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Towards blast furnace ironmaking decarbonization via alternative reductants : a techno-economic and carbon assessment

Mario Alonso Ávila Muñoz (UGent) , Sofie Verbrugge (UGent) , Inge Bellemans (UGent) and Kim Verbeken (UGent)
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Abstract
The steel sector is one of the largest industrial contributors to global CO₂ emissions, making the decarbonization of ironmaking essential for achieving net-zero targets. This study investigates lower-carbon blast furnace (BF) operation through the partial substitution of fossil fuels with waste-derived reductants, linking industrial decarbonization with resource recovery and circular economy principles. A representative European BF-based ironmaking system was assessed under four scenarios: a conventional Benchmark Scenario (BS); the AlterCoal Scenario (AS), in which non-recyclable waste plastics partially replace coke oven coal; the Torero Scenario (TS), where pulverised coal is substituted with bio-coal from torrefied waste wood; and a combined AlterCoal–Torero Scenario (ATS).Life-cycle and techno-economic assessments were conducted to quantify the environmental and economic performance of each pathway. The results indicate reductions in total CO2 emissions of 0.55% (AS), 1.09% (TS), and 1.64% (ATS), primarily driven by the lower upstream carbon intensity and biogenic content of the alternative fuels. Economically, average gross profit increased by 9.3% (AS), 7.8% (TS), and 17.2% (ATS), mainly due to reduced exposure to energy market volatility and carbon pricing. Sensitivity and uncertainty analyses indicate enhanced economic resilience for the alternative scenarios, particularly under elevated coal and carbon price conditions. Overall, the results demonstrate that integrating waste-derived fuels into BF ironmaking can simultaneously reduce emissions and improve economic performance, offering a pragmatic transition pathway for advancing sustainable process innovation in energy-intensive industries.
Keywords
Ironmaking, Blast furnace, Solid recovered fuel, Techno-economic assessment, Waste wood, Cleaner production, WASTE PLASTICS, COKE-OVEN, BIOMASS, GAS, PRETREATMENT, IRON, TORREFACTION

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MLA
Ávila Muñoz, Mario Alonso, et al. “Towards Blast Furnace Ironmaking Decarbonization via Alternative Reductants : A Techno-Economic and Carbon Assessment.” SUSTAINABLE PRODUCTION AND CONSUMPTION, vol. 66, 2026, pp. 104–26, doi:10.1016/j.spc.2026.05.005.
APA
Ávila Muñoz, M. A., Verbrugge, S., Bellemans, I., & Verbeken, K. (2026). Towards blast furnace ironmaking decarbonization via alternative reductants : a techno-economic and carbon assessment. SUSTAINABLE PRODUCTION AND CONSUMPTION, 66, 104–126. https://doi.org/10.1016/j.spc.2026.05.005
Chicago author-date
Ávila Muñoz, Mario Alonso, Sofie Verbrugge, Inge Bellemans, and Kim Verbeken. 2026. “Towards Blast Furnace Ironmaking Decarbonization via Alternative Reductants : A Techno-Economic and Carbon Assessment.” SUSTAINABLE PRODUCTION AND CONSUMPTION 66: 104–26. https://doi.org/10.1016/j.spc.2026.05.005.
Chicago author-date (all authors)
Ávila Muñoz, Mario Alonso, Sofie Verbrugge, Inge Bellemans, and Kim Verbeken. 2026. “Towards Blast Furnace Ironmaking Decarbonization via Alternative Reductants : A Techno-Economic and Carbon Assessment.” SUSTAINABLE PRODUCTION AND CONSUMPTION 66: 104–126. doi:10.1016/j.spc.2026.05.005.
Vancouver
1.
Ávila Muñoz MA, Verbrugge S, Bellemans I, Verbeken K. Towards blast furnace ironmaking decarbonization via alternative reductants : a techno-economic and carbon assessment. SUSTAINABLE PRODUCTION AND CONSUMPTION. 2026;66:104–26.
IEEE
[1]
M. A. Ávila Muñoz, S. Verbrugge, I. Bellemans, and K. Verbeken, “Towards blast furnace ironmaking decarbonization via alternative reductants : a techno-economic and carbon assessment,” SUSTAINABLE PRODUCTION AND CONSUMPTION, vol. 66, pp. 104–126, 2026.
@article{01KT142EPHDVT52HWXH7Z51QE2,
  abstract     = {{The steel sector is one of the largest industrial contributors to global CO₂ emissions, making the decarbonization of ironmaking essential for achieving net-zero targets. This study investigates lower-carbon blast furnace (BF) operation through the partial substitution of fossil fuels with waste-derived reductants, linking industrial decarbonization with resource recovery and circular economy principles. A representative European BF-based ironmaking system was assessed under four scenarios: a conventional Benchmark Scenario (BS); the AlterCoal Scenario (AS), in which non-recyclable waste plastics partially replace coke oven coal; the Torero Scenario (TS), where pulverised coal is substituted with bio-coal from torrefied waste wood; and a combined AlterCoal–Torero Scenario (ATS).Life-cycle and techno-economic assessments were conducted to quantify the environmental and economic performance of each pathway. The results indicate reductions in total CO2 emissions of 0.55% (AS), 1.09% (TS), and 1.64% (ATS), primarily driven by the lower upstream carbon intensity and biogenic content of the alternative fuels. Economically, average gross profit increased by 9.3% (AS), 7.8% (TS), and 17.2% (ATS), mainly due to reduced exposure to energy market volatility and carbon pricing. Sensitivity and uncertainty analyses indicate enhanced economic resilience for the alternative scenarios, particularly under elevated coal and carbon price conditions. Overall, the results demonstrate that integrating waste-derived fuels into BF ironmaking can simultaneously reduce emissions and improve economic performance, offering a pragmatic transition pathway for advancing sustainable process innovation in energy-intensive industries.}},
  author       = {{Ávila Muñoz, Mario Alonso and Verbrugge, Sofie and Bellemans, Inge and Verbeken, Kim}},
  issn         = {{2352-5509}},
  journal      = {{SUSTAINABLE PRODUCTION AND CONSUMPTION}},
  keywords     = {{Ironmaking,Blast furnace,Solid recovered fuel,Techno-economic assessment,Waste wood,Cleaner production,WASTE PLASTICS,COKE-OVEN,BIOMASS,GAS,PRETREATMENT,IRON,TORREFACTION}},
  language     = {{eng}},
  pages        = {{104--126}},
  title        = {{Towards blast furnace ironmaking decarbonization via alternative reductants : a techno-economic and carbon assessment}},
  url          = {{http://doi.org/10.1016/j.spc.2026.05.005}},
  volume       = {{66}},
  year         = {{2026}},
}

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