DigitalManufacturinginIndiaStateofreadinessandadoptionofSmartFactoryTowardsGreenerSteelSteeringtheTransition2TowardsGreenerSteel-SteeringtheTransition3TowardsGreenerSteel-SteeringtheTransitionSteeliscriticaltocontinuedeconomicdevelopmentandisthebackboneofglobalsustainableinitiatives,includingenergytransition.Itisalsooneoftheworld’smostsustainablematerials—permanent,foreverreusableandthemostrecycledmaterialontheplanet.Therefore,buildingmoresustainablesteelproductsthroughanenvironmentallyfriendlyprocessisalong-terminvestmentthatwillyieldenormousenvironmentalbenefitsoverthefulllifecycleofsteel.Today,thesteelindustryisoneoftheworld’smostenergyintensiveandaccountsforaround8%-9%ofglobalcarbondioxideemissions.Forsteelmakers,reducingemissionsandspecificenergyconsumptioniscriticalastheglobaldecarbonizationagendaspeedsup.Steelmakersthatmovenowonajourneytoimprovethesustainabilityofoperationscangetaheadofdevelopingcarbonregulationsandcapitalizeonenvironmental,socialandgovernance(ESG)metricstogainacompetitiveedge.Therehasbeenaconsistentimprovementinmetricsofsustainabilityoverthelastfewyearsforthesteelindustry.However,theintensityofenvironmentalimpactofthisindustryneedsanexecutionofacompellingandawellthoughtoutactionplan.Dependingontheregionandtheexistingassetbaseofsteelproduction,wediscusstheForewordreasonsforwhichsuchanactionplanwillbeuniqueforeachsteelmaker.Thequantumandtimingofinvestmentswilldependonthechoiceofpathwayandtheurgencyofcomplyingwithsustainabilitytargets.Wealsopresentourpointofviewontheoptionsavailabletosteelmakerstomeetthelong-termtargetsofcarbonneutrality.Asafirststep,awell-planned,stagegatedroadmap/pathwayswillbecriticalforasuccessfulsetup.Allsuchpathwayswillrepresentaninformedchoiceofcleantechnologieswhilebalancingbusinessrisk,qualityofendproductandcapitalcostwhileimprovingsustainabilitymetricsacrossthesteelvaluechain.Stakeholderslikegovernments,theUN,academia,communitiesandsteelassociationsarelikelytoplayanimportantroleinsupportingtheimplementationstrategiesofsteelmakers.Otherthancarbonpricingmechanisms,governmentswillneedtoprovidesupportforR&Dandfinancestoencourageandcatalyzechange.Reducingthecarbonemissionsandenergyconsumedinsteelproductioncanboostthelong-termcommercialandsocietalvalueofoneoftheworld’smostsustainablematerialslikesteel.Thereareseveralpathwaysofgettingthere.Thechoiceoftheuserspecificjourneywithitsintendedconsequencesshouldbemadenow.SaurabhBhatnagarEYIndiaNationalMining&MetalsConsultingLeader4TowardsGreenerSteel-SteeringtheTransitionChina’sandIndia’ssteelmakingsectoraretheworld’sfirstandthesecondbiggest,3bothstokedbytherapideconomicgrowthofthesecountries.Asproductiongrows,thecarbondioxideemissionfromtheirsteelsectorisexpectedtotripleby2050.4DecarbonizingthesectorwillbeapriorityforbothIndiaandChinaandothersteelmakingcountries,asmeetingmoreambitiouscarbongoalsbecomesurgent.AttheClimateActionSummit2019,morethan60countries,includingtheEUandtheUK,committedtofullcarbonneutralityby2050.ChinaplanstoreducetheemissionsintensityofitsGDPbyover65%by2030(from2005levels)andbecomecarbon-neutralby20605,6.IndiaintendstoreducetheemissionsintensityofitsGDPby33%–35%duringthesametimeframe7.Reducingtheenergyintensityofsteelmakingwillbeintegraltoachievingthisgoal.Thesteelindustryisoneoftheworld’smostenergyintensive,accountingforaround8%ofglobalcarbondioxideemissions.1Foreverytonneofsteelproduced,anaverageof1.85tonnesofcarbondioxideareemittedintotheatmosphere.2Steelisoneofthemostcriticalmaterialsforcontinuedeconomicdevelopment,andthebackboneofglobalsustainableinitiativesincludingenergytransition.Reducingtheenergyintensityofitsproductionprocesswillbecriticaltoachievingthispotentialandacceleratingglobaldecarbonizationgoals.Transitioningtomoresustainablesteelmakingwillrequireamulti-pronged,collaborativeapproachthatwillcreateamoreefficient,competitiveandsustainableindustry.1IRENA2,3WorldSteelAssociation4“CarbonemissionsbyIndia’ssteelsectortotripleby2050”,TheEconomicTimes,https://economictimes.indiatimes.com/industry/indl-goods/svs/steel/carbon-emissions-by-indias-steel-sector-to-triple-by-2050/articleshow/73927391.cms?from=mdr,accessedinJanuary20215“China'sXitargetssteepercutincarbonintensityby2030”,Reuters,https://www.reuters.com/article/climate-change-un-china-idUSL1N2IS0DY,accessedinJanuary20216“Climatechange:Chinaaimsfor'carbonneutralityby2060’”,BBC,https://www.bbc.com/news/science-environment-54256826,accessedinJanuary20217MinistryofEnvironment,ForestandClimateChange,GoI8https://corporate.arcelormittal.com/media/press-releases/arcelormittal-launches-xcarb-signalling-its-commitment-to-producing-carbon-neutral-steelClimatechangeisanoverwhelmingsocietalpriority.AtArcelorMittal,wehaveanimportantroletoplayinhelpingsocietydelivertheobjectivesoftheParisAgreementandaredeterminedtoleadourindustry’stransitiontocarbonneutralsteel.Wehavethescale,resourcesandtechnologicalprowesstomakeasignificantimpact,andhavealreadyidentifiedtheroutestocarbonneutralsteelmakingthroughourSmartCarbonandInnovativeDRIpathways.8AdityaMittal,CEO,ArcelorMittalAdityaMittal,CEO,ArcelorMittal""5TowardsGreenerSteel-SteeringtheTransitionOfcourse,thequesttobuildamoresustainablesteelmakingsectorisnotnew.Overthepast50years,advancesintechnologyandamovetowardstheelectric-arcfurnace(EAF)havereducedenergyuseinsteelproductionby60%,withsteelmakersreducingconsumptionby0.35%-0.40%year-on-yearforthepastdecade.ThecontinuedmovetoEAFwillhelpdrivedownemissionsfurtherbuttherealityisthattheindustrywillneedtoconsiderbroadermeasures,iftheyaretocreateagenuinelysustainableindustrythatcanmaintainqualitystandardsandcompetitivenesswhilemeetinghighercommunityandinvestorexpectationsaroundenvironmental,socialandgovernance(ESG)measures.TheWEF(WorldEconomicForum)hasproposedasetofuniversalESGmetrics,developedwithleadingCEOsandfirmsincludingEY,tomeasurehowcompaniesarecreatingandreportingonlong-termvaluebeyondthebottomline.Flowsheetofanintegratedsteelmill,showingcarbon-bearingmaterialinput,CO2emissions,expressedinvolume(kg/tofhot-rolledcoil)andconcentrationinfluegas(volume%)Source:Carbondioxide(CO2)captureandstoragetechnologyintheironandsteelindustry,WoodheadPublishingLimitedAndinvestorsareincreasinglyaligningthemselveswithorganizationsthatperformwellagainstESGmeasures,believingthemtobelessrisky,betterpositionedforthelongtermandbetterpreparedforuncertainty.Forsteelmakers,anacceleratingdecarbonizationagendaandthegrowingimportanceofESGperformancerepresentbothachallengeandanopportunity.Certainly,reducingtheenergyintensityandenvironmentalimpactoftheindustrywillrequireasignificanteffortacrossthelifecycleofsteel.Playerswillneedtocommittodeployingenergy-efficientmeasures,adoptingandinvestingincirculareconomyprinciples,improvingmaterialefficiencyandwastemanagementandinvestinginlow-carbonemissiontechnologiesforsteelproduction.Toimproveontheseparameters,theusageofhigh-qualityironoreandcoalwillincreasetoachievehigherefficiency.Limestone109kgLimekiln57kg30%CO2Coal12kgLimestone133kgSinterstrandpelletplant288kg5-10%CO2Blastfurnace285kg25%CO2CokeplantCoal382kg329kg25%CO21255kgeqCO2InBFgasPowerplantHotstripmill709kg20%CO284kg10%CO2Flaresetc.63kgStovesSteelplantCoal=1710kgCO2Limestone=105kgCO2TotalCO2emission:1815kg/trolledcoilConvertergasCokeovengasHotblast72kWh138kgscrapCokeBFgasCoal187kg6TowardsGreenerSteel-SteeringtheTransition7TowardsGreenerSteel-SteeringtheTransitionDecarbonizationisacriticalchallengeinthesteelindustryTheworld’ssteelmakingindustryisintransition,adoptingnewtechnologies,differentwaysofworkingandrethinkingoldproblemstolaythefoundationforgenuinelygreensteel.Steelmakershavelongprioritizedenergyefficiencyandmorerecentlyhavemadeaconcertedefforttoadoptcirculareconomyprinciples.Themajorchallengethatremainsinthefaceofmorestringentemissionstargetsistosignificantlyreduceemissionsinthesteelmakingprocess.Ananalysisofthekeymetricsofthetopglobalsteelmakersreflectsthatwhilesomecompaniesarecontinuouslyimproving,othersarestillattheearlystagesofdevelopment.Forouranalysis,wedividedsteelcompaniesintothreebroadrangesofemissionsandenergyintensity:low,mediumandhigh.Inthebest-casescenario(low),productionfacilitiesmayattainenergyneeds0.1xofglobalaverageandemissionsmaybe0.2xoftheglobalaverage.CompaniesinthehighrangeweretheoneslargelyusingBlastFurnaces(BF).AsmostBFprocessesarealreadytechnologicallymature,CO2abatementisnotpossiblewithoutsignificantinvestmentsinradicaltechnologiessuchascarboncaptureandtopgasrecycling.Note:UpperlimitincludedinlowerrangeThenumberbesidesLow,MediumandHighdenotesthenumberofcompaniesfallinginthoserangesrespectively.Gj/t-gigajoules/tonne,t/t-tonne/tonne,kg/t-kilogram/tonneSources9:Companyreports,EYanalysisSpecificEmissionsandEnergyIntensity:RangeforSteelManufacturing9Forthesteelscoring:•Thedatapointsareconsideredfrom2016-2019,notconsistentlyavailableforallcompanies•Specificdatapointsfromsteelbusinessconsideredwherereportedseparately,elsegroupvaluesconsidered•Foranalysis,Scope1and2CO2equivalentandCO2emissionsconsideredunderGHGemissions•Plantshavedifferentproductiontechnologiesinuse•Forapproximation,valuepercaststeelandcrudesteelproductionconsideredassameLow(4)Medium(7)High(5)Energyintensity(GJ/t)2-1515-2525+GHGemissionintensity(t/t)0.5-11-22+NOxemissionintensity(kg/t)0.05-11-22+SOxemissionintensity(kg/t)0.1-11-22+8TowardsGreenerSteel-SteeringtheTransitionCarbonintensityandageofsteelplantsbyregionNorthAmericaCarbonintensity:1t/tAverageageofplants:53EF:68%Scrapratio:67%CCSfacilities:38SouthAmericaCarbonintensity:1.4t/tAverageageofplants:34EF:32%CCSfacilities:1MiddleEastandAfricaCarbonintensity:1.5t/tAverageageofplants:42EF:90%Scrapratio:13%CCSfacilities:5AsiaCarbonintensity:2.1t/t(IndiaandChina)Averageageofplants(IndiaandChina):15EF:19%Scrapratio:24%CCSfacilities:7SouthAmerica:1.3%otherprocessesCIS:6.4%otherprocessesScrapratioisdefinedasscrapconsumption/crudesteelproductionAsia:ScrapratiocalculatedforChina,JapanandKoreaRepublicNorthAmerica:ScrapratiocalculatedforCanadaandtheUSMiddleEastandAfrica:Scrapratiodeterminedbyassuming100%scrapusedinEAFproductionCCS:ValuesforcommercialCCSfacilities;facilitiesarenotspecifictoironandsteelindustryonlyEFShare>BFShareBFShare>EFShareOtherprocessesonlyCISandotherEuropeCarbonintensity:1.4t/tAverageageofplants:50EF:CIS-29%,OtherEurope–66%Scrapratio:Russia-42%,Turkey-83%CCSfacilities:4(allinotherEurope)EU28Carbonintensity:1.3t/tAverageageofplants:45EF:41%Scrapratio:55%CCSfacilities:9Weunderstandthatrawmaterialprocessingtechnologyisextremelyimportantintheresearchanddevelopmenttowardscarbonneutrality.WehavealonghistoryworkingcloselytogetherwithBHPcollaboratingtostudyrawmaterialutilizationtechnologyandminedevelopment.ItisverysignificantforustobeabletoworktogetherwithBHPtowardsreductionofCO2emissions,whichisanextremelyimportantagendaforthesteelmakingsector.10YoshihisaKitano,YoshihisaKitano,PresidentandChiefExecutiveOfficer,PresidentandChiefExecutiveOfficer,JFEJFE""10BHPpressrelease,https://www.bhp.com/media-and-insights/news-releases/2021/02/bhp-partners-with-jfe-to-address-decarbonisation-in-the-steel-industry/9TowardsGreenerSteel-SteeringtheTransitionUnderstandably,somenationsandregions,suchastheUSandtheEU,arebetterpositionedtoinvestinsustainablesteelmaking,withothernon-BRICnationsalsomakinggreatstridestowardsgreensteel.TheUSsteelsectorisnow70%EAF,comparedtoaglobalfigureof30%.11BFproductionisstilldominantinJapanandSouthKorea,butbothcountriesaremakingsignificantinvestmentsinR&Dtoexplorehowtoreduceemissionsfromproduction.Forexample,JFESteeliscurrentlytestingferrocokeproductionthatcanreduceenergyconsumptionandCO2emissionsinironmakingprocessbyapproximately10%.12Nipponsteelisexploringthedeploymentofinputtinghydrogen/gasbasedDRIand100%scrapintolargescaleEAFswithpowersourcedfromrenewablesourcesformakinghighgradesteel13.Ofallsteelproducingregions,theEUhasthemoststringentdecarbonizationpolicies,whichhassignificantlyreducedtheindustries’useofcarbonoverthepastfewyears.CarbonpricingandapushformorerenewableshaveincreasedcostsforEUsteelmakersandreducedtheirglobalcompetitiveness,butsustainabilityinitiativeshavealsospurredincreasedinvestmentinR&D–thisshouldleadtolowerproductioncosts,continuetoimprovethedecarbonizationofprocessesand,overtime,improvecompetitiveness.Forexample,steelworksintheDutchportofIjmuidenhavedevelopedanewtechnologycalledHIsarnawhichismoreefficient,reducesenergyuseby20%andcutsCO2emissionsbyremovingnumerouspre-processingsteps.HIsarnaproducesalmostpureCO2,whichcanbeusedincarboncaptureforstorageoruse,potentiallyachievingCO2savingsof80%throughoutthesteelproductionprocess.14Togetanunderstandingoftheprogressofglobalsteelmakersinreducingemissions,wecomparedtheinitiativesofkeysteelplayersinBRIC(Brazil,Russia,IndiaandChina)andnon-BRICnations.Inanotherbreakthrough,SSAB,LKABandVattenfallplantoindustrializefossil-freesteelmakingtechnologydevelopedthroughHYBRIT(HydrogenBreakthroughIronmakingTechnology).HYBRITcanreduceSweden’sCO2emissionsby10%andFinland’sby7%ifimplementedatfull-scale.Companiesplantostarttheworld’sfirstdemonstrationplantforproducing1.3mtfossil-freespongeironby2026inSweden.15TheEUalsohasastrongpolicyframeworkforgreenhydrogendeployment.TheEUHydrogenStrategyaimstobuildlarge-scalegreenhydrogencapacitiesby2050,pavingthewayforregion’ssteelmakerstotransitionmoreeasilytohydrogen-basedproduction.AmongBRICnations,especiallyRussia,ChinaandIndia,thetrajectoryofcarbonreductionislikelytobemoregradualthantheoneseenintheWest.Manyoftheregion’sBFsarelessthan15yearsold,makingreplacementuneconomicalatthistime.Moreover,sectorconsolidationinChinaandIndia,theworld’stwolargeststeelproducingcountries,isbelowglobalaverage,withmanysmallcapacityenterprisesoperatingwithlessefficiency,morepollutantsandalackofinvestmentinnewtechnologies.ChinaintendstoincreaseitsEAFshareinoverallsteelmakingtoreach15-20%by2025from10%in2019.16AllBRICcountriesarecommittedtosignificantlyreducingthecarbonemissionsoftheirsteelmakingindustries,butacredibleroadmapisurgentlyneededtomakeitarealitythroughmoreconsolidation,agreatermovetoEAFproductionandinvestmentinarobustrecycledsteelsupplyforsteelmaking.Asdemandforgreensteelincreases,countrieswithmoresustainablesteelmakingindustriesarelikelytoreapacompetitiveadvantage.AsoriginofsteelbecomesabiggerpartoftradenegotiationsbetweensteelproducersandOEMs,wearelikelytoseeBRICnationsacceleratetheiradoptionofsustainablealternativestoretaincompetitivenessinthelongrun.BRICNon-BRICAcomparisonofBRICandnon-BRICsteelmaking11WorldSteelAssociation12https://www.jfe-steel.co.jp/en/release/2020/201012.html13“NipponSteelZeroCarbonInitiative”reportreleased30thMarch2021byNipponSteel14https://www.tatasteeleurope.com/ts/sites/default/files/TS%20Factsheet%20Hisarna%20ENG%20jan2020%20Vfinal03%204%20pag%20digital.pdf15https://www.ssab.com/company/sustainability/sustainable-operations/hybrit16“Chinasteelmillsplanaround2030carbonpeak”,HellenicShippingNews,https://www.hellenicshippingnews.com/china-steel-mills-plan-around-2030-carbon-peak/,accessedinMay202110TowardsGreenerSteel-SteeringtheTransition11TowardsGreenerSteel-SteeringtheTransition17OECD18“Pathwaystodecarbonisationepisodetwo:steelmakingtechnology”,BHP,https://www.bhp.com/media-and-insights/prospects/2020/11/pathways-to-decarbonisation-episode-two-steelmaking-technology/,accessedinJanuary2021Howshouldsteelmakerssteerthetransition?Achievingsustainabilitywillrequiresteelmakerstorolloutstrategiesacrosstheentirevaluechain,withfivestepscriticaltosuccess:Steelmakersneedtotakeapragmaticapproachtoimplementingcleaneralternatives.Ensuringoverallproductioncapacityremainsinlinewithdemandtomaintainprofitabilityandcompetitivenesswillrequirecompaniestobalancerisk,cost,qualityandtheirchosentrajectorytodecarbonizesteelproduction.Thatsaid,controllingemissionswillbethecentralchallengeofsteelmakersoverthedecadestocome,andthosethatfindthecapitaltoinvestingreenerproductionwillultimatelyemergeaswinners.Allnewsteelproductionshouldadoptgreeneralternatives,althoughcompanieswillneedtomakejudiciouschoicesaroundwhenandwheretoadoptcleantechnologies.Forexample,around18%ofnewsteelprojectsoverthenextdecadewillbeintheMiddleEastwhereanaffordablesupplyofnaturalgasmakesEAFsanaturalchoice.17Incomparison,Indiansteelmakershavestruggledtogainapprovaltoexpandgreenfieldcapacity–brownfieldexpansionswilllikelymakeupmostofIndia’snewproductioncomingonline.Aligninginvestmentswithcyclicalgainscanmitigatefinancialrisksashigherinitialcapitalcostsarelikelytobeoffsetbythelong-termbenefitsofmoresustainableoperationsandimprovedESGperformance.Akeyconsiderationforintegratedsteelmillscurrentlyinproductionwillbetheneedtofactorinthecostsofreliningblastfurnaces.AplantwithcapitalcostsofUS$1b/mtpaandaremaininglifeof40yearswillneedtoberelinedtwiceoveritslifetime.Thisaccountsforaroundaquarterofthemill’scapitalcost.18Aseachreliningperiodapproaches,steelmakersshouldperformacost-benefitanalysisofextractingthefulllifecomparedwithmovingtoalternativetechnologies.Steelmakerswillneedtoforgeapaththatcombinesretiringassetsandreplacingthemwithnew,cleanertechnologiesandimprovingthesustainabilityofexistingassets–allwhileensuringthatcommitmentsaroundreducinggreenhousegases(GHG)andachievingcarbonneutralityaremetwithintheagreedtimeframe.Assessandadoptcleantechnologiesensuringabalanceofrisk,capitalcostandquality11Assessandadoptcleantechnologiesensuringabalanceofrisk,capitalcostandquality2Increaseproductionofsustainablesteel3ImproveESGperformance5Collaboratewithallstakeholders4Embracedigitalizationtounlockvalue12TowardsGreenerSteel-SteeringtheTransitionSource:EYanalysisInitiativestoimprovethesustainabilityofexistingsteelmakingassets:ExistingCommercialTechnologiesBF/BOFCOREXwithO2converterNoncokingcoal-basedDRI/EAFNG-DRI/EAFScrap-EAFEnergyefficiency►Substitutionofcoalinjectioninblastfurnacebybiomass►OptimizationofbackpressureturbineandhotblasttemperaturecontrolsystemforBF►Optimaldesignofplantwidefansystems:ASDs,flowandpressurecontrol►DeploymentofCDQ(Cokedryquenching)andheatrecoveryfromsintering►MaximizePCIinjectioninmeltergasifier►Directandautomaticuseofexportgasforpowergeneration►Optimizingmetallizationrates►AdvancedanalyticsforC/Feratio►Improvingwasteheatrecovery►Useofadvancedcontroltechnologiesforpowergenerationandusage►Optimizingmetallizationrates►AdvancedanalyticsforGas/Feratio►Improvingwasteheatrecoveryinrecoveryboilers►Controlofsyn-gasqualitytoensurethermalefficiencyofEAF►Useofanalyticsforoptimizingandreducingvariationinbatchcycletimes►Realtimesynchronicityofgridpowerusage►LadleschedulingTaptopowerONtimeoptimizationformultifurnaceoperations►UseofadvancedcontroltechnologiesforpowerAtJSWSteel,wearen’tonlyresponsiblyaddressingtheenvironmentalimpactofouroperations,butalsowantoursustainableproductstosafeguardtheenvironmentandconserveresources.WearerelentlesslydrivinginitiativestobenchmarkouroperationswiththebestintheworldontheEnvironment,SocialandGovernanceparameterstodelivervaluetoallourstakeholders.DrVinodNowal,DeputyMDJSWDrVinodNowal,DeputyMDJSW""13TowardsGreenerSteel-SteeringtheTransitionDecarbonizationCircularEconomyUtilityefficiency►Exploitationofsynergiesofplantwideinstallationandintegrationofsensordataforcarbonemissions►OptimizationofbalanceofCO/CO2generationinrealtime►Replacementofcokewithnaturalgasinjectionforreduction►Deployelectricvehiclesforintra-minelogistics►Settingupainboundsupplychainforscrapsourcing,storage,handlingandmonitoring►MaximizationofusageofscrapinSMS►Efficientsystemsofminimizationformationandrecyclingscale►Rainwaterharvestingbothonthesurfaceaswellasrechargingtheaquifersasadditionalsources►Digitallyenabledplantwidesteammanagementsystemwitharealtime“Pinchcontrolsystem”►AutomationandcontrolofcycloneseparationsandESPs►Useofhighqualitynon-cokingcoalforcarbongeneration►Re-useofgasfromconvertorsintoreductionfurnace►Deployelectricvehiclesforlogistics►Digitalizedmaintenanceofscrubbersandfinesseparationunitsandgasscrubbersformeltergasifiers►Useofbiomass/solidwaste/non-fossilinkilns►Deployelectricvehiclesforlogistics►Settingupainboundsupplychainforscrapsourcingstorage,handlingandmonitoring►MaximizationofusageofscrapinSMS►Useofbiomass/solidwaste/nonfossilingasgenerators►Controlofyieldofgasthroughdigitalautomaticcontrol►DeployelectricvehiclesforlogisticsInthecurrentstateoftechnologicalevolution,supplydemandgapofsteel,BFBOFroutewillcontinuetobemosteconomicalandrelevantforallsteelmakersforthenext10years.ThesolutionforreducingthecarbonloadingbyindustryatlargeliesinembracingauniquecombinationofjudicioususeofcarbonTax,economicalavailabilityofscrap,selectiverawmaterialsourcingandscalingupoftechnologiesforreplacementofCarbonwithH2,MethaneandCokeOvengasasaprimaryreducingagent.UttamSingh,VP.IronMaking,TataSteelUttamSingh,VP.IronMaking,TataSteel""14TowardsGreenerSteel-SteeringtheTransitionEmergingtechnologiesthathelpintegratedsteelmakersreduceemissionsTopgasrecyclingcombinedwithcarboncapturestorageand/orutilization(CCUS)technologymayofferasolutiontosignificantlyreducingemissions.Topgasrecyclingcanrecycleupto90%oftheexhaustgasfromBFs,reusingitforcombustionwiththeremaininghighlyconcentratedCO2storedand/orused.19Determiningwhethercarboncaptureissuitablemaydependonoveralloperatingcosts.Technologycostsarestillhighatthisrelativelyearlystageofdevelopment,thoughtheyshouldcomedownoverthenextfewyears.Steelmakerswillalsoneedtoinvestintransportandstorageiftheyaretoscaleupoperations.Findingstoragecapacitymaybedifficult,withpotentialsiteshavingtoundergositecharacterizationtoensuresuitabilitytosafelystoreCO2,incompliancewithregulations.CO2capturedinsteelmakingcanbereusedasfuelsinotherindustrialproduction,thoughweseeonlylimitedexamplesofitslarge-scalecommercialutilizationatthisstage.OneisanAbuDhabiprojectwhereCO2capturedfromfluegaswithinanEmiratesSteelplantisusedinenhancedoilrecovery(EOR)attheAbuDhabiNationalOilCompany.20Otherstrategiescenteraroundinnovationsintheproductmix,includingusinghigherqualityinputsorchangingthemix.Weseesteelmakersinjectingpulverizedcoalorbiofueltoreapcost,efficiencyandemissionbenefits.Asplantsneartheirendoflife,companieswillneedtoevaluateallalternativeswhilebearinginmindthelong-termsustainabilityagenda.Forintegratedsteelplayersconsideringatransitiontoscrap-basedEAFproduction,theaffordabilityandavailabilityofscrapandthequalityoftheendproductwillbeimportantdeterminantsofthestrategyandtechnologicalchoicebetween:1.FullyscrapbasedEAF2.PrimarysteelthroughDRIwithnaturalgasastheprimaryreductantfollowedbyEAF(NG-DRI/EAF)3.PrimarysteelthroughDRIwithgreenhydrogenastheprimaryreductantfollowedbyEAF(H2-DRI/EAF)MaintainingthequalityofcertainhighgradesofsteelwilllimitthequantityofscrapthatcanberecycledthroughEAF.CarboncaptureInnovationsinproductmix19ULCOStopgasrecyclingblastfurnaceprocess(ULCOSTGRBF),EuropeanCommission20CarbonSequestrationLeadershipForum15TowardsGreenerSteel-SteeringtheTransitionAcomparisonofemergingandnewtechnologyproductionmethodsforgreenersteelNote:PotentialCO2reductionforscrap-basedEAF,smeltingreductionprocessconsideredascomparedtoblastfurnaceEstimatesmajorlyfortransitiontolow-emissionssteelmakinginEuropeIncrementalproductioncosts(OPEXandCAPEX)comparedwithaverageannualnetincomeofsteelindustryValuescomparedforcrudesteelproductionChallengesBenefitsIncrementalprod.costsEmergingCommercialTechnologiesCommercialhorizonPotentialCO2reductionScrap-EAF-Commercial80%HighpotentialofCO2reduction;technologyreadilyavailable;usefulincaseoflowsupplyofhighqualitycoalHighscrapsupplyrequired;energyneedsofEAFcanaddtoemissionsBF/BOFwithbiofuel-Commercial20-50%EasiertoimplementbyalteringtheinputmixinblastfurnaceHighquantityofbiofuelrequired;Increasedstorageandtransportationcost;HighmoisturecontentofbiofuelsBF/BOFwithhydrogen-~10years-Potentialtoreduceemissionsbothincokeplant(reducedamountofcoalrequired)andblastfurnaceDifficulttoreplacereducingagentbyhydrogenbeyondapointtomaintainoperationsBluehydrogenDRI(H2-DRI/EAF)+35-55%10-20years-Flexibility;scalabilityofproducingbluehydrogeninsomeareasProductioncostofbluehydrogen:~US$2/kgcomparedtoblackhydrogen:~US$1.7/kg;DoesnotaddressemissionsfrompelletsIronelectrolysisNotdetermined20-30years~90%LargestpotentialinCOreductionStillatanearlystageofdevelopment,onlybeentriedatalabscaleSmeltingreduction-Commercial4-20%Loweroperatingcost;Possibleeliminationofsinter/pelletandcokeplantsHighcalorificvalueexportgasgenerated;LowereconomicscaleofoperationsBF/BOFwithcarboncapture+30-50%5-10years30%CaneasilybeintegratedtoBF-BOF;AdvantagefromR&DgoingonsincelongtimeLargeinfrastructureinvestmentforstorageandtransport;DifficulttocaptureallCOemissionsNaturalgasDRI(NG-DRI/EAF)-Commercial40%HighenergyandemissionssavingsAdequateandafford-ablesupplyofnaturalgascriticaltodetermineprofitabilityGreenhydrogenDRI(H2-DRI/EAF)+60-90%10-20years80-95%IncreasedflexibilityashydrogenandHBIcanbestoredHighgreenhydrogencosts:~US$5/kgcomparedtoblackhydrogencostsof~US$1.7/kg16TowardsGreenerSteel-SteeringtheTransitionInthemediumtolongterm,replacingcoalornaturalgaswithhydrogencansubstantiallyreduceGHGemissions.Basedonthemostrecentresearch,useofgreenhydrogen(generatedbyrenewables)withDRI/EAFislikelytobethecleanestalternativeforsteelmakersinthefuture.21ResidualemissionsmaystillariseinEAFsduetotheconsumptionofgraphiteelectrodesanduseoflimeandnaturalgas,buttacklingtheseislikelytobefareasierthanthechallengeofloweringtheemissionsofBFsrunoncokingcoal.However,itwillbesometimebeforehydrogeniseconomicallyfeasibleandscalable.Othercommercializedsmeltingreductionprocesses,suchasCOREX,FINEXandHIsarnacanofferbetteremissioncontrol,comparedwithintegratedplants.However,theeconomicviabilityoftheseprocessesdependsontheeffectiveutilizationofexportgasesandoverallpowerconsumption.Thelowrateofadoptionthusfarofthesedesignsalsounderminestheiremissionbenefits,andweseeonlylimiteduseoftheseprocessesincertainregions.Ascompaniesandindustriesfacemorepressuretomeasure,reportandreducescope3emissions,demandforlowcarbonsupplies,includingsteel,isgrowing.Thepushtodecarbonizetheautomotivesector,whichaccountsfor12%oftheworld’stotalsteeluse,ispromptingautomakerstoseekcleanerinputs.22Governmentincentivesarestokingdemandfurther;theUSsupportforcarbon-neutralconstructionmaterialsandelectricvehicle(EV)infrastructureislikelytofurtherincreasetheappealofgreenersteel.23Forsteelmakers,meetingdemandrequiresalteringtheirproductmixtoensureagreatershareofgreenproducts.Wealreadyseesomedominantplayers,suchasArcelorMittal,offeringcertifiedgreensteelproductswithmoresettofollow.NewZealandgrewby34%toreachaboutUS$31t,withEuropeandtheUSaccountingfor85%ofthistotal.24Atthesametime,manygovernmentsareenforcingcarbonabatementstrategies,includingcarbontaxregimesandtheEmissionTradingSystems(ETS)seenintheEUandincountriesincludingCanadaandMexico.ImprovingESGmetricswillreapbenefitsforsteelmakersbeyondcompliancewithregulationsandstakeholderexpectations.CompanieswithabetterESGperformancewillsecureprojectfinancingatalowercost,enhancehowtheymanageresources,reduceoperationalriskandbemoreresilientagainsteconomicshocksandanychangestoagovernment’senvironmentalregulations.WeseesomesteelmakerstakingaproactiveapproachtotheESGagenda,forexampleincludingtheimpactofcarbonemissionsinassessingtheprofitabilityofcapitalinvestments-JSWSteelhasadoptedashadowinternalcarbonpriceofUS$20/tCO2,whileTataSteelhasmarkedUS$15/tCO2.25Thishelpsfirmstoidentifysustainabilityinefficienciesthatmaybeincreasingoverallcostsandthepotentialimpactofalowcarboneconomyoncosts.Internalcarbonpricingalsoencouragesfirmstoearmarkfundsforfuturelow-carbonefforts.Forsteelmakersyettointegratenon-financialframeworksintoinvestmentdecisions,fourstepscanhelpguidetheprocess:1.AssesscurrentESGmaturityagainstthekeymetricsoftheTaskforceforClimate-relatedFinancialDisclosures(TCFD),includingthoseofbusinessgovernanceandpeople.2.Buildaspecificshort-tomedium-termroadmapfortheorganizationtoimproveperformancearoundkeymetricsincludingdecarbonization,climatechange,landuse/ecologicalsensitivityandwaterusage.3.Committhenecessaryresourcesi.e.,budgets,people,technology/digitalandexternalpartnerships,toexecutetheroadmapatspeed,andwiththerightdata-driven4.Real-timecoordinationofcompliance(measure,monitor,disclose),valuecreation(strategize,goalsetting,execution)andcomplianceforperpetuity.Inmanyways,steelmakersarealreadyleadersintheuseofdigitalsolutions,withmanyusingtechnologytoimprovedefectrecognition,processsafetyandqualityManyinvestorsareseekingmoresustainableportfolios,demandinggreaterESGcomplianceandperformancefrompotentialinvestmenttargets.Between2016-18,thevalueofassetsinsustainableinvestmentportfoliosinthemajormarketsofEurope,theUS,Japan,Canada,AustraliaandHydrogenAlternativesmeltingreductionprocessesIncreaseproductionofsustainablesteeltocapitalizeongrowingdemand2ImproveESGperformancetomeetstakeholderexpectations3Digitalizationtounlockvalue421BNPParibas22Statista23https://corporate.arcelormittal.com/sustainability/xcarb/xcarb-green-steel-certificates24GlobalSustainableInvestmentReview2018,GlobalSustainableInvestmentAlliance25https://www.jsw.in/groups/sustainability-framework-measuring-success-climate-change;https://www.tatasteel.com/tata-steel-brochure/sustainability.html17TowardsGreenerSteel-SteeringtheTransitionassurance.WeseesomeorganizationsexploringintegratedarchitecturesoftechnologiesincludingIoT,bigdataanalytics,cloudcomputingandAIatvariouspointsinthevaluechain,includinge.g.,digitaltwinsandvariableprocessprediction.Butthere’spotentialtomakegreateruseofdigitalizationtoimprovesustainabilitymetricsandunlockgreaterlong-termvalue.Datacanhelpsteelmakersquantify,monitor,recordandassessprocessestoenhanceperformanceandensurereportingrequirementsaremet.Digitalizationcanalsohelpinimprovingproductivityofoperationsbyoptimizingenergyconsumption,minimizingwastegenerationandcontrollingemissions.Forexample,digitalsolutionscansupportenthalpyandthecarbonbalancingofgasnetworksofvaryingcompositionandcalorificvaluegeneratedatvariousflowstagesofsteelmanufacturing.Real-timedynamicroutingandallocationofgasesusedinheatingstoves,powerplants,sinter,pellet,cokeovenplantsandrollingmillscanhelpminimizeflareburninginIntegratedSteelPlants(ISP)and,whererelevant,evenbeusedinDRI-basedEAFs.Digitalsolutionscanoptimizethelogisticsforinboundandoutboundmaterialsflowstomaximizematerialthroughputinamulti-modaltransportworldandensuretheleastfuelburntpertonofmaterialmoved.Blockchaincanverifythesustainabilityquotientofsteelvaluechains,givingendusersreliabledatatoassesstheirnetcarbonimpact.Italsohelpscreatemoreagilesupplychains,withcloudcomputingallowsforcentralcommandandcontrolcenterstooverseegeographicallydispersedminetometalvalue-chains.Assteelmakersfurthertheirsustainabilityagenda,theadoptionofmoredigitalsolutionswillbeacriticalstep,toensureorganizationscancollectandmonitorthehigh-quality,timelydatarequiredforactionableinsights.Decisionsmadearoundsustainabilityinitiativescannotbebasedpurelyonfinancialcoststothebusiness.Instead,steelmakersmustactwithallstakeholdersinmind,andbepreparedtomakeabalancedtrade-offbetweenindustry,endconsumersandtheenvironment.Aligningstakeholdersaroundthechangesthatmustbemadewillbecriticaltoquickenthepaceofthestructuralshiftrequired.Collaborationisneededtoco-developfeasiblesolutionstocomplexsustainabilitychallenges.IntheEU,weseemanyexamplesofpartnershipsbetweensteelmakers,rawmaterialproviders,OEMsandrenewableenergyprovidersthathaveacceleratedthedevelopmentofsustainablealternativestotraditionalmethods.Theseeffortsarenotjustadvancingthesustainabilityagenda–theyarecreatingacompetitiveadvantagefortheregion’ssteelmakersandtheirecosystemofpartners.Asnewermethodsmaturetowardsimplementationreadiness,steelmakersmayneedtointegratetheirusewithmoreestablishedmethodstomaintainprofitability.Thiswillrequireworkingintandemwithsupplychainpartners.Collaboratingwithcommunitiescanensurethattheimpactofnewtechnologiesonlocallanduseandotherresourcesisminimizedtoensuresustainedproductioninregions.Regulatorybodiesandgovernmentscanactascatalyststoincentivizebothproductionanddemandforgreenersteel.Aligningpolicieswithsteelmakers’initiativesrequireseffortsfrombothsides.Organizationswillneedtoensurethatactionstakenarerelevanttotheirregionofoperation,tobetteradvancetheirsustainabilityagenda.Collaboratewithallstakeholders5People►Employees►Neighboringcommunities►Government►Academia►Industrybodies►GlobalgoverningbodiesProfit►Supplychainpartners►Endconsumers►Channelpartners►Ecosystemenablers►Othercompetitors►InvestorsPlanet►GlobalGHGemissionsandenergyreduction►Waterresources►LanduseminimizationKeystakeholdersSource:EYAnalysis18TowardsGreenerSteel-SteeringtheTransition19TowardsGreenerSteel-SteeringtheTransitionBuildingthefutureofgreensteelThesteelindustry’stransitiontogreenersteelwillnotbeuniformacrossregions.SteelproducersinwesternregionsandthosecountriesalreadyinvestinginimprovingsustainabilityarelikelytoseeamorerapidadoptionofnewerlowcarbontechnologiescomparedwithsteelproducersinChinaandIndiawherethecombinationofnewercapitalassetsandcostpressureswillforceamoregradualtransition.Eveninregionsandcountrieswhereprogresswillbeslower,steelmakersshouldcontinuetomakeincrementalinvestmentsinprocessimprovementstodecreaseenergyintensity,reducecarbonemissions,increasematerialefficiencyandpromotethecirculareconomy.Forallsteelmakers,thejourneytogreensteelwillbeanindividualone,wherecapexcosts,qualityofproductionandbusinessriskarewellconsideredandbalanced.Businesseswillneedtomeetlocallegislation,retrofittingassetswhennecessary,andmakinginvestmentsthatfittheirownbusinessstrategy,existingassetbaseandcapacitytotakeriskswithemergingtechnology.Giventherelativelylargecarbonfootprintofsteelproduction,evensmallstepswillmakeabigdifferenceinreducingitsimpactontheenvironment,andmovingtheindustryclosertocarbonneutrality.Astheglobalagendatocombattheclimatecrisis,throughregulatorychangesandcarbontaxes,accelerates,steelmakersthatproactivelyshifttosustainableprocesseswillreapacompetitiveadvantage.Makingthisshiftwillrequireastageddigitalroadmaptorealizethefullpotentialofnewtechnologiestoachieveeconomiesofscalewhileimprovingsustainabilityacrossthesteelvaluechain.Earlyexperimentationandconsequentadoptionwillenablebothbetterassessmentandimprovementofsustainabilitymatrix.Thiswillbecriticalindevelopingcost-efficient,integratedsolutionsacrossplantoperations.Otherstakeholders,includinggovernments,theUN,academia,communitiesandtheWorldSteelAssociationalsohaveanimportantroletoplayinbuildingagreenersteelindustry.Governmentsarelikelytoimposemorecarbonpricingmechanisms,butmoredirectfinancialsupportandinvestmentinresearchanddevelopmentisalsoneededtoincentivizepositivechanges.Thereisanurgentrequirementtolaunchaframeworkofglobalstandardsandsustainabilityyardsticksthatcanhelpsteelproducersworkwithendconsumerstodesignsustainableproducts,withtheoveralllifecyclecostinmind.Creatingdemand-sideincentivescanboostthemarketforvalue-addedsteels,whichgovernmentsshouldsupportintheearlyyearstoensurestability.Alreadyweseeencouragingsignsofprogresstowardsmoresustainablesteelmaking.IntegratedEuropeansteelmakersareleadingthewaybyimplementinghydrogen-basedpilotinitiativeswhichhavethepotentialtodrasticallyshifttheindustry’srelianceoncoal.Whilethecostofsourcingandtransportinggreenhydrogentoexistingsteellocationswillneedfinancialsupport,inthemeantime,useofDRI-basedEAFsisexpectedtoincrease,contributing50%oftotalcrudesteelproductionby2030.Weexpectthecontinuedadoptionofnewtechnologiestoshifttherawmaterialsmixtowardstheuseofmorerecycledscrap.Withinnewsteelmaking,we’llseeagrowingshifttowardsnaturalgas/hydrogenbasedDRI/HBIproduction.Andallofthesechangeswilltakeplaceascallsgrowfromendconsumers,particularlytheautomotivesector,fortransparencyaroundsteel’scountryoforiginaseffortstominimizevaluechainemissionsincrease.Steelisoneoftheworld’smostsustainablematerials.Essentialtomodernsociety,steelispermanent,foreverreusableandthemostrecycledmaterialontheplanet.Buildingamoresustainablesteelproductionprocessisalong-terminvestmentthatwillyieldenormousenvironmentalbenefitsoverthefulllifecycleofgreensteel.HydrogenisthekeytoturningthebigleverwehaveinreducingCO2emissionsinthesteelindustry,”explainsDr.ArndKöfler,ExecutiveBoardMemberforProductionatThyssenkruppSteel.Byusingclimate-neutralhydrogen,thyssenkruppcanavoid20milliontonsofCO2ayearinsteelinthelongterm.26Dr.ArndKöfler,ExecutiveBoardMemberThyssenkruppSteelDr.ArndKöfler,ExecutiveBoardMemberThyssenkruppSteel""26Thyssenkrupppressrelease,https://engineered.thyssenkrupp.com/en/green-hydrogen-for-green-steel/20TowardsGreenerSteel-SteeringtheTransition21TowardsGreenerSteel-SteeringtheTransitionEYcontactsVikramMehtaPartnerIndiaRegionLeader–Mining&MetalsEYGmemberfirmChaitanyaKaliaPartnerandNationalLeaderClimateChangeandSustainabilityServices(CCaSS),EYIndiachaitanya.kalia@in.ey.comPaulMitchellPartnerandGlobalLeaderMiningandMetals,EYpaul.mitchell@au.ey.comSaurabhBhatnagarEYIndiaNationalMining&MetalsConsultingLeadersaurabh.bhatnagar@in.ey.comMichaelRundusOceaniaMining&MetalsIndustryLeadermichael.rundus@au.ey.comShivaniJoshiMining&MetalsanalystGlobalMarketsEYKnowledgeshivani.joshi1@gds.ey.comRobertStallPartnerandUSLeaderMiningandMetals,EYrobert.stall@ey.comManojChauhanSeniorMining&MetalsanalystGlobalMarketsEYKnowledgemanoj.chauhan@gds.ey.com22TowardsGreenerSteel-SteeringtheTransition23TowardsGreenerSteel-SteeringtheTransitionOurofficesAhmedabad22ndFloor,BWing,PrivilonAmbliBRTRoad,BehindIskconTemple,OffSGHighwayAhmedabad-380059Tel:+917966083800Bengaluru12th&13thfloor“UBCity”,CanberraBlockNo.24,VittalMallyaRoadBengaluru-560001Tel:+918067275000GroundFloor,‘A’wingDivyasreeChambers#11,O’ShaughnessyRoadLangfordGardensBengaluru-560025Tel:+918067275000ChandigarhElanteoffices,UnitNo.B-613&6146thFloor,PlotNo-178-178AIndustrial&BusinessPark,Phase-IChandigarh-160002Tel:+911726717800ChennaiTidelPark,6th&7thFloorABlock,No.4,RajivGandhiSalaiTaramani,Chennai-600113Tel:+914466548100DelhiNCRGolfViewCorporateTowerBSector42,SectorRoadGurugram-122002Tel:+9112444340003rd&6thFloor,Worldmark-1IGIAirportHospitalityDistrictAerocity,NewDelhi-110037Tel:+9111473180004th&5thFloor,PlotNo2BTower2,Sector126GautamBudhNagar,U.P.Noida-201304Tel:+911206717000HyderabadTHESKYVIEW1018thFloor,“SOUTHLOBBY”SurveyNo83/1,RaidurgamHyderabad-500032Tel:+914067362000Jamshedpur1stFloor,ShantiniketanBuildingHoldingNo.1,SBShopAreaBistupur,Jamshedpur–831001Tel:+916576631000Kochi9thFloor,ABADNucleusNH-49,MaraduPOKochi-682304Tel:+914844334000Kolkata22CamacStreet3rdFloor,Block‘C’Kolkata-700016Tel:+913366153400Mumbai14thFloor,TheRuby29SenapatiBapatMargDadar(W),Mumbai-400028Tel:+9122619200005thFloor,BlockB-2NirlonKnowledgeParkOff.WesternExpressHighwayGoregaon(E)Mumbai-400063Tel:+912261920000PuneC-401,4thfloorPanchshilTechPark,Yerwada(NearDonBoscoSchool)Pune-411006Tel:+912049126000EYexiststobuildabetterworkingworld,helpingtocreatelong-termvalueforclients,peopleandsocietyandbuildtrustinthecapitalmarkets.Enabledbydataandtechnology,diverseEYteamsinover150countriesprovidetrustthroughassuranceandhelpclientsgrow,transformandoperate.Workingacrossassurance,consulting,law,strategy,taxandtransactions,EYteamsaskbetterquestionstofindnewanswersforthecomplexissuesfacingourworldtoday.EYreferstotheglobalorganization,andmayrefertooneormore,ofthememberfirmsofErnst&YoungGlobalLimited,eachofwhichisaseparatelegalentity.Ernst&YoungGlobalLimited,aUKcompanylimitedbyguarantee,doesnotprovideservicestoclients.InformationabouthowEYcollectsandusespersonaldataandadescriptionoftherightsindividualshaveunderdataprotectionlegislationareavailableviaey.com/privacy.EYGmemberfirmsdonotpracticelawwhereprohibitedbylocallaws.Formoreinformationaboutourorganization,pleasevisitey.com.Ernst&YoungLLPisoneoftheIndianclientservingmemberfirmsofEYGMLimited.Formoreinformationaboutourorganization,pleasevisitwww.ey.com/en_in.Ernst&YoungLLPisaLimitedLiabilityPartnership,registeredundertheLimitedLiabilityPartnershipAct,2008inIndia,havingitsregisteredofficeat22CamacStreet,3rdFloor,BlockC,Kolkata-700016©2021Ernst&YoungLLP.PublishedinIndia.AllRightsReserved.EYIN2106-012EDNoneThispublicationcontainsinformationinsummaryformandisthereforeintendedforgeneralguidanceonly.Itisnotintendedtobeasubstitutefordetailedresearchortheexerciseofprofessionaljudgment.NeitherEYGMLimitednoranyothermemberoftheglobalErnst&Youngorganizationcanacceptanyresponsibilityforlossoccasionedtoanypersonactingorrefr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