Work

Life cycle assessment of metallurgical options for recycling high-alloy tool steels

Year: 2025

Type: article

Abstract: The iron and steel sector accounts for around 8 % of global energy-related CO₂ emissions, prompting the need for sustainable approaches in steel recycling. In Denmark, steel recycling is currently insignificant without large-scale steelmaking facilities, most high-alloyed steel scrap is exported—despite local potential for alternative powder metallurgical options. To explore the potential of high-alloyed steel recycling in Denmark, this study applies ex-ante life cycle assessment (LCA) to compare the environmental impacts of current and potential alternative recycling routes, including powder metallurgy approaches like gas atomization (GA) and spray forming (SF). Results indicated that local reprocessing using SF could reduce climate impacts by approximately 50 % compared to the current export and reprocessing by electric arc furnaces (EAF). SF shows the lowest impact overall, achieving only 40 % of secondary production using EAF. Metal remelting steps are the critical process to further decrease the impacts by either avoiding and/or improving efficiency.

Source: Resources Conservation and Recycling

DOI: 10.1016/j.resconrec.2025.108655

Authors: Suiting Ding, Valentina Pusateri, Thomas Dahmen, Caroline Semarak, Venkata Karthik Nadimpalli, Ciprian Cimpan

Institutions: University of Southern Denmark, Technical University of Denmark, RWTH Aachen University

Language: English

Topic: Iron and Steelmaking Processes

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDGs: Responsible consumption and production, Climate action

Open Access status: hybrid

Estimated APC paid: $5,270