{"id":7126,"date":"2025-09-03T09:30:17","date_gmt":"2025-09-03T06:04:33","guid":{"rendered":"https:\/\/steelworldreview.com\/hydrogen-injection-into-blast-furnaces-transitional-technology-or-a-misleading-path-in-steel-decarbonization\/"},"modified":"2025-09-06T14:21:45","modified_gmt":"2025-09-06T10:51:45","slug":"hydrogen-injection-blast-furnace","status":"publish","type":"post","link":"https:\/\/steelworldreview.com\/en\/hydrogen-injection-blast-furnace\/","title":{"rendered":"Hydrogen Injection into Blast Furnaces: Transitional Technology or a Misleading Path in Steel Decarbonization?"},"content":{"rendered":"

<\/h1>\n

Injecting hydrogen (H\u2082) into blast furnaces (BF) is often seen as a transitional technology for decarbonizing steel.<\/a> However, this method is inefficient in terms of hydrogen utilization, faces technical limitations, and cannot achieve deep emissions reductions. Even in the best scenarios, the reduction remains far below carbon neutrality, while large volumes of carbon dioxide (CO\u2082) continue to be emitted \u2014 which, with rising carbon prices, will become an increasing economic liability In comparison, hydrogen-based direct reduction (H\u2082-DRI)<\/a> combined with renewable electricity is far more efficient \u2014 requiring 40\u201360% less hydrogen per ton of steel and capable of achieving near-zero emissions. In terms of cost per ton of CO\u2082 avoided, H\u2082-DRI already represents a more attractive path for long-term competitiveness.<\/p>\n

Understanding the differences in efficiency and long-term sustainability of various decarbonization pathways remains critical for shaping the future of steel. Questions such as the cost of avoided emissions, the strategic allocation of capital between transitional and transformative technologies, and the role of policy in guiding investments highlight the complexity of these choices.<\/p>\n

\n

Blast Furnace Injection of Hydrogen in the Steel Industry<\/strong><\/h2>\n<\/div>\n
<\/div>\n
\n
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The use of hydrogen as a reducing agent for iron ore, in place of coke, is gaining attention as a decarbonisation measure in the steel sector, since it generates water rather than CO2<\/sub>\u00a0during the ore reduction process. Steelmakers across the world are already trialling hydrogen co-firing in BFs, the most emission-intensive part of primary steel making, with the aim to reduce the carbon intensity of steel production and utilise existing iron and steel making infrastructure.<\/p>\n

In India, Tata Steel carried out a multi-day hydrogen injection trial at its Jamshedpur works in April 2023, reporting a potential ~10% coke-rate reduction, equivalent to a 7\u201310% cut in CO2<\/sub>\u00a0per tonne of crude steel.1<\/sup><\/p>\n

In Japan, Nippon Steel announced in December 2024 that its 12m3<\/sup>\u00a0Super COURSE50 (the company\u2019s own brand of BF adaptation) test furnace had demonstrated up to a 43% reduction in CO2<\/sub>\u00a0emissions, and equipment is now being installed to enable hydrogen-rich gas injection at the Kimitsu No. 2 BF from 2026.2<\/sup><\/p>\n

In China, Baowu Steel commissioned the world\u2019s first 400 m3<\/sup>\u00a0HyCROF (hydrogen-enriched carbonic oxide recycling oxygenate furnace) in 2022, achieving a breakthrough in top-gas recycling under pure oxygen conditions; reported outcomes included a 30\u201340% increase in production capacity and more than a 30% reduction in the solid fuel rate.3<\/sup>\u00a0Earlier, in 2021, Shanxi Jinnan Iron and Steel succeeded in large-scale continuous hydrogen injection into a BF, cutting the average fuel rate by 36 kg\/t and CO2<\/sub>\u00a0emissions by around 5.6%.4<\/sup><\/p>\n

European steelmakers are also pushing ahead. Thyssenkrupp Steel in Germany became the first company worldwide to inject hydrogen into an operating BF in 2019, demonstrating that up to 20% of CO2<\/sub>\u00a0emissions could be avoided by partially substituting coke with hydrogen.5<\/sup>\u00a06<\/sup>\u00a0Dillinger and Saarstahl, German steelmakers, are advancing coke-oven-gas injection and plan to move towards pure hydrogen injection in two furnaces, aiming for a 40% reduction in CO2<\/sub>\u00a0by 2035.7<\/sup>\u00a0ArcelorMittal\u2019s Asturias plant in Spain began hydrogen injection in 2021 using hydrogen extracted from natural gas and coke-oven gas, and similar projects are under consideration at Bremen and Dunkirk.8<\/sup>\u00a09<\/sup><\/p>\n<\/div>\n<\/div>\n

Technical Challenges<\/strong><\/h2>\n
\n
\n

BFs are optimised for coke, so adapting them to handle hydrogen injection requires major modifications. Given the significant investment involved in retrofitting BFs for hydrogen co-firing, it raises the question: is hydrogen co-firing a practical step toward a lower-carbon future, or an expensive diversion of capital that delivers only partial decarbonisation? Several technical challenges related to hydrogen injection in BFs are outlined below:<\/p>\n

1. The first issue is scale. Small-scale test furnaces are hundreds of times smaller than their commercial counterparts, raising concerns about whether the same performance can be reliably achieved at full industrial scale.10<\/sup>\u00a0In China, where hydrogen injection has been implemented in a 1,860 m3<\/sup>\u00a0BF, the reduction in emissions has been limited to just 5.6%, highlighting the challenges of scaling up the technology.11<\/sup><\/p>\n

2. A second challenge concerns a potential increase in energy consumption. Much of the waste heat and gases generated during the steel making process, including that from coke oven gas, is already recovered and reused in the form of steam or electricity. As such, diverting coke oven gas, which has a typical hydrogen content of 55%, for use in a BF may result in a need to procure additional electricity or fuel. Although some projects also aim to compensate for this by recovering currently unused waste heat, it remains uncertain whether this will be sufficient to fully offset the shortfall.12<\/sup>\u00a0Furthermore, since the reduction of iron ore with hydrogen is an endothermic reaction, hydrogen injection is expected to increase overall energy requirements.13<\/sup><\/p>\n

3. A further, well known limitation arises from the design of the BF itself, which is optimised for reduction reactions using coke. Coke not only acts as a reductant but also provides mechanical stability within the furnace, facilitating the smooth flow of materials and gases.14<\/sup>\u00a0Hydrogen lacks these stabilising properties, and its partial injection can alter the heat and mass transfer dynamics, potentially resulting in issues such as unstable gas flow and thermal imbalance.<\/p>\n

4. A fourth challenge is the BF\u2019s refractory lining, which is not designed for high hydrogen use. Unlike DRI shaft furnaces\u2014built to handle up to 60% hydrogen with advanced, oxidation-resistant materials\u2014BFs rely on carbon- and alumina-based bricks suited for coke-based reduction. Injecting hydrogen creates more oxidizing and thermally volatile conditions, which can degrade these linings prematurely. To operate safely at high hydrogen levels, a costly and complex furnace relining with more robust materials would likely be required, likely undermining the perceived economic benefit of using existing infrastructure to produce low(er) carbon steel.15<\/sup><\/p>\n<\/div>\n<\/div>\n

Effectiveness of Greenhouse Gas Reduction with Hydrogen<\/strong><\/h2>\n

A review of several studies indicates that, under simulated BF operating conditions, around 2.1\u20132.8 kg of H2<\/sub>\u00a0per tonne of crude steel (tcs) is required via the conventional BF\u2013BOF route to achieve a 1% reduction in CO2<\/sub>\u00a0emissions.16<\/sup>\u00a017<\/sup>\u00a0Calculations based purely on chemical reactions, however, suggest a somewhat lower figure of roughly 1.7\u20132.4 kg H2<\/sub>\/tcs.18<\/sup>\u00a019<\/sup>\u00a0For the H2<\/sub>-DRI process, the equivalent requirement\u2014based on substituting BF-produced pig iron with H2<\/sub>-DRI\u2014is approximately 0.7 kg H2<\/sub>\/tcs. This means that, under BF operating simulations, the requirement is around 40% or less of that for hydrogen injection into BFs. Using hydrogen in a BF for iron ore reduction is generally less efficient than using it in a DR shaft furnace due to several factors related to process control, reaction kinetics, and material properties. Crucially, BFs are optimised for a reducing gas mixture dominated by carbon monoxide, while DR shafts excel at using hydrogen.20<\/sup>\u00a021<\/sup>\u00a022<\/sup>\u00a0Furthermore, owing to the faster reduction kinetics of hydrogen compared with carbon monoxide (CO), complete metallisation can in principle be achieved more rapidly in a shaft furnace, further enhancing its overall efficiency. In BF, a considerable share of the injected hydrogen leaves with the top gas without fully reacting.23<\/sup><\/p>\n

Looking at overall hydrogen demand, the H2<\/sub>-DRI process requires roughly 62 kg H2<\/sub>\/tcs to fully reduce iron ore into sponge iron. By comparison, under simulated BF operating conditions, injecting enough hydrogen to achieve a 21.4\u201326.1% reduction in CO2<\/sub>\u00a0emissions requires about 29\u201334 kg H2<\/sub>\/tcs. These results highlight two key problems, first, that hydrogen use in the BF is only about half as efficient as in a DR shaft, and secondly, that there is an upper limit, albeit not yet certain, to hydrogen use as a reductant in a BF, thus drastically limiting any green credentials. To summarise, this process is less efficient and achieves lower emissions reductions compared to other more established technologies.<\/p>\n

Conclusion<\/strong><\/h2>\n

At higher injection rates, BFs require large volumes of hydrogen, yet the abatement efficiency remains relatively low. This means that more hydrogen must be used to avoid each tonne of CO2<\/sub>, driving up costs and reducing overall effectiveness. Importantly, hydrogen injection into BFs cannot achieve near-zero emissions, leaving significant residual CO2<\/sub>\u00a0that will become an increasing liability as carbon pricing and regulatory frameworks tighten in the future.<\/p>\n

Hydrogen injection into BFs faces significant technical challenges and is expected to take significantly longer to reach commercial viability compared to H2<\/sub>-DRI, which is already nearing commercialisation. Compared to H2<\/sub>-DRI, hydrogen injection into BFs not only delivers lower emissions reduction potential, its actual upper limit is still uncertain. While falling hydrogen prices are expected to enhance the cost competitiveness of H2<\/sub>-DRI, the future cost for hydrogen injection into BFs remains uncertain, at risk of being shaped by carbon pricing and, more broadly, by additional costs associated with managing residual CO2<\/sub>\u00a0emissions.<\/p>\n

In summary: hydrogen injection in blast furnaces is a transitional technology that delivers only partial emission reductions, whereas H\u2082-DRI represents a more sustainable, efficient, and near-zero-emission pathway for the future of steel.<\/p><\/blockquote>\n","protected":false},"excerpt":{"rendered":"

Injecting hydrogen (H\u2082) into blast furnaces (BF) is often seen as a transitional technology for decarbonizing steel. However, this method is inefficient in terms of hydrogen utilization, faces technical limitations, and cannot achieve deep emissions reductions. Even in the best scenarios, the reduction remains far below carbon neutrality, while large volumes of carbon dioxide (CO\u2082) […]<\/p>\n","protected":false},"author":1,"featured_media":7124,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"jnews-multi-image_gallery":[],"jnews_single_post":{"format":"standard","override":[{"template":"1","single_blog_custom":"497","parallax":"1","layout":"right-sidebar-narrow","sidebar":"default-sidebar","second_sidebar":"default-sidebar","sticky_sidebar":"1","share_position":"float","share_float_style":"share-normal","show_share_counter":"1","show_view_counter":"1","show_featured":"1","show_post_meta":"1","show_post_author_image":"1","show_post_date":"1","post_date_format":"default","post_date_format_custom":"Y\/m\/d","show_post_category":"1","post_reading_time_wpm":"200","post_calculate_word_method":"str_word_count","zoom_button_out_step":"2","zoom_button_in_step":"3","show_post_tag":"1","show_prev_next_post":"1","show_popup_post":"1","number_popup_post":"1","show_post_related":"1"}],"image_override":[{"single_post_thumbnail_size":"no-crop","single_post_gallery_size":"crop-500"}],"trending_post_position":"meta","trending_post_label":"\u062f\u0631 \u062c\u0631\u06cc\u0627\u0646","sponsored_post_label":"\u062d\u0645\u0627\u06cc\u062a \u0634\u062f\u0647 \u062a\u0648\u0633\u0637","disable_ad":"0","subtitle":""},"jnews_primary_category":[],"jnews_review":[],"enable_review":"","type":"percentage","name":"","summary":"","brand":"","sku":"","good":[],"bad":[],"score_override":"","override_value":"","rating":[],"price":[],"jnews_override_counter":{"view_counter_number":"0","share_counter_number":"0","like_counter_number":"0","dislike_counter_number":"0"},"footnotes":""},"categories":[249],"tags":[918,916,917,837,915,945,919],"class_list":["post-7126","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-jahan-foulad-articles","tag-co-emissions","tag-green-steel-en","tag-hydrogen","tag-optional","tag-steel-decarbonization-technologies","tag-steel-decarbonization-technologiesco-emissions","tag-steel-decarbonization-technologiesoptional"],"yoast_head":"\nHydrogen Injection into Blast Furnaces: Transitional Technology or a Misleading Path in Steel Decarbonization? - steelworldreview<\/title>\n<meta name=\"description\" content=\"Hydrogen injection into blast furnaces can achieve partial CO\u2082 reductions, but never near zero. 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