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IRON & STEEL

Engineering Competitive Steel Production Through Integrated Systems

Approach image

OUR APPROACH

We design integrated systems that optimize blast furnace operations, enable pragmatic DRI (Direct Reduced Iron) pathways, embed process improvements at design stage, and convert waste streams into value—reducing energy intensity and costs while achieving substantial emission reductions as the natural outcome of superior engineering.

Our solutions balance growth and operational excellence with economic viability, ensuring steel producers remain competitive while meeting regulatory requirements.

Our Services

01

Process Optimization & Energy Integration

Blast furnace efficiency improvements, heat recovery systems, energy cascade optimization, coke oven gas utilization, waste heat-to-power integration reducing energy consumption 15-25%

Solution challenges

02

Gasification-Based Iron & Steel Production

Syngas-based DRI systems using domestic coal, coke gasification for DRI production, integrated design, multi-product portfolios (steel + chemicals)

Solution challenges

03

Alternative Ironmaking Technologies

Smelting reduction processes (COREX, FINEX), direct reduction shaft furnaces optimized for local feedstocks, rotary hearth furnace systems for low-grade ores/waste utilization

Solution challenges

04

Waste Stream Valorization

Slag utilization in cement/aggregates, dust and sludge recycling pathways, waste heat recovery for power generation or district heating, CO₂ conversion to building materials and chemicals

Solution challenges

05

Scrap-Based EAF Optimization

Energy efficiency improvements, renewable electricity integration, electrode consumption reduction, carbon injection strategies, optimal scrap mix design

Solution challenges

06

Hydrogen Integration Pathways

Blue hydrogen from coal/petcoke gasification, hydrogen-enriched DRI, future-ready infrastructure for hydrogen blending, techno-economic analysis across hydrogen routes

Solution challenges

07

Techno-Economic & Financial Analysis

CAPEX/OPEX modeling across production routes, scenario analysis, compliance strategy, bankable feasibility studies, subsidy and incentive optimization

Solution challenges
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Our Solutions

Gasification for Clean Ironmaking

Convert domestic coal or refinery waste (petcoke) into syngas for:

  • DRI Production: Syngas replaces natural gas in shaft furnaces, providing fuel flexibility and reducing import dependency
  • Hydrogen Generation: Extract H₂ from syngas via PSA for hydrogen-based DRI
  • Chemical Co-Production: Convert CO₂ to methanol or acetic acid
  • Cost Advantage: $4-5/MMBTU syngas vs. $12-15/MMBTU imported LNG (60-70% savings)

AI-Driven Process Optimization

Machine learning models for:

  • Blast furnace control: Real-time optimization of burden distribution, blast parameters
  • Energy forecasting: Predictive models for electricity demand, enabling grid flexibility
  • Quality prediction: Reduce off-spec production through advanced analytics
  • Maintenance optimization: Predictive maintenance reducing downtime 20-30%

Grid Integration & Energy Storage

Steel plants as grid flexibility assets:

  • Demand response: Shift EAF operations to low-price/high-renewable hours
  • Thermal storage: Store waste heat for later use or grid balancing
  • Battery integration: Smooth power demand, capture arbitrage opportunities
  • Ancillary services: Provide frequency regulation, voltage support to grid operators

Embedded Process Improvements

Design integration from project inception, not as retrofit:

  • Blast furnace gas optimization: 15-25% CO₂ concentration ideal for economic recovery
  • DRI off-gas management: High-purity streams for process integration
  • Cost efficiency: 30-50% lower implementation cost vs. post-construction retrofit
  • Utilization pathways: CO₂-to-chemicals, EOR, mineralization in slag/concrete
Featured Project

Featured Project

Dastur Energy prepared the preliminary engineering design and cost estimate for the production of low-carbon-emission steel by capturing almost 3 mtpa of CO2 at one of the largest BF-BOF-based steel plants in the United States.

VIEW PROJECTS
Project

Blast Furnace Optimization

Scope

Process optimization and waste heat recovery

Value Delivered

12% coke consumption reduction, 18% energy intensity reduction, 90 ktpa hydrogen co-production at $0.40-0.50/kg

Project

Integrated Steel Complex, Odisha

Scope

5 MMTPA expansion using high-ash Indian coal gasification

Value Delivered

Syngas-fed DRI with methanol/acetic acid co-production, comprehensive feasibility completed

Project

Clean Steel Production, Greta Energy

Scope

0.4 mtpa coal gasification to DRI steel

Value Delivered

Integrated electrolyzer, CO₂-to-methanol/acetic acid conversion, demonstrates gasification pathway

Project

DRI Technology Assessment

Scope

Multiple clients comparative analysis

Value Delivered

Shaft furnace, rotary hearth, fluidized bed evaluation for coal-based syngas feedstock flexibility

Project

Hydrogen Strategy Development

Scope

20-year roadmap for steel manufacturer

Value Delivered

Phased blue-to-green hydrogen integration, economic analysis across scenarios

Why Dastur Energy

Decades of experience in steel industry transformation combining metallurgical process expertise, gasification technology, process integration, and energy systems optimization. We deliver commercially viable, investment-ready solutions that strengthen competitiveness while achieving substantial cost reductions and operational improvements.

FEEDSTOCK BLENDS

Feedstock formulation enabled through blending and other preprocessing strategies allows low-cost, low-quality biomass to be blended with higher cost and higher quality to achieve the in-feed specifications at the conversion facility.