Technical and economic analysis on hydrogen based direct reduction steelmaking co-driven by photovoltaic and power grid

doi:10.11949/0438-1157.20250077

Abstract

Abstract:

Direct reduced iron-electric arc furnace (DRI-EAF) is a short steelmaking route for decarbonization in the iron and steel industry. Its large-scale green hydrogen metallurgical application needs to pay attention to renewable energy utilization, time-series source-load interaction, and economic feasibility. This work established an integrated model of hydrogen-based DRI-EAF plant co-driven by photovoltaic and power grid. The energy consumption, carbon emission and economic benefits of the process were evaluated based on the technical and economic parameters of typical geographic regions in China. The results show that a renewable energy share ratio of 90.26% could be achieved with the scale of 2500 MW photovoltaic station in Urumqi, Xinjiang. Carbon emissions are reduced by 84.54%, 81.35% and 68.28% compared to grid-only operation, blast furnace-basic oxygen furnace route and natural gas based DRI-EAF process, respectively. At the scale of 100 MW photovoltaic station, Shanghai is difficult to pay back the initial investment cost since its grid electricity price is too high. Regional grid electricity price is one of the key factors influencing the economics of hydrogen-based DRI-EAF process integrated with renewable energy. When the hydrogen production cost is fixed, as the carbon price rises from 90 CNY/t to 1614 CNY/t, payback period of the 2500 MW photovoltaic project in Urumqi, Xinjiang decreases from 8.28 years to 3.45 years.

Key words: photovoltaic, power grid, hydrogen production, direct reduced iron, steelmaking, technical and economic analysis

摘要：

直接还原铁-电弧炉（direct reduced iron-electric arc furnace，DRI-EAF）是钢铁工业减碳的一种短流程炼钢工艺，其大规模绿氢冶金应用须关注可再生能源利用率、时序源荷交互、经济可行性等。本研究建立了光伏与电网协同驱动的氢基DRI-EAF工艺模型，基于典型地理区域的技术经济参数，评估了该工艺的能耗、碳排放及经济效益。结果表明，新疆乌鲁木齐2500 MW光伏电站规模可实现可再生能源渗透率90.26%，相比于纯电网运行、高炉-转炉工艺和天然气DRI-EAF工艺，分别减少碳排放84.54%、81.35%和68.28%。100 MW光伏电站规模下，以上海为代表的高电价地区难以回收投资成本，地区电网电价是影响可再生能源氢基DRI-EAF工艺经济性的关键因素之一。制氢成本一定时，碳价由90 CNY/t上涨到1614 CNY/t，新疆乌鲁木齐2500 MW光伏电站回收期由8.28年降低至3.45年。

关键词: 光伏, 电网, 制氢, 直接还原铁, 炼钢, 技术经济分析

CLC Number:

TQ 116.2

Yitong ZHOU, Mingxi ZHOU, Ruochen LIU, Shuang YE, Weiguang HUANG. Technical and economic analysis on hydrogen based direct reduction steelmaking co-driven by photovoltaic and power grid[J]. CIESC Journal, 2025, 76(8): 4318-4330.

周奕彤, 周明熙, 刘若晨, 叶爽, 黄伟光. 光伏与电网协同驱动氢基直接还原铁炼钢的技术经济分析[J]. 化工学报, 2025, 76(8): 4318-4330.

Figures/Tables 17

Fig.1 Hydrogen based DRI-EAF plant co-driven by PV and power grid

Table 1 Key component parameters of PV and inverters

项目		数值
单晶硅光伏组件	转换效率/%	20.64
	峰值功率/W	580.0
	开路电压/V	40.9
	短路电流/A	18.2
	工作电压/V	33.8
	工作电流/A	17.2
组串式逆变器	最大输入电压/V	1500
	额定输入电压/V	1080
	最小MPPT电压/V	600
	最大MPPT电压/V	1500
	额定输出电压/V	800
	转换效率/%	98.43

Table 2 Annual average direct normal irradiance （DNI） of solar energy， CO2 emission factor of electricity and the proportion of renewable energy in the grid in different geographical locations

地区	地理位置	太阳能年均DNI/(W/m²)	电力二氧化碳排放因子^[20]/( $k g C O 2$ /kWh)	电网电力可再生能源占比/%^[21]
新疆乌鲁木齐	43.82°N 87.61°E	221.65	0.6231	22.5
广东湛江	21.28°N 110.35°E	127.86	0.4403	28.1
河北张家口	40.82°N 114.87°E	240.02	0.7252	24.4
上海	31.24°N 121.47°E	127.48	0.5849	30.3

地区	地理位置	太阳能年均DNI/(W/m²)	电力二氧化碳排放因子^[20]/( $k g C O 2$ /kWh)	电网电力可再生能源占比/%^[21]
新疆乌鲁木齐	43.82°N 87.61°E	221.65	0.6231	22.5
广东湛江	21.28°N 110.35°E	127.86	0.4403	28.1
河北张家口	40.82°N 114.87°E	240.02	0.7252	24.4
上海	31.24°N 121.47°E	127.48	0.5849	30.3

Fig.2 24 h industrial and commercial electricity prices in July and December in Urumqi, Xinjiang; Zhanjiang, Guangdong; Zhangjiakou, Hebei and Shanghai

Table 3 Parameters of the electrolyser

参数	输入值
电解槽额定容量/MW	20^[14]
电解槽模块数量/套	34
电解槽制氢电耗/(kWh/ $k g H 2$ )	50
电解槽设计容量冗余度/%	50^[14]
氢气电加热效率/%	60^[22]

Table 3 Parameters of the electrolyser

参数	输入值
电解槽额定容量/MW	20^[14]
电解槽模块数量/套	34
电解槽制氢电耗/(kWh/ $k g H 2$ )	50
电解槽设计容量冗余度/%	50^[14]
氢气电加热效率/%	60^[22]

Table 4 Parameters of the hydrogen storage

参数	输入值
地下储氢容量/m³	32000^[23]
压缩机/膨胀机额定容量/MW	1.7^[24]
压缩机/膨胀机模块数量	1～120
压缩机/膨胀机电效率/%	70

Table 5 Parameters of DRI-EAF

参数	输入值
DRI金属化率/%	94^[25]
铁矿石电加热效率/%	85^[14]
铁矿石杂质SiO₂的质量分数/%	3^[18]
铁矿石杂质Al₂O₃的质量分数/%	2^[18]
电弧炉电效率/%	60^[22]
电弧炉石灰消耗量/(kg/t_LS)	50^[26]
电弧炉焦炭消耗量/(kg/t_LS)	20^[26]
电弧炉石墨电极消耗量/(kg/t_LS)	3^[26]

Fig.3 Flow chart for calculation of the hourly power supply and demand

Table 6 Technical and economic parameters of hydrogen-based DRI-EAF plant

参数		输入值
工厂年产能/t		1×10⁶
换热器效率/%		60^[22]
竖炉氢气过量供应与需求量比率		1.5^[14]
铁矿石价格^①/(CNY/t)		851^[27]
工商业用水价格/(CNY/t)		4.74^[28]
焦炭价格^②/(CNY/t)		2004
石灰价格^③/(CNY/t)		782^[29]
光伏电站	建设成本/(CNY/kW)	3400^[30]
	运营成本/%	3^[31]
	使用寿命/a	30^[31]
电解槽	建设成本/(CNY/kW)	2136^[32]
	运营成本/%	3^[33]
	使用寿命/a	20^[33]
压缩机	建设成本/(CNY/kW)	8546^[34]
	运营成本/%	4^[34]
	使用寿命/a	20^[14]
地下储氢	建设成本/(CNY/m³)	359^[35]
	运营成本/%	2^[35]
	使用寿命/a	30^[35]
膨胀机	建设成本/(CNY/kW)	4409^[36]
	运营成本^④/%	4
	使用寿命/a	20^[14]
竖炉	建设成本/(CNY/t_DRI)	1780^[31]
	运营成本/%	3^[37]
	使用寿命/a	20^[37]
电弧炉	建设成本/(CNY/t_LS)	1638^[31]
	运营成本/%	2^[37]
	使用寿命/a	20^[37]
劳动力成本/(CNY/(人·a))		9.76万^[29]
粗钢售价^⑤/(CNY/t)		4629^[38]
碳市场碳价^⑥/(CNY/t)		90
税率^⑦/%		25
折现率/%		7^[18,39]
残值率^⑧/%		5

Fig.4 Hourly PV power generation, grid output power and carbon emissions, excess renewable energy hydrogen storage capacity and renewable energy share ratio of the 1000 MW PV power station in Urumqi, Xinjiang

Fig.5 Energy consumption, carbon emission intensity, and renewable energy share ratio of the DRI-EAF plant under different scales of the PV power station in Urumqi, Xinjiang

Fig.6 Construction cost, total cost and payback period of the DRI-EAF plant under different scales of the PV power station in Urumqi, Xinjiang

Fig.7 Energy consumption, carbon emission intensity and renewable energy share ratio of the DRI-EAF plant with 100 MW PV power station at different locations

Fig.8 Total cost and payback period of the DRI-EAF plant with 100 MW PV power station at different locations

Fig.9 History carbon price of the China carbon market during 2021 to 2024, and the predicted carbon price from 2030 to 2060[40]

Fig.10 Carbon emission reduction intensity and effects of carbon price of the DRI-EAF plant under different scales of the PV power station in Urumqi, Xinjiang

Fig.11 Carbon emission reduction intensity and effects of carbon price of the DRI-EAF plant with 100 MW PV power station at different locations

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