Towards Circular Steelmaking: Hydrogen-Based Valorization of Electric Arc Furnace Dust

Electric arc furnace dust (EAFD), a hazardous waste from galvanized steel recycling, presents a significant challenge to sustainable steel production. Here, we show that hydrogen reduction, under industrially relevant conditions, offers a transformative solution for EAFD valorization. Compared to conventional carbothermic reduction, hydrogen achieved higher zinc recovery (98.8–99.7% vs. 86.2–90.0%), enhanced iron metallization, and superior removal of sulfur and phosphorus. This is attributed to hydrogen's enhanced diffusivity and reactivity, which prevents the microstructural degradation (pore closure) that limits carbothermic reduction. Importantly, we demonstrate the feasibility of selective zinc extraction, allowing EAFD recycling even without simultaneous iron reduction. This work provides a pathway for transforming EAFD from a hazardous waste into valuable resources, contributing to a lower-carbon and more resource-efficient steel production process.