Work

Green Hydrogen Production for Decarbonizing the Steel Industry: Energy and Economic Assessment of Electrolysis and Ammonia Cracking Systems

Year: 2026

Type: article

Abstract: The global transition toward a low-carbon economy has intensified the interest in green hydrogen as a key enabler of industrial decarbonization. In particular, the steel sector, one of the most carbon-intensive industries, offers significant opportunities for emissions reduction through H2-based technologies. This study presents a techno-economic assessment of alternative green hydrogen supply pathways, namely alkaline electrolysis and ammonia cracking, and evaluates their integration into hydrogen-based direct reduction (HyDR) routes. Process simulations are performed using Aspen Plus® V14 to quantify the energy consumption, hydrogen demand, and associated CO2 emissions across multiple configurations and case studies. A comprehensive 3E (energy, economics, and environmental) evaluation framework is applied to compare system performance and assess the suitability of each pathway for large-scale deployment. The results indicate that ammonia cracking represents a technically viable and potentially competitive hydrogen supply option for steel decarbonization under the assumed operating conditions, highlighting its relevance as a transitional pathway toward low-carbon steel production.

Source: Energies

DOI: 10.3390/en19030717

Authors: Elvira Spatolisano, Antonio Trinca, Domenico Flagiello, Giorgio Vilardi

Institutions: Politecnico di Milano, Istituto Superiore per la Protezione e la Ricerca Ambientale, Sapienza University of Rome, University of Naples Federico II

Language: English

Topic: Iron and Steelmaking Processes

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDGs: Industry, innovation and infrastructure, Climate action, Affordable and clean energy, Responsible consumption and production

Open Access status: gold

Estimated APC paid: $3,137