Optimizing Circular Economy in Electric Arc Furnace Steel Production: A Comprehensive 4Rs Approach

The circular economy plays a vital role in achieving net zero emissions within the iron and steel industry by addressing both production and consumption practices that contribute to climate change. This research offers an in-depth examination of the implementation of circular economy principles in the Electric Arc Furnace (EAF) steel production method, which represents 30% of the world’s steel production. By applying the 4Rs framework—Reduction, Reuse, Recycle, and Remanufacture—the study evaluates the EAF process in a steel facility that utilizes a combination of 20% scrap, 15% Cold Briquette Iron, and 65% Direct Reduced Iron. Through thermodynamic simulations conducted with Aspen Plus software, the study identifies essential criteria for assessing the EAF sector concerning material, energy, and pollutant flows. The findings reveal gaps between optimal and actual operational processes, highlighting both challenges and opportunities for enhancing circularity. Projects aligned with the 4Rs, along with profitability, actions, indices, and types of investments, were defined and categorized. The key takeaways suggest that adopting circular economy principles in EAF steelmaking can lead to substantial reductions in resource use and emissions while enhancing overall efficiency. Future research should prioritize the development of advanced technologies for improved scrap sorting and processing, the exploration of alternative reducing agents, and the optimization of energy recovery systems. Additionally, fostering industry-wide collaboration to create standardized circularity metrics and integrating digital technologies for real-time process optimization are recommended. This study offers significant insights into optimizing EAF steelmaking within a circular economy context, presenting actionable strategies to enhance sustainability in the steel sector and facilitate the transition to a more circular and environmentally responsible production model.