Energy and Exergy Analysis of an Improved Hydrogen-Based Direct Reduction Shaft Furnace Process with Waste Heat Recovery.

Featured Application: The work in this paper provides some basic theoretical and practical reference value for the energy and exergy analysis, calculation, process optimization, and energy conservation research of the hydrogen-based direct reduction shaft furnace process, which is helpful for promoting its further industrial application. The traditional production mode using coal as the main energy source is not conducive to the sustainable development of the iron and steel industry (ISI). The hydrogen-based direct reduction shaft furnace (HDRSF) process is a feasible technical route for promoting the green development of the ISI. However, there is a lack of comprehensive analysis with respect to the energy utilization and process flow of the HDRSF method. To address these issues, a systemic material–energy–exergy model of HDRSF is established. An improved HDRSF process incorporating waste heat recovery is also proposed, and energy consumption intensity and exergy intensity are used as assessment metrics. This study's findings indicate that the proposed waste heat recovery can considerably lower gas demand and energy consumption intensity, but exergy intensity has little effect. The reducing gas demand drops from 2083 m³ to 1557 m³, the energy consumption intensity drops from 2.75 × 10⁷ kJ to 1.70 × 10⁷ kJ, and the exergy intensity drops from 1.08 × 10⁷ kJ to 1.05 × 10⁷ kJ when the reducing gas temperature is 900 °C, H₂:CO = 1:1; meanwhile, the recovery rate of waste heat reaches 40%. This study can serve as a reference for actual HDRSF process production. [ABSTRACT FROM AUTHOR]