Dr. Heike Denecke-Arnold, Chair of the Conference, Chief Operations Officer, thyssenkrupp Steel Europe AG, Germany

Abstract:
Opening of METEC & 6th ESTAD 2023

Dr. Henrik Adam, Chairman of Steel Institute VDEh, Vice President European Corporate Affairs of Tata Steel, Tata Steel Ltd, Netherlands

Abstract:
Welcome address of the host

Prof. Karsten Pinkwart, Member of the Hydrogen Council of the German Government, University Karlsruhe, Germany

Abstract:
Climate change needs them and their industry to play a decisive role in stopping it, otherwise we will meet again under water. No joke, because only 0.1 degrees more global temperature increase means a rise in the world's oceans of 7 metres and you can imagine what this will result in. With a share of about 4% of anthropogenic CO2 emissions in Europe and 9% worldwide, the massive use of coal in the steel industry contributes to this. It must and is the goal to tackle an industry-wide conversion to green hydrogen. However, it is already clear that this technological change will require gigantic amounts of solar and wind energy. But it also requires corresponding infrastructures and ultimately also investors and financing possibilities, to list just a few of the points on your wish list. However, this is the only way forward, so let us discuss openly how we can succeed together.

Ronald E. Ashburn, Executive Director, Association for Iron & Steel Technology (AIST), United States

Co-Author:
Brian J. Bliss, General Manger Programs and Publications, Association for Iron & Steel Technology
Samuel J. Kusic, Jr, News Editor, Association for Iron & Steel Technology

Abstract:
Never in the last half century has the global steel industry faced as many challenges at once: overcapacity, supply chain insecurity, energy shortages, unfair competition and climate change. The problems are immense and have catalyzed the imperative for global steel decarbonization. North American steel producers are actively engaged in technology evolution to innovate process and product, and have invested in an advanced fleet of production assets that are highly automated, efficient, and above all, clean. This presentation will provide an overview of decarbonization strategies for North American steel producers and related efforts to rise above the current challenges.

Dr. Heike Denecke-Arnold, Chair of the Conference, Chief Operations Officer, thyssenkrupp Steel Europe AG, Germany

Co-Author:
Arnd Köfler, Chief Technology Officer, thyssenkrupp Steel Europe AG

Abstract:
Each integrated steel mill and its production portfolio is unique – and therefore, each mill must find its individual way to decarbonize. At thyssenkrupp Steel Europe, we defined our path towards a green and sustainable future through a new and innovative DR-SAF-BOF steel route. For a successful transformation, we are taking bold action and aim to produce 5 Mt of low-CO2 bluemint® steel by 2030. This keynote outlines our decarbonization strategy and how it supports our customers in their decarbonization.

Dr. Peter Juchmann, Director Technology Development Direct Reduction, Salzgitter Flachstahl GmbH, Germany

Co-Author:
Ulrich Grethe, Unit Manager Steel Production, Chairman of the Executive Board Salzgitter Flachstahl GmbH

Abstract:
Steel is and remains a universally applicable, fully recyclable and therefore probably the most sustainable material of the future. As a key economic sector, the steel industry has a particular responsibility for future generations in terms of sustainability and climate protection. In close cooperation with society, politics, suppliers and customers, the way has been paved for a rapid reduction in greenhouse gas emissions and the achievement of climate neutrality by 2045. The individual CO2 roadmaps of European steel producers favor a natural gas- and increasingly hydrogen-based direct reduction of iron ore combined with a growing recycling share as the most sustainable route for primary steel production. With its Strategy 2030, Salzgitter AG is focusing on an intensified circular economy and the SALCOS® (Salzgitter Low CO2 Steelmaking) transformation project. In this context strong partnerships along the complete value chain, from raw materials, renewable energy and green hydrogen to plant construction and the growing customer base for climate-friendly steel products, including closed loops of high-grade scrap, are an important factor of success. The implementation of SALCOS® has begun and is speeding up considerably. By 2026, the first transformation stage with direct reduction plant, electric arc furnace and water electrolysis will go into operation. In 2033, the entire conversion of the integrated steel works in Salzgitter is scheduled to be completed. What is important now are clear international definitions and suitable regulatory framework conditions for climate-neutral hydrogen and green steel as well as the accelerated expansion of energy infrastructure and hydrogen economy. Salzgitter is further proceeding consistently. The new demonstration plant for the direct reduction of iron ore (µDRAL), which was successfully commissioned, has already produced the first CO2-free sponge iron based on 100% hydrogen, a further important step in our SALCOS® transformation.

Dr. Luc Bol, Director Optimization Iron and Steel, Tata Steel IJmuiden B.V., Netherlands

Co-Author:
Jeroen Klumper, Director Sustainable Transition, Tata Steel Ltd
Mark Denys, Director Technology Transition / Decarbonisation, Tata Steel Ltd
Bart van der Meulen, General Manager Long Term Asset Strategy, Tata Steel Ltd

Abstract:
Tata will transform its steelmaking facilities in IJmuiden, the Netherlands, to produce hydrogen-based green steel. To facilitate this multi-phased transformation, a Clean, Green & Circular strategy is being deployed, aiming at substantial improvements on these key themes. Clean: A significant decrease of environmental emissions (NOx, SO2, PM10, PAH, heavy metals) will result from the Roadmap+ programme and closure of existing assets in the new configuration. Reduction of emissions and nuisance in the nearby townships is targeted, for example, by dedusting and deNOxing the pellet plant, and by limiting emissions at the coke plants. Implementation timeline of these projects is 2019-2025 and investigations to further reduce emissions is ongoing. Green: Transition to green hydrogen-based steel making by replacing current blast furnace-technology with DRI-plants fed with blast furnace-grade pellets and using electric furnaces to produce hot metal. The target is to reduce CO2 emissions with 35-40% by 2030 (first blast furnace out of operation), 68-75% after 2035 (second blast furnace out of operation), to ‘zero’ in 2045. Zeremis Carbon Lite is the brand under which today low-CO2 mass-balanced green steel is supplied to customers. This product bridges the time gap to fully embodied decarbonised steel. Circular: An increased share of recycled steel is possible up to 30% by 2030 by increasing scrap input in the blast furnaces, converters and electric furnaces. This also includes an ambition for nearly 100% re-use of reverts on-site, for example by using Hisarna technology. The steel works in IJmuiden are well positioned for the green transformation, given that many success factors are in place or being developed. These include the proximity to off-shore wind farms and connection to a national hydrogen backbone currently under development, the existing deep sea port and railway connections, and a deep pool of young talent in schools, universities and technical institutes.

Dr. Shin Myungkyun, Senior Vice President, POSCO, Korea, Republic of

Abstract:
In line with the global steel industry’s common goal to meet the Paris Agreement, POSCO has declared in December 2020 the achievement of ‘Net-Zero Carbon’ by 2050. The first objective is 10% reduction in CO2 emission until 2030 improving the efficiency of blast furnace operation by using high grade ores, hydrogen-rich gas, and AI-based operation. The second objective is 50% reduction until 2040 incorporating electric arc furnaces and HyREX process. The latter is a new hydrogen ironmaking process under development by POSCO which will gradually replace the current blast furnaces. The third objective is to reach net zero by 2050. Carbon-based ironmaking process will be completely replaced with hydrogen- and electricity-based process.. The HyREX process consists of multi-staged fluidized bed reactors (FBR) and electric smelting furnaces (ESF). Sinter feed is charged as the major iron source and hydrogen is the main reducing gas. The advantage of the direct use of sinter feed is in the availability and cost relative to high quality DR-grade pellets, whereas the larger amount of impurities in the form of gangue mineral need to be removed by slag-making in an electric smelting furnace. This route has the potential to resolve the restriction in the raw material shortages of H2-based DRI-EAF route. HyREX demo plant engineering is under progress on a fast track based on more than 20 year of in-house commercial plant construction and operational experience of FINEX FBR and ferro-alloy ESF. In this talk, the updated roadmap towards carbon neutrality of POSCO as well as the demo- and commercial-scale plant construction and process evaluation plan will be addressed. Additionally, the discussion on the R&D and pre-engineering results of hydrogen-based ironmaking process development will follow.

Burkhard Dahmen, Chief Executive Officer, Chairman of the Managing Board, SMS group, Germany

Abstract:
The metals industry is facing a historical transformation. Around 10 percent of global CO2 emissions are generated in the production of steel, aluminum and copper. Since humankind will need more steel and metals in the future, one thing is obvious: without the sustainable production of metals, we will not be able to save the climate. However, there is good news. The technologies and solutions for "turning metals green" are ready. As SMS group, we don't just see ourselves as pioneers in this. We are already showing that it works. With H2 Green Steel, the world's first climate-neutral steel mill is currently being built in Sweden, for which the SMS group is supplying the entire process equipment. The direct reduction plant will be the first commercial facility in the world operating 100 percent with hydrogen. This project demonstrates that the future of steel production is possible on an industrial scale. But in addition to greenfield projects, there are also solutions for existing steel mills. By injecting hydrogen or hot synthesis gases, we can reduce the carbon footprint of an existing blast furnace by around 30 percent. Our metallurgists are currently working on a new furnace with a CO2 reduction potential of up to 70 percent - a milestone on the way to decarbonizing existing steel mills. Recycling also plays a central role in this. Returning recyclable materials to the product cycle is the most efficient way of avoiding CO2. Electronic scrap, motherboards, cell phones - there is enormous potential here. And last but not least the possibilities of digitalization: digital tools and methods such as predictive analytics expand the service for our customers and enable us to significantly reduce the energy consumption of an entire plant. Concluding: The path to climate-neutral metal production is challenging, but it is right in front of us.

Maria Persson Gulda, Chief Technology Officer, H2 Green Steel, Sweden

Abstract:
H2 Green Steel was launched February 2021 with the ambition to decarbonize hard-to-abate industries, starting with steel. By 2025 we will have production up and running, in Boden, Sweden, scaling volumes in 2026 to 2,5 million tonnes of steel. In phase two of our project, we will produce 5 million tonnes of steel per year. Our production site in northern Sweden, will hold one of the world’s largest electrolysis plants for green hydrogen production to date, a DRI tower for the production of sponge iron and an ultra-modern steel mill to produce the green steel. The renewable electricity locally sourced in northern Sweden is key to making this happen. Our founder and largest investor is Vargas, which is also co-founder of Swedish battery maker Northvolt and several other green impact companies. Over the course of the past two years since launch, we have obtained our permissibility permit, started construction in Boden and on top of a €86 million series A financing, we closed our series B equity round at €260 million October last year. In addition, leading financial institutions, including major commercial banks and the European Investment Bank, have announced their intention to back our debt funding with €3,5 billion. We have presold about 60% of our initial volumes to customers like BMW, Mercedes, Miele, Electrolux, Scania, Adient, Schaeffler and Kingspan who have validated the demand for green steel. We are also looking into prospects on the Iberian peninsula, in Brazil and locations in North America that have the special prerequisites in terms of land and access to renewable electricity production.

Dr. Alexander Fleischanderl, SVP, Head of Green Steel, Chief Technology Officer Upstream, Primetals Technologies Austria, Austria

Abstract:
Steel is an invaluable material for many sectors. However, in the context of the climate crisis, the sector has come under increased scrutiny due to its reliance on carbon-intensive fossil fuels, primarily coal. Strong political pressure guided by a strict taxonomy as increasing carbon emission cost and requirements from the steel demand side have motivated major steel producers to develop a dedicated decarbonization roadmap, expressing the strategic way to net-zero. The steel sector’s actual sustainability achievements and the technology options for the transition including their technology readiness level (TRL) and respective timeline will be discussed. However, the transition pathways are facing multiple roadblocks, which are different in the regions around the globe. One of the roadblocks is the availability and quality of raw materials like scrap and iron ore, another one the availability and cost of renewable energy and low-carbon hydrogen, the approach to carbon capture utilization and storage (CCUS) as well as the available regional taxonomy and political support. The steel growth rate (CAGR) until 2050 is modest, but the technology transition is huge. Might the major OEMs become a bottleneck? Digitalization plays an enormous role in the transition and educated young engineers will become another limitation. Some regions have realized their advantages related to cheap energy and raw materials. The energy intense up-stream process steps might be relocated to such regions and green metallics might be traded to a much larger extent. Despite of all these limitations the first green steel projects have been kicked-off and are under implementation. A status report will be provided.

Dr. Michael Skorianz, Chief Technology Officer, Danieli Corus B.V, Netherlands

Abstract:
Today’s climate regulations exert increasing pressure on CO2 emitting industries to effectively reduce emissions and many major economies are deploying drastic greenhouse gas emission reduction programs as stipulated by the Paris Agreement. Europe is leading this transition with a 55% CO2 emission reduction for 2030 (compared to 1990) in place since 2021. In this scenario, the steel industry plays an important role since it accounts for 7–8% of global carbon dioxide emissions. Progressive decarbonization of steel production is possible, following a sustainable capital investment plan. Starting from an existing BF-BOF setup, CO2 emissions may be reduced in steps of up to 30 % by optimizing the BF process and installing an EAF pre-melter to maximize BOF scrap usage during the transition phase. By adopting natural gas-based direct reduction using DR grade pellets feeding an electric arc furnace, emission abatement reaches 55 %. DRI with a higher gangue content could be charged to an electric smelting furnace to produce hot metal, which allows for retaining BOF steelmaking facilities, while carbon capture systems for CCS and CCU applications offer further emission reduction potential. Several leading European players are already starting their conversion from BF to DRI with many relying on hydrogen, the energy source of the future, for their zero-emission strategies for 2050. The ENERGIRON direct reduction technology, jointly developed by Danieli and Tenova, is the only technology available that uses high percentages of hydrogen. In the future, when hydrogen will be available economically and can be used in quantities up to 100 % with the same plant, all future emission targets can be met.

Paolo Argenta, Executive Vice President, Upstream Business Unit, Tenova S.p.A., Italy

Abstract:
Tenova’s innovative technologies can directly reduce environmental impact, enhance circularity through recycling and reusing waste, and be used to produce metals crucial to the energy transition. There are multiple approaches to sustainable development - Tenova partners with companies to develop customized solutions designed to reflect local conditions and sustainability regulations.

Robert Baron, Director Corporate Strategy , Swiss Steel Group, Germany

Abstract:
Swiss Steel Group (SSG) is Europe’s largest electrical steel producer and the leading producer of specialty steel long products worldwide. Thanks to scrap-based steel production, SSG is also one of Europe’s largest recyclers and a leading provider of Green Steel solutions with a re-utilization rate of up to 100%. By closing the recoverable material cycle and the intelligent use of scrap, SSG and their products can considerably reduce the emissions of all supply chains at the starting point – compared to the blast furnace production route, e.g., for CO2, by more than 80%. Scope 3.1 emissions from purchased materials represent by far the largest share of the carbon footprint of SSG products. To further reduce it, SSG is extending its recycling expertise to include additional secondary raw materials and is increasingly working with its suppliers. The ongoing project to reclaim alloying elements from industrial waste is the only one of its kind world-wide! It provides a way to continue to reduce the use of primary ore-containing alloys in future and thus dramatically improve the footprint of stainless steels. Another crucial element is the close cooperation with suppliers and the collection of primary emission data. SSG is leading the way and is the first European steel manufacturer to contact its suppliers in a structured manner to be able to specifically measure and control the footprint of its own purchased raw materials.

Dr. Jean-Frédéric Castagnet, Director Technology & Innovation, Georgsmarienhütte Holding GmbH, Germany

Abstract:
Global climate change is due to the very sharp increase in CO2 emissions over the past 60 years. The steel industry, being one of the largest CO2 emitters, must therefore significantly reduce its CO2 emissions, in order to meet the 1.5° Paris Climate Agreement' s target. The GMH Gruppe is already playing a pioneering role in the decarbonization of the industrial value chain. For more than 25 years, this medium-sized group of companies has relied on steel production in electric arc furnaces. By using this technology, the CO2 emissions of crude steel are already significantly below the industry average, at 0.4 tones per 1 tone of steel. Their long-term goal is to produce steel in a climate-neutral way by 2039. As an interim step, emissions are to be halved by 2030. There are a number of decisive steps for achieving climate neutrality in electric steel production, such as the use of green electricity in production which can significantly reduce CO2 emissions. Other measures include, the use of biogenic carbon carriers as well as the use of hydrogen instead of natural fossil gas. The use of by-products such as slag or waste heat also makes a decisive contribution to decarbonization. In the long term, it is crucial to look at the entire supply chain, which is why the focus on upstream emissions (so-called Scope 3) is also becoming increasingly relevant.

Thomas Reiche, Managing Director, FEhS-Institut für Baustoff-Forschung GmbH, Germany

Co-Author:
David Algermissen, Head of the Secondary Raw Materials Department, Institut für Baustoff-Forschung e.V.
Andreas Ehrenberg, Head of Department Building Materials, Institut für Baustoff-Forschung e.V.

Abstract:
The main challenge of the steel industry for the next decade is the steel production transformation process. The CO2 intensive blast furnace/BOF route will be substituted by a combination of Direct Reduced Iron (based on natural gas, later on "green" hydrogen) with an Electric Arc Furnace (EAF) or a Submerged Arc Furnace (SAF), heated with renewable energy. Thus, the well-known latent-hydraulic granulated blast furnace slag (GBS) being successfully used in cement and concrete since more than 140 years will vanish step by step! GBS is used as a supplementary cementitious material not only, but in particular due to its CO2 reduction potential in the cement/concrete production. Whereas the DRI process itself does not generate any slag, EAF and SAF will do. EAF and SAF slags will be very different. The reasons are e.g. the different oxidizing (EAF) or reducing (SAF) atmospheres and different shares of scrap input (EAF). Moreover, the new EAF slags will be also different compared to today's scrap based EAF slag. For example, the heavy metal content will be lower (but much higher compared to GBS). However, specific slag/metal ratios, slag volumes, chemical and mineralogical compositions and physical properties of the new slags are yet unknown. Thus, also their cementitious and environmental properties are still unknown! Different projects aim mainly to create slags being similar to GBS. The main objective is to offer furthermore a reactive material to the cement and concrete industry. The presentation gives an overview on the different approaches within the steel industry, main goals, main technical and legal challenges and some current FEhS projects. For example, "SaveCO2" - a project with thyssenkrupp Steel, HeidelbergMaterials et al. - is focused on the DRI/SAF route whereas "DRI-EOS" - a project with Salzgitter, Holcim et al. - is focused on the DRI/EAF route.