Hydrogen metallurgy for decarburisation in the steel industry

Sustainable technologies play a central role in shaping the industry of the future – and this is exactly where we come in. As a partner for engineering solutions, cross-ING is deeply engaged in innovative approaches to reduce emissions and promote sustainable processes. A compelling example of this is hydrogen metallurgy, which opens new possibilities for decarbonizing steel production.

The steel industry, a cornerstone of global infrastructure and manufacturing, is undergoing a transformation to reduce its CO₂ footprint. As one of the largest industrial emitters of CO₂, the sector is under increasing pressure to adopt sustainable practices and technologies. Hydrogen metallurgy, a novel approach to steelmaking, has emerged as a promising solution to decarbonize the industry and align it with global climate goals.

In hydrogen metallurgy, hydrogen is used as a reducing agent to replace traditional carbon-based agents like coke in the steelmaking process. The core principle involves reducing iron ore (Fe₂O₃) to metallic iron (Fe) using hydrogen gas (H₂). Unlike carbon, which produces CO₂ as a by-product, hydrogen reacts with oxygen to form water (H₂O), significantly reducing greenhouse gas emissions from steel production. This shift to hydrogen-based steelmaking could reduce CO₂ emissions by up to 90% compared to conventional blast furnace operations, making it a pivotal technology in the industry’s decarbonization efforts [1].

CO₂ emissions from steel production compared to other materials.

One of the most notable initiatives in this field is the HYBRIT (Hydrogen Breakthrough Ironmaking Technology) project, led by SSAB, LKAB, and Vattenfall in Sweden. HYBRIT aims to produce fossil-free steel by replacing coke with hydrogen in the reduction process. Early trials have shown promising results and demonstrated the feasibility of large-scale hydrogen-based steel production. The project marks a significant step toward climate neutrality in the steel industry by 2045, as outlined in the EU's climate action plan [2].

Despite its potential, hydrogen metallurgy faces several challenges that must be addressed to achieve widespread adoption. One of the main hurdles is the high cost of green hydrogen, produced via electrolysis using renewable energy. Additionally, the production and storage infrastructure for hydrogen requires substantial investment, posing economic barriers for many steelmakers. Converting existing steel plants to hydrogen-based processes also involves considerable technical and financial challenges [3].

Overcoming these obstacles will require collaborative efforts between governments, industry, and research institutions. Policy measures such as subsidies for green hydrogen production, carbon pricing, and investment in hydrogen infrastructure can play a crucial role in accelerating the transition. Research and development initiatives are also focused on optimizing hydrogen production technologies and integrating them into existing steelmaking processes (Ziegler et al., 2022).

The environmental and economic impact of hydrogen metallurgy is significant. In addition to reducing emissions, hydrogen-based steel production can enhance energy security by reducing reliance on fossil fuels. It also creates opportunities for new supply chains and green jobs, contributing to economic growth in regions investing in hydrogen technologies. As we move toward a low-carbon future, the adoption of hydrogen metallurgy will be critical for achieving global climate goals and promoting sustainable development.

Switzerland is actively advancing hydrogen metallurgy as part of its efforts to decarbonize the steel industry, leveraging its strong research and industrial ecosystem. Institutions such as Empa and the Swiss Steel Group are leading initiatives to integrate hydrogen as a reducing agent and replace traditional carbon-intensive methods. Pilot projects supported by green hydrogen production from hydropower are testing the feasibility of hydrogen-based steelmaking with promising results. Switzerland’s investments in hydrogen infrastructure – including production, storage, and distribution – further facilitate the scaling of these technologies. The collaboration between research institutions, industry, and government, along with participation in European hydrogen initiatives, positions Switzerland as a key player in the transition to sustainable steel production [4].

How can cross-ING support you?

Hydrogen metallurgy demonstrates how innovative technologies can drive the transition to more sustainable processes. At cross-ING, we support companies in integrating such innovations into their manufacturing – from process optimization and material selection to the implementation of new technologies.

Get in touch with us to learn how we can develop sustainable solutions for your projects – together.

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References:

• Raabe, Dierk, et al. Circular Steel for Rapid Decarbonization: Thermodynamics, Kinetics, and Microstructure Behind Upcycling Scrap into High-Performance Steel. Annual Report on Materials Research 54.2024 (2024): 247-297.

• HYBRIT Initiative (2023). "Fossil-Free Steel Production." Retrieved from https://www.hybritdevelopment.com

• World Steel Association (2023). Sustainability Report: Towards Net-Zero Steel Production. https://www.worldsteel.org

• Empa (Swiss Federal Laboratories for Materials Science and Technology). Hydrogen Projects and Applications in Industrial Processes. https://www.empa.ch

*Translated with deepl.ch