Optimisation strategies and technological advancements for sustainable direct reduction iron production—a systematic review

Abstract

This systematic review examines optimisation strategies and technological advancements to foster sustainable direct reduction iron (DRI) production. The evaluation encompassed a meticulous review of journal articles, industrial reports, and conference papers published between 2002 and 2025, ultimately identifying 65 pertinent studies. A qualitative thematic analysis of the optimisation strategies enabled the identification of three primary themes: life cycle assessment strategies, modelling tools, and technological innovation strategies. This review highlights innovative approaches to using alternative reductants such as biomass and hydrogen, incorporating renewable energy sources in the process, and the economic feasibility of adopting these optimisation strategies. The research findings indicated that there is an urgent need to enhance waste management strategies, especially for coal-based reduction processes, as they are linked to environmental issues. Hydrogen-based reduction has been identified as an innovative methodology for waste control with the potential to reduce carbon dioxide emissions by up to 90%, though it has its limitations. The Circular Economy approach has been proposed as a viable strategy to reduce waste generation and extend the lifespan of materials used in the DRI process. This review provides essential insights on resource optimisation and utilisation and promotes technological innovation to improve the sustainability of DRI.