(589i) Evaluating the Impact of H2/COx Ratios on Methanol Production from Blast Furnace Gas

The steel industry emits substantial CO₂ through blast furnace operations, producing Blast Furnace Gas (BFG), a by-product rich in CO, CO₂, and H₂. While BFG is currently used as a low-efficiency fuel, its utilization for methanol synthesis has gained attention as a pathway to reduce emissions and create value-added products. Methanol, a versatile fuel and chemical feedstock, is industrially synthesized from syngas (CO/H₂/CO₂) over Cu/ZnO/Al₂O₃ catalysts under elevated pressures and moderate temperatures. Reaction performance is highly sensitive to the composition of syngas, especially CO₂ concentration, which affects methanol yield, catalyst stability, and by-product formation. Recognizing these sensitivities, this study presents a preliminary process design and simulation for converting BFG to methanol under both H₂-deficient and H₂-sufficient conditions. A focus is placed on adjusting the CO/CO₂/H₂ ratios to optimize methanol yield while minimizing hydrogen demand. Techno-economic analysis (TEA) and life cycle assessment (LCA) are applied to assess the impact of key operating variables on economic viability and environmental performance. The results demonstrate that under optimized conditions, BFG-based methanol production is more sustainable and cost-effective than conventional fermentation-based routes. This integrated approach offers a promising strategy for low-carbon transition in the steel industry through effective off-gas utilization.