Iron Ore Smelting System Using a Sustainable Coal-Based Direct Reduction and CO₂ Sequestration

13 May 2026, 09:10
20m
Washington room (Milan Marriott Hotel)

Washington room

Milan Marriott Hotel

Oral presentation (paper for Ironmaking & Steelmaking special issue) EMECR 4. Circularity and by-product management in steel industry Integration of Renewable Energy & Biochar Applications

Speakers

Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano) Gianluca Dall'Osto (Politecnico di Milano)

Description

This study presents an innovative system developed within the AdriatiCO2 Project for the direct reduction of iron ore via a smelting process. The system substitutes conventional coking coal with sustainable carbon sources and/or biochar—a renewable reducing agent produced from biomass pyrolysis—and integrates efficient CO₂ capture to minimize the carbon footprint of steelmaking.
In the designed high-temperature reactor, the reducing agents act as both a reductant and an energy supplier. Its high reactivity and low impurities facilitate efficient iron oxide reduction while minimizing the slag formation. The resulting CO₂ emissions are captured using post-combustion sequestration techniques, such as amine scrubbing or mineral carbonation, to ensure near-zero emissions.
Preliminary assessments indicate this approach could reduce CO₂ emissions by up to 80% compared to traditional blast furnace methods. Furthermore, the use of biochar derived from agricultural or forestry waste supports circular economy principles by valorizing biomass residues. The AdriatiCO2 Project will optimize reactor design, biochar properties, and CO₂ sequestration efficiency to enable industrial scalability. This system represents a viable transitional pathway toward greener steel production, aligning with global decarbonization goals while maintaining cost-effectiveness and material performance.

Speaker Company/University Politecnico di Milano
Speaker Country Italy

Primary authors

Aldo Fiorini (Marcegaglia) Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano) Prof. Davide Mombelli (Politecnico di Milano - Dipartimento di Meccanica) Gianluca Dall'Osto (Politecnico di Milano) alessandro ferraiuolo (Marcegaglia Ravenna)