| Abstract Scope |
The decarbonization of steelmaking is challenged by limited DR-grade iron ore availability and the inefficient use of high-gangue ores in conventional DRI–EAF routes. Study compares the techno-economic and environmental performance of DRI–EAF and a novel DRI–ESF–BOF flowsheet using a comprehensive value-in-use model. Six scenarios covering beneficiation, pelletization, ironmaking, and steelmaking were evaluated through mass balance, operating cost, iron recovery, and CO₂ emission analyses. Results show that high-gangue DRI processed in EAFs increases slag generation, flux consumption, and metallic losses, reducing efficiency. However, the ESF route effectively rejects gangue, lowering slag production by approximately 40% and improving iron recovery. Economic assessment indicates that producing DR-grade pellets through intensive beneficiation offers limited benefits because of higher processing costs and yield losses. Emission analysis reveals that scrap utilization has a greater influence on reducing CO₂ emissions than ore grade. Results highlight DRI–ESF–BOF as a promising pathway for scalable, low-carbon steel production. |