danieli (Düsseldorf: 2024); https://www.wire-tradefair.com/en/Media_News/News/Industry_News/Tata_Steel_receives_DR_technology_from_Danieli
  32. ENERGIRON for Empresa Siderrgica del Mutn (ENERGIRON: 26/10/2023); https://www.energiron.com/media/news/energiron-for-empresa-siderurgica-del-mutun
  33. HIsarna Cast Iron Production Process (MFG Robot: 2024); https://ru.mfgrobots.com/mfg/mpm/1010021131.html