Energy and Exergy Analysis of an Improved Hydrogen-Based Direct Reduction Shaft Furnace Process with Waste Heat Recovery

The traditional production mode using coal as the main energy source is not conducive to the sustainable development of the iron and steel industry (ISI). The hydrogen-based direct reduction shaft furnace (HDRSF) process is a feasible technical route for promoting the green development of the ISI. However, there is a lack of comprehensive analysis with respect to the energy utilization and process flow of the HDRSF method. To address these issues, a systemic material–energy–exergy model of HDRSF is established. An improved HDRSF process incorporating waste heat recovery is also proposed, and energy consumption intensity and exergy intensity are used as assessment metrics. This study’s findings indicate that the proposed waste heat recovery can considerably lower gas demand and energy consumption intensity, but exergy intensity has little effect. The reducing gas demand drops from 2083 m3 to 1557 m3, the energy consumption intensity drops from 2.75 × 107 kJ to 1.70 × 107 kJ, and the exergy intensity drops from 1.08 × 107 kJ to 1.05 × 107 kJ when the reducing gas temperature is 900 °C, H2:CO = 1:1; meanwhile, the recovery rate of waste heat reaches 40%. This study can serve as a reference for actual HDRSF process production.