Transitioning to Green Steel Manufacturing through the Adoption of Hydrogen-Based Technologies and Processes for Securing Net-Zero Carbon Dioxide Emissions by Aspen Plus

Abstract

Conventional green steel production heavily relies on coal, resulting in high levels of carbon dioxide emissions. This research focuses on hydrogen-based steelmaking as a cleaner alternative that supports global decarbonization goals. Traditional steelmaking methods like the BF-BOF process emit large amounts of CO₂, contributing significantly to global warming. Technologies such as Electric Arc Furnaces (EAF) powered by renewable energy and Carbon Capture and Storage (CCS) offer further emission reductions. Jindal Shadeed Iron & Steel aims to transition to hydrogen-based methods to achieve net-zero emissions by 2050. The novelty of this research lies in simulating a full-scale hydrogen-based steel plant using Aspen Plus, showing a 99.6% efficiency rate and zero CO₂ emissions. Comparison with JSIS showed zero emissions versus 1.4–1.8 tons CO₂/ton in current practice. The results revealed that hydrogen steelmaking significantly lowers emissions, energy usage, and water consumption. The system showed 99.6% efficiency, a return on investment of 51%, and a payback period under two years. RSM analysis showed that increasing shaft temperature from 800 °C to 1000 °C and pressure from 1 bar to 5 bar improved HDRI steel conversion efficiency by over 35%, while FEL values varied by less than 5% across all tested conditions. The comparisons with Jindal Shadeed’s existing systems highlighted substantial improvements in emission control and energy performance. In conclusion, hydrogenbased steel production is both practical and scalable. The supportive policies and investment analysis can drive a major shift toward sustainable industrial practices. The outcomes from this simulation provide a strong foundation for broader adoption of green steel technologies.