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<p>The electric arc furnace (EAF) steelmaking process using scrap and coke oven gas-based direct reduced iron (COG-DRI) offers a sustainable alternative to traditional integrated steelmaking, though the optimal use of DRI in EAF is still unclear. This study employs mathematical modeling and techno-economic analysis to evaluate material, energy consumption, and production costs based on the world’s first COG-DRI-based EAF production line for automotive sheets, using a 120-ton AC electric arc furnace. The optimization focuses on achieving improved energy efficiency and cost-effectiveness. The calculation results show that when the scrap and DRI prices are 389 USD/t and 386 USD/t, respectively, the optimal EAF steelmaking process considering electricity consumption, heat loss and economic performance uses a 20 pct COG-DRI ratio with 15.66 kg/t of carbon powder and 4.38 Nm<sup>3</sup>/t of natural gas, resulting in a minimum production cost of 504 USD/t. This research provides practical guidance for achieving low energy consumption, high efficiency, and cost-effective EAF steelmaking, supporting the industry’s transition to decarbonization.</p>

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Effect of Coke Oven Gas-Based Direct Reduced Iron Charging on Techno-Economic Analysis of Electric Arc Furnace Steelmaking

  • 期刊论文

  • 发表日期：

    2025年7月9日

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  • Botao Xue,
  • Afan Xu,
  • Guangsheng Wei,
  • Fengya Qin,
  • Alberto N. Conejo,
  • Hongbin Wang,
  • Rong Zhu

摘要

The electric arc furnace (EAF) steelmaking process using scrap and coke oven gas-based direct reduced iron (COG-DRI) offers a sustainable alternative to traditional integrated steelmaking, though the optimal use of DRI in EAF is still unclear. This study employs mathematical modeling and techno-economic analysis to evaluate material, energy consumption, and production costs based on the world’s first COG-DRI-based EAF production line for automotive sheets, using a 120-ton AC electric arc furnace. The optimization focuses on achieving improved energy efficiency and cost-effectiveness. The calculation results show that when the scrap and DRI prices are 389 USD/t and 386 USD/t, respectively, the optimal EAF steelmaking process considering electricity consumption, heat loss and economic performance uses a 20 pct COG-DRI ratio with 15.66 kg/t of carbon powder and 4.38 Nm3/t of natural gas, resulting in a minimum production cost of 504 USD/t. This research provides practical guidance for achieving low energy consumption, high efficiency, and cost-effective EAF steelmaking, supporting the industry’s transition to decarbonization.