Technoeconomic Analysis of the Electrorefining Process\nfor Copper and Carbon Removal from Scrap Steel for Green Steelmaking

This\nstudy presents an economic assessment of integrating an electrorefining\nprocess into conventional electric arc furnace (EAF) mini-mills for\nthe production of hot-rolled coil (HRC) steel with low copper (710\nppmw), sulfur (<10 ppmw), and carbon (197 ppmw) content from 100%\nscrap steel containing copper tramp elements (0.43 or 0.21 wt % Cu).\nThe research extrapolates laboratory results to develop an industrial-scale\ncombined process using electrorefining cells. Economic evaluations\nwere performed through scenario, financial, and sensitivity analyses.\nThe total levelized cost of HRC steel production from 100% scrap was\nestimated at $941.73 per tonne for 0.43 wt % Cu steel and $783.24\nper tonne for 0.21 wt % Cu steel. The net profit (NPV) and internal\nrate of return (IRR) were low at the current HRC price, with figures\nof −$5.67 million and 4.9% for 0.43 wt % Cu steel, and $225\nmillion and 9.8% for 0.21 wt % Cu steel. Sensitivity analysis shows\nthat the NPV and IRR are significantly influenced by electrolyte material\ncosts and scrap prices. The study highlights limitations of the proposed\nprocess and suggests future research directions to improve its technoeconomic\nviability.