Quantifying the Carbon Mitigation Potential of Waste Heat Recovery Systems (WHR) in Sponge Iron Plant: A study of Decarbonisation

Avantika Saha; Rashmi Mishra; Sapan Kumar Saha

Quantifying the Carbon Mitigation Potential of Waste Heat Recovery Systems (WHR) in Sponge Iron Plant: A study of Decarbonisation

Author(s)	Ms. Avantika Saha, Ms. Rashmi Mishra, Dr. Sapan Kumar Saha
Country	India
Abstract	The iron and steel sector is a major contributor to global greenhouse gas (GHG) emissions, with coal-based Direct Reduced Iron (DRI) or sponge iron production exhibiting a severe carbon footprint. A critical inefficiency in conventional rotary kiln sponge iron plants is the rejection of 30% to 40% of thermal energy input via high-temperature flue gases (800°C–1000°C) directly into the atmosphere. This paper evaluates the thermodynamic feasibility and carbon mitigation potential of integrating Waste Heat Recovery (WHR) systems within the sponge iron industry under the governance of the United Nations Framework Convention on Climate Change (UNFCCC) Clean Development Mechanism (CDM). The sponge iron industry, a vital component of the global steel supply chain, is highly energy-intensive and historically associated with a massive carbon footprint. As countries strive to meet stringent net-zero emission targets, industrial decarbonization has transitioned from an environmental ideal to a regulatory and economic necessity. Among the various technological interventions available, Waste Heat Recovery Systems (WHR) have emerged as one of the most commercially viable and impactful solutions for reducing greenhouse gas emissions in energy-heavy manufacturing. Adhering to the approved consolidated baseline methodology ACM0012, this study models mass-and-energy balancing alongside carbon accounting equations to quantify the net reduction in carbon dioxide (CO2) emissions achieved by displacing carbon-intensive grid electricity with clean, captive power generation. The findings indicate that WHR integration significantly decreases localized thermal pollution while providing a highly predictable volume of Certified Emission Reductions (CERs) to bolster project financial additionality. However, sensitivity analysis reveals that the long-term carbon mitigation value is heavily vulnerable to the progressive decarbonization of the regional power grid, which systematically reduces the baseline grid emission factor over time. By employing a combination of thermodynamic mass-and-energy balancing and carbon accounting methodologies, this study quantifies the potential reduction in (CO2) emissions achievable through optimal waste heat integration. Using process-based mass and energy balance calculations from a standard 3x100 Tons per day (TPD) rotary kiln plant, it is estimated, how much grid-purchased electricity can be replaced by recovered heat? This study reveals that WHRB based captive power plant, mitigates approximately 50934 tonnes of CO2 per year by avoiding emissions from coal-fired grids. Ultimately, this research aims to provide policymakers and industry stakeholders with a data-driven framework to accelerate energy efficiency improvements and advance the circular economy within the iron and steel sector.
Keywords	Waste Heat Recovery (WHR), Sponge Iron Plant, Carbon Mitigation, Clean Development Mechanism (CDM), ACM0012, Energy Efficiency, Industrial Decarbonization.
Field	Engineering
Published In	Volume 17, Issue 9, September 2026
Published On	2026-09-22

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Quantifying the Carbon Mitigation Potential of Waste Heat Recovery Systems (WHR) in Sponge Iron Plant: A study of Decarbonisation

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