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Methanation as a Low-Risk, Low-Emission Pathway for the Integrated DRI-ESF-BOF Process Route — Part 1

Many steel producers are considering direct reduced ironmaking (DRI) with subsequent hot metal production using an electric smelting furnace (ESF) as a decarbonization strategy. Little attention has been paid to the potential reuse of carbon-containing offgases when the DRI process is co-located with the ESF and an existing basic oxygen furnace (BOF) shop. Methanation of the CO-rich ESF and BOF offgases enables the recycling of carbon contained in these offgases back to the DRI plant as synthetic natural gas. Part 1 of this study focuses on methanation as an innovative way to use H2 without modifying the operation of the DRI plant, reducing technical risk to the steel plant operator. In Part 2, an economic assessment of the new integrated DRI-ESFBOF process route is presented.
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2025/08 AIST Iron & Steel Technology August
PR-PM0825-3
Takshi Sachdeva, Kamal Joubarani, Daysi Perez, Sa Ge, Ian Cameron, Richard Elliott
August 01, 2025
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