Innovative Hydrogen-Based Reduction and Carburization Strategies for Renewable Energy-Based Ironmaking (HYCARE)

The HYCARE project has recently been approved for funding by Formas and aims to address some of the pressing challenges in decarbonizing the iron and steel industry.

Project Summary:

Globally, the steel sector is among the largest emitters of greenhouse gases (GHGs), primarily through carbon dioxide (CO₂) emissions. In Sweden, the iron and steel industry alone is responsible for approximately 6.6 million tons of fossil CO₂ emissions annually, representing around 9% of the country’s total emissions. Achieving net-zero emissions by 2045 is a national goal and one that places significant pressure on the steel industry to find cost-effective and scalable low-carbon solutions.

One of the promising strategies is replacing fossil carbon with green hydrogen in ironmaking. Sweden is already leading this transition through several initiatives. However, key challenges remain, particularly around:

• The handling and processing of carbon-free hydrogen-reduced iron (H-DRI)
• Ensuring a stable and continuous supply of green hydrogen
• The need for carbon in the steelmaking process for energy efficiency, slag foaming, and alloy formation

HYCARE's Three Innovative Approaches:

1. Bio-Syngas as a Renewable Carbon Source
   A small amount of bio-syngas is introduced alongside hydrogen in the reduction shaft, enabling the simultaneous reduction and carburization of iron oxide pellets. This approach not only incorporates the required carbon into H-DRI but also keeps the process fossil-free and promotes circular use of bio-based byproducts.
   
   
2. CO₂ as a Carburizing Agent
   By leveraging the reverse water-gas shift (RWGS) reaction, a hydrogen + CO₂ gas mix is used to both reduce and carburize the iron oxide. This not only adds carbon to H-DRI but also offers a pathway to negative CO₂ emissions, transforming steelmaking from an emitter into a potential carbon sink.
   
   
3. Methanol and Ethanol as Hydrogen Carriers
   Methanol and ethanol are explored as dual-function agents: reducing iron oxide and supplying carbon. This strategy addresses hydrogen availability challenges while introducing flexibility and redundancy into the process.

Expected Impact:

• Significant reduction in CO₂ emissions from iron and steel production
• Enhanced energy security and air quality
• Greater process flexibility and resource efficiency
• Creation of new market opportunities for biomass-derived energy products
• Support for Sweden's and the EU’s climate and industrial competitiveness goals

The project is strategically relevant not only for Sweden but also for other European countries with access to biomass and green electricity. As renewable energy infrastructure expands, HYCARE aims to help build a more sustainable, competitive, and climate-aligned steel industry for the future.