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.

Thomas Hansmann, SMS group GmbH , Germany

Abstract:
Steel is the backbone of the future low-carbon society. As the demand for steel is set to increase for several reasons such as steel intensity of renewable energy infrastructure and further developments of emerging markets, steel is also unique in its ability to be almost infinitely recyclable. In addition, steel can plot credible technological pathways for significant reductions in greenhouse gas emissions. However, the decarbonization of the iron and steel industry faces very different regional challenges. Among the others, clear incentives lead to decisive action in Europe, with pathways mainly based on direct reduction followed by various types of electric (s)melting. The transition towards green steel though is not limited to the European steel industry but has become a global priority. In different regions of the world we are facing various initiatives to convert existing steel plants into low carbon steel production, our experience reaches from greenfield fully hydrogen based steel production up to innovative solutions for existing integrated facilities. As a global player, the SMS group faces indeed the challenge of serving these diverse conditions. Thanks to 150 years of experience we have developed a deep understanding of all the technologies and processes. Continuously searching for innovative products and methods we have made our mission to create a carbon neutral metal industry.

Jorge Martinez, Tenova HYL, Mexico

Co-Author:
Jorge Martinez, Tenova HYL

Abstract:
Among the various approaches for decarbonization of the steelmaking industry, Direct Reduction has proven to be the right solution, thanks to the readiness of the technology, effectiveness in abatement of the GHG emissions and cost effectiveness. When using DRI, two main routes should be considered, based on the intensive use of hydrogen (H2) (CDA) and capture and use of CO2 (CCU). One consists of the progressive conversion of the BF-BOF facilities to direct reduction-electric arc furnace (DRI-EAF). The second alternative is the production of hot metal (HM) by installing a gas-based direct reduction plant feeding DRI to an open slag bath furnace (DRI-OSBF). ENERGIRON®, the DRI technology by Tenova and Danieli, is the benchmark for sustainability and provides the needed flexibility during the current historic period of energy transition. Schemes for liquid steel production with reduced or practically nil carbon input by using H2, its equivalent cost for DRI production and the reduction of CO2 emissions are analyzed

Gerald Wimmer, Primetals Technologies Austria, Austria

Co-Author:
Bernhard Voraberger, Primetals Technologies Austria
Johannes Rosner, Primetals Technologies Austria

Abstract:
"Today the iron and steel industry is the largest global industrial CO2 emitter, its main emissions coming from iron making via the blast furnace. Direct reduction using low-carbon hydrogen is at the moment the most promising solution to achieve the industry target of climate neutrality. However, the common solution to use EAF for processing of DRI is only beneficial for high grade ores, while most of the iron ores globally available is of lower grade with higher gangue content. New solutions for profitable processing of such lower grade direct reduced iron are required. A two-step process combining a Smelter for green hot metal production with a BOF converter can handle such lower grade ores and might become a prefered solution for an implementation in existing integrated plants. The Smelter is designed to handle wide range of direct reduced materials coming from MIDREX, HyREX or HYFOR plants. The Smelter allows for efficient separation of slag and metal; after granulation the slag from the Smelter can be used in the cement industry as an latent hydraulic active binder similar to blast furnace slag today, promoting the circularity of ironmaking. The Smelter is designed for continuous operation with a large hot heel and charging and tapping during power on. Annual productivity up to 1,5mta can be achieved with one Smelter, for higher productivity two Smelters will be operated in parallel. In the paper the principles of the two-step process as well as the main design features of the Smelter will be presented together with an outlook on the implementation and upscaling plan."

Hagen Fuchs, Primetals Technologies Germany, Germany

Co-Author:
Ali Hegazy, Primetals Technologies GmbH
Michel Hein, Primetals Technologies Germany
Hans-Jörg Krassnig, Primetals Technologies Germany

Abstract:
Fueled by net-zero prompts and to comply with the most stringent environmental targets, the world is about to witness a fast-paced transition into green steelmaking. DRI-based EAF route will play a crucial role in this green steel transition due to its significantly lower carbon footprint compared to the integrated route, while still ensuring the highest product quality. This paper will illustrate the position of DRI and EAFs within the green steel market regarding raw material quality, feedstock market, and CO2 emissions. The paper will also discuss the process design for DRI-based EAFs and provide an inside on the combination with multiple direct reduction technologies such as MIDREX, HyREX, and HYFOR. Features of the latest state of the art 220-t DRI-EAF by Primetals Technologies for Salzgitter Flat Steel in the heart of Europe will be highlighted (start-up in Y2025). Latest operational results will be reviewed, including project execution, productivity, consumption figures, slag control, product quality, and maintenance for cold and hot DRI-based EAFs from Primetals Technologies.

Ian Cameron, Hatch Ltd., Canada

Co-Author:
Mitren Sukhram, Hatch Ltd.
Nicholas Aubry, Hatch Ltd.
Takshi Sachdeva, Hatch Ltd.
Pauli Baumann, Hatch Ltd.
Sa Ge, Hatch Ltd.
Terrance Koehler, Hatch Ltd.
Richard Elliott, Hatch Ltd.

Abstract:
Many steel producers are focused on replacing their blast furnaces with direct reduced ironmaking (DRI) as a greenhouse gas (GHG) reduction strategy. While several producers have announced plans to smelt DRI with a standard electric arc furnace (EAF), others are considering electric smelting furnace (ESF) technology to produce hot metal suitable for basic oxygen furnace (BOF) steelmaking. Drivers for the adaption of the DRI-ESF-BOF route include the ability to use traditional higher gangue iron ore, slag valorization for cement manufacturing, better impurity control such as nitrogen and phosphorous in the liquid steel and to avoid stranding existing BOF steelmaking assets. Most producers have selected the DRI route for its potential to start with the well-understood natural gas-based technologies and then transition to greater amounts of green hydrogen as this becomes available. Carbon in hot metal will be essential for the ESF and BOF stages of the new process route even as natural gas is replaced with hydrogen. How best to carburize the ESF hot metal when iron ore is reduced to metallic iron using hydrogen is an open opportunity for technical innovation. Little attention has been paid to the re-use of the CO and CO2 rich gases generated from the ESF and BOF to carburize the DRI prior to smelting. The authors will present technical approaches to re-use these off-gases in-plant to minimize the GHG emissions from the DRI-ESF-BOF value chain, especially in the context of a transition to green hydrogen-based iron ore reduction. Needed technologies such as effective gas separation, methanation, reverse water gas shift, and carbon cycling will be discussed, and a new integrated flow sheet will be proposed.

Peter Kinzel, Paul Wurth S.A., Germany

Co-Author:
Fernand Didelon, Paul Wurth S.A.
Miriam Valerius, Paul Wurth S.A.
Jihong Ji, Paul Wurth S.A.

Abstract:
In view of the new economic reality, Paul Wurth has reassessed the existing integrated steel plant assets in the light of the European CO2 emission ambitions. Natural gas not being available in the short term and seeing the scarce scrap and high grade pellet availability after 2030, it will be of the essence for cost efficient European steel plants to count on a CO2 lean process for massive steel production based on the well established reduction melting process. Paul Wurth has in this respect come up with a concept allowing the easy substitution of the traditional blast furnace by a compact direct reduction and melting furnace. This new furnace, EASyMelt™ can be the key in existing steel plant set ups allowing highly cost efficient steel production as well as satisfying the net zero carbon target

Nicole Voigt, Boston Consulting Group, Germany

Abstract:
Growing pressures from consumers and regulators, and as a result downstream producers, are driving a push to de-carbonize supply chains. Steel is often one of the largest emitters in supply chains. Stakeholders along the steel value chain have an opportunity to capture value by abating emissions and communicating lower than competitor emissions using Product Carbon Footprint (PCF), cradle to gate LCA. By using PCF to differentiate green goods, companies can drive P&L gains: 1) gain a price premium and 2) capture market share. PCF also drives second-order value: a) allows for portfolio optimization toward green products, b) facilitates supplier ecosystem management, c) provides continued access to sell into markets with increasingly restrictive regulatory and carbon pricing landscapes, d) improves trust in brand. This value from PCF is expected to be transient, reaching a maximum in the mid-term (2025-2035). To gain this value, businesses must begin measuring PCF in the near-term. Long-term, PCF will become commoditized and required for market participation. Calculating PCF can be challenging. Best practice is to leverage estimates where needed (BOMs preferred), to build capabilities and a leadership position. Initial PCF estimates will be based on emission factors, leveraging digital tools, such as CO2 AI, Ellipse, etc. Companies should try to progressively improve the quality of their estimates using direct measures and PCF of their inputs, shared by suppliers. Inter-company data sharing tools are required to achieve this, such as CO2 AI x CDP Product Ecosystem, Integrity Next, etc. Finally, gaining value requires PCF be high-quality, verifiable, and communicable. In this paper, we take a deep dive into how PCF drives value and explore best practices for calculating PCF using a case study. We describe challenges in deriving PCF for a complex steel value chain, considering technologies, and various forms of final product

Martin Theuringer, German Steel Federation, Germany

Abstract:
Green lead markets are a central policy component to flank the decarbonisation of the steel industry. The aim is to provide regulatory support for the demand side in order to relieve state start-up financing and replace it in the medium term. The problem, however, is that a definition of low-CO2 and near-zero steel in the long term is not yet available. Therefore, despite the Steel Action Plan and the National Hydrogen Strategy, no progress has been made on "green lead markets" in Germany (or in the EU). Internationally, the discussion is being conducted in a multitude of initiatives with high dynamics. There is a danger that regionally different standards will emerge with disadvantages for Germany / the EU as an industrial location. The proposal of the International Energy Agency within the framework of the G-7 is also a robust starting point from the point of view of the steel industry: However, further development is necessary.

Agnes Ritter, McKinsey & Company , Austria

Co-Author:
Marlene Weimer, McKinsey & Company, Inc.

Abstract:
Steel industry is under pressure as climate targets aim for net-zero GHG emissions by 2045 in EU. Doing so requires increasing annual investment into new technology and assets. Demand for low-CO2—or “green”—products is ramping up as end customers, manufacturers, and governments push for increased sustainability and circularity. Primary materials processing makes up the majority of GHG emissions for many industrial products, which has led to increased attention on decarbonizing core contributing commodities and will strengthen the need for recycling materials. In turn, time-bound green premiums are emerging for certain steel applications. This paper lays out the observed and potential supply–demand balances across four core commodities: Understanding where the extra cost for green steel can be captured will influence industry transition path and needed innovation. We assessed premiums for low-CO₂ materials premiums by modelling the expected demand, supply of green steel by technology, and green premiums required. McKinsey steel team – authors and presentation tbd BZ or Agnes

Felix Firsbach, Badische Stahl-Engineering, Germany

Co-Author:
Andrea Pezza, Badische Stahl-Engineering
Per Lückhoff, Badische Stahl-Engineering
Peter van der Velden, Badische Stahl-Engineering
Patrick Hansert, Badische Stahl-Engineering

Abstract:
Decarbonization of iron- and steelmaking needs different approaches for different steel plants and aggregates. It can be categorized into three pillars: 1) process optimization, 2) adapting existing technology, and 3) investing in new technology. This paper addresses the implementation of new EAFs into existing melt shops with a focus on EAF design possibilities, their up- and downsides, and the challenges of switching from BOF to EAF operation.

Eros Faraci, Rina Consulting – Centro Sviluppo Materiali S.p.A, Italy

Abstract:
The steel production trough electric arc furnace (EAF) plays an increasingly important role in modern steelworks concepts. Today the electric arc furnace steel of the overall steel production in the EU-27 is just over 40 % (59 Mtons/year). The share of the global steel production by EAF route is expected to increase due to its more flexibility, less investment and lower environmental impact respects to the BF-BOF steel production route. Moreover, on the ongoing projects, related to green steel production by Direct Reduction, Integration (DRI) of renewable electricity and hydrogen production (as SALCOS and HYBRIT projects) will provide many opportunities to increase the EAF steel production route but in order to catch these opportunities a strategy for decarbonization and thus sustainability for EAF steel production must be implemented. In this frame the main objective of DevH2forEAF, project founded by RFCS, is to set up and test a EAF burner fed with hydrogen to replace natural gas. This project is coordinated by: RINA Consulting – Centro Sviluppo Materiali SPA (RINA-CSM) and the partners are: 1) Rheinisch-Westfaelische Technische Hochschule Aachen (RWTH); 2) Compania Espanola de Laminacion Sl (CELSA); 3) Ferriere Nord SPA (FeNo); 4) Nippon Gases Industrial SRL (NG Ind.) 5) SMS group SPA (SMS) 6) AFV Acciaierie Beltrame SPA (AFV Beltrame) This project provides a comprehensive analysis of H2 hydrogen burner in EAF through the main activities: 1) Design and realization of EAF burners, able to work with NG/H2 mixture, up to 100% hydrogen (SMS) 2) Design and realization of H2 pipeline from the tube trailer to EAF in safety conditions (NG Ind.) 3) Analysis the performance of hydrogen burner in replacement of NG through experimental trials at lab and pilot scale (RWTH and CSM) an at two industrial sites (FeNo and CELSA). The final results of this project will represent a milestone for the utilization of H2 in steelmaking and the first key step for the decarbonization of the steel industry.

Hannes Beile, tripleS GmbH & Co KG, Germany

Co-Author:
Michael Hötzel, SHS - Stahl-Holding-Saar GmbH&Co.KGaA
Dirk Deckers, SHS - Stahl-Holding-Saar GmbH&Co.KGaA
Dominik Schöne, SHS - Stahl-Holding-Saar GmbH&Co.KGaA
Andreas Schneider, SHS - Stahl-Holding-Saar GmbH&Co.KGaA
Markus Abel, tripleS GmbH & Co. KG

Abstract:
A comprehensive process transformation from a conventional integrated steel plant with blast furnace and converter into a modern electric steel plant with the aim of drastically reducing CO2 emissions is technically not easy and requires a careful consideration of all possible solutions. In particular, the effects on both - productivity and the quality of steel grades to be produced should not be underestimated or neglected. This article describes one of several possible solutions for the transformation of integrated steel plants: The implementation of an electric arc furnace - possibly together with a new reduction reactor to use direct reduced iron. Various considerations and challenges are identified in this paper, such as: Maintaining the original tapping weight or working with a different tap weight (partial tapping), is the necessary electrical connection capacity available or the given network stability sufficient and what solutions are available if not, is enough space available in a steel plant that has grown over decades for an integration of a new melting unit with reduction reactor, how will the raw material situation look like in 10 or 20 years? What is possible with an electric arc furnace? Is it realistic to produce actual steel grade qualities using an EAF as melting unit - and if yes - with how much virgin material? Does the possible or needed raw material scenario change the overall productivity? Can existing equipment in secondary metallurgy be reused or is there additional investment needed as well? All these questions and challenges will be explained and described in this article based on existing reference examples in cooperation with Stahl-Holding Saar for the locations in Dillingen and Völklingen.

Benedikt Zeumer, McKinsey & Company , Germany

Abstract:
The European steel industry is facing a fundamental challenge that will disrupt core steel production processes across the continent. Across the world (but particularly in Europe), steel companies are facing increasing pressure—from regulators, customers, investors, and society at large—to decarbonize production. Recycling scrap will be contraint to meet steel demand in terms of either quantity or quality; for this reason, most steel companies are also looking to use direct reduced iron (DRI). Steel producers need to decide on the two two DRI procurement options to assess the transformation: they neeed to develop prioritoes to use either hot DRI (HDRI), or they buying hot briquetted DRI (HBI) from overseas. The crucial determinant of the relative cost competitiveness of these two sourcing options will be the medium-term cost and price of green hydrogen, which depend on the cost and availability of renewable-energy sources. Each steel producer will need to consider their own strategy, as well as broader industry and geopolitical trends. Companies will need to understand the likely development of European and the technology choice, including access to energy, raw materials, and timely implementation capabilities McKinsey steel team – authors and presentation tbd Agnes or Toralf

Thorsten Hauck, VDEh-Betriebsforschungsinstitut GmbH, Germany

Co-Author:
Jean Borlée, Centre de Recherches Metallurgiques
Tobias Kempken, VDEh-Betriebsforschungsinstitut GmbH

Abstract:
To achieve the set EU climate strategies & targets the European steel industry is in an extensive transformation process towards climate-neutral steelmaking. Over the last years promising technology pathways were developed and steel producers created specific roadmaps for their implementation. The implementation along these roadmaps lead to decarbonisation scenarios for the European steel industry. This process is highly dependent on relevant external framework conditions. In the RFCS project “Green Steel for Europe” (grant agreement number 882151) relevant framework conditions were identified and seven decarbonisation scenarios were developed. So called external framework conditions include the availability of green electricity and hydrogen, natural gas, alternative carbon sources, CO2 storage locations, iron ore & pellets, steel scrap and the demand for CCU products. Additionally, framework conditions such as the industrial maturity of technologies, investment cycles, financial and legislative conditions were taken into consideration. Three scenarios for 2030 show how the set climate target can be achieved and what influence a delayed implementation or increased hydrogen availabilities can have. Four scenarios for 2050 display the road towards carbon-neutral steelmaking with or without further breakthrough technologies and dependent on scrap availability. For these scenarios the implementation of four dedicated technology routes for primary steel production was investigated: optimized operation of the conventional route via blast furnace and basic oxygen furnace, direct reduction based on natural gas and/or hydrogen, smelting reduction and iron ore electrolysis. The project concluded in 2021, thus before the Russian war on Ukraine and its consequences for European framework conditions. This paper gives an update on the changed framework conditions, revised roadmaps and resulting decarbonisation scenarios. The transformation process of the European steel industry will result in a heterogeneous situation in the next decades with hydrogen-based direct reduction and electrification playing major roles.

Nicola Zecca, Politecnico di Milano, Italy

Co-Author:
Paul Cobden, Swerim AB
Giampaolo Manzolini, Politecnico di Milano

Abstract:
The iron and steel industry is one of the most carbon and energy intensive industrial sectors and efforts have to be made to reduce its carbon footprint [1]. In this work the techno-economic assessment of four different plant configurations is carried out: Midrex + EAF plant Midrex + EAF plant with integration of SEWGS Industrial symbiosis between BF-BOF plant and Midrex + EAF plant Midrex + Open slag bath furnace + BOF The first plant considered is a conventional DR-EAF plant. Natural gas is used as feedstock for the synthesis of the reducing gases. Some natural gas is also directly added to the shaft furnace. The DRI from the shaft furnace is then sent to an EAF to produce steel. The main direct emissions points are the flue gas of the reformer and the direct emissions of the EAF. The above described process can be decarbonised adopting the SEWGS technology. This technology allows to produce a hydrogen rich stream from the top-gas and use it as fuel in the reformer. In the third considered plant scheme, the industrial symbiosis between a BF-BOF plant and a DRI-EAF plant is analysed. The core of this process is the SEWGS technology that allows to produce an H2/N2 stream using the blast furnace gas (BFG) and the basic oxygen furnace gas (BOFG) as feedstock. The H2/N2 stream is in part used as fuel in the reformer and in part recycled back to the integrated steel mill. The last case considers the adoption of an open slag bath furnace and a basic oxygen furnace downstream the DR process. The cases have been modelled and simulated in Aspen Plus, using available plant data in literature. Environmental and economic KPIs are used for the assesment: energy consumption, specific emissions, carbon capture rate, carbon avoidance and SPECCA indicator.

Yakov Gordon, Hatch Ltd., Canada

Co-Author:
Sunil Kumar, Hatch Ltd.

Abstract:
To address climate change the steel industry is increasingly focusing on the reduction of energy consumption as well as Green-House Gas (GHG) emissions. A methodology that incorporates a sound technical element to the assessment of improvement opportunities, was developed to create strategic roadmap for reducing CO2 Emission and Energy Consumption. The methodology is bottom-up, and is applied in much more detail to the specific operations of the iron and steel industry. The methodology was adopted at several operating iron and steel plants (integrated plants and mini-mills) to generate Levelized Cost Curves (LCC) which formed the basis of the strategic roadmaps that were developed. This paper describes the key points of the methodology which helps identify and quantify potential energy savings and CO2 abatement within the iron and steel plants for short term (1-5 years), medium term (5-10 years) and long term (>10 years).

Bernd Weiss, Primetals Technologies Austria, Austria

Co-Author:
Hermann Völkl, Primetals Technologies Austria
Robert Millner, Primetals Technologies Austria

Abstract:
Steel industry is responsible for about 8% of worldwide CO2 emissions and faces significant challenges to meet defined climate targets for the upcoming years. Recently the evaluation of transition solutions for state-of-the-art steel making process routes and finally carbon neutral steel production are the focus of investigations of steel producers. Massive changes in production routes are required to achieve a carbon net-tero steel production. The metallurgical model library “m.simtop” developed by Primetals enables the implementation of digital twins for any production scenario and enhances all kind of evaluations. The digital twins are fully based on chemical and metallurgical first principle modelling and capable of precisely depicting all kinds of integrated and alternative steel production routes. Utilizing this powerful platform, Primetals implemented a study on numerous process routes covering different technologies. In this work a selection of a comparison of state-of-the-art direct reduction steel making routes including variations thereof and also for emerging technologies is provided. Production routes covered are Midrex natural gas and hydrogen based as well as new processes such as Hyfor and HyREX. A comparison of consumption figures, OPEX as well as CO2 emissions will be discussed.

Mo Ahmed, Schneider Electric USA, United States

Co-Author:
Ling Dou, Schneider Electric
Rajesh Sharma, Schneider Electric

Abstract:
The steel industry has embarked on a decarbonization journey to address significant carbon footprint, with hydrogen a key abatement lever for decarbonization, steelmakers are facing challenges to scale hydrogen production at attractive cost, including sourcing of sufficient renewable energy. Scaling green hydrogen production to giga-watt scale requires intense efforts in terms of analysis around electrical designs, electrolyser selection and optimization across the complete value chain. Technologies like digital twins which help in analysis of hybrid electrical networks and the process needs are helping engineering companies to design the green hydrogen production facilities which are fit for purpose and scalable. Similarly, automation with integrated architecture helps in managing the complete production cycle from choosing the cheapest energy source to management of intermittency of power generation and associated downstream continuous process. Digital twins developed during design phase support efficiency improvement during operate and maintain phase supporting energy optimization and reduced unscheduled downtime. We will discuss how during different phases of the project, such digital solutions help de-risk the projects, improve performance and reduce overall cost.

Elena Jipnang, SMS group, Germany

Co-Author:
Atsushi Sugiyama, Midrex Technologies, Inc.
Leander Reuter, SMS group
Tim Kleier, SMS group
Brett Belford, SMS group

Abstract:
In view of the global climate emergency, the iron and steel industry bears a special responsibility. Around 30% of global industrial CO2 emissions are generated in the steelmaking value chain. Since there are several alternative ways to reduce CO2 emissions, which perform differently depending on factors like energy infrastructure and raw material availability and prices, an individual transition roadmap to less carbon-intensive steelmaking must be analyzed for each steel mill. The overall process simulation and subsequent analysis help to make the right decision between different green steel production route options. This paper focuses on a steady-state flowsheet simulation in HSC, which was defined and performed using a case study to illustrate how the simulations can be effectively applied to design and optimize the steel value chain in a DRP-OBF-BOF-EAF configuration. This thermochemical process simulation enables process designers and plant operators to rapidly determine the impacts on CO2 footprint and OPEX due to variations in pellet quality, fuels, point of raw material addition and distribution of the products within the flowsheet. It is further demonstrated how scrap and waste circularity within the process can be optimized to balance OPEX and CO2 impacts.

Paul Uhl-Hädicke, Fesios GmbH, Austria

Co-Author:
Matthias Stöckl, Fesios GmbH
Andreas Schneider, AG der Dillinger Hüttenwerke

Abstract:
Like many other steel producers in Europe and around the world, Stahl-Holding-Saar (SHS) has developed a master plan to significantly reduce CO2 emissions within the next decades. For the production site in Dillingen, a transition to a DRI-EAF production route shows the most promising effects, which means turning away from the traditional BF-BOF production route. Within the melt shop, two potential locations for the EAFs were identified to undergo a detailed investigation and comparison. Since the two locations are at very different ends of the melt shop, the new transport routes and logistics of ladles will undergo a large change and be very different to the original routes and logistics. A 3D production and logistics simulation of the entire melt shop was developed to quantitatively compare these layout alternatives, to iteratively optimize these concepts, and to reduce logistical bottlenecks and deficiencies. The two final layout concepts have been compared and rated according to the terms of productivity and logistics. With the final simulation results, it was clear that one EAF position is logistically favorable, as it allows higher productivity and flexibility within the melt shop. Finally, the results of this study have been used to deliver quantitative answers to assist in a qualified decision-making process with the objective of de-risking and verifying the future production concept.

Timo Haimi, Metso Outotec Oy, Finland

Abstract:
Case study: Three different feeds to a DRI smelting furnace Timo Haimi, Metso Outotec Metals Oy Abstract The decarbonization of Iron and Steel Industry has been progressing rapidly in the recent years with many projects advancing into next stages. The standard solution for lower CO2 emissions in steel making has been using the shaft kiln based direct reduction plant and a scrap melting electric arc furnace instead of blast furnace. However, if the majority of the primary steel making plants would follow the same approach, there would be a shortage of DRI-quality iron ore and high quality steel scrap. Hence there is a need to utilize new technological solutions to enable use of standard, blast furnace grade iron ore, especially to deal with the excess gangue and higher amount of slag. Metso Outotec has been checking whether the existing non-ferrous and ferroalloys smelting furnaces could be used in smelting of direct reduced iron feed, with the target of removing the slag from the DRI feed without causing extra iron losses into the slag. As there are many different types and qualities of DRI available for the smelting feed, there is also a need to evaluate the differences of each feed and all different DRI types would naturally generate different type of metal product as well. The following paper describes three case studies about different DRI feeds into the Metso Outotec DRI smelting furnace. The first case is high quality DRI with 0% carbon content, the second case is BF-grade DRI with 0% carbon content and the third case is BF-grade DRI with 4% carbon content. The carbon contents of these product metals made out of these feeds have been assumed to be 1%, 2% and 4% respectively. The case studies are showing different process parameters for each cases

Stefan Tjaden, K1-MET GmbH, Austria

Co-Author:
Christopher Harris, voestalpine Stahl GmbH
Bernhard Rummer, voestalpine Stahl GmbH
Bernd Weiss, Primetals Technologies Austria
Walter Wukovits, TU Wien
Andreas Spanlang, voestalpine Stahl GmbH

Abstract:
Steel plants in Europe are committed to reduce their carbon emissions by 80-95% by 2050 in accordance with the EU Climate targets. Today the majority of the global steel production is performed via the conventional BF-BOF route and responsible for 7% of global carbon dioxide emissions. While most of European steel plants are already running at a high efficiency through various optimization strategies, the transition towards more sustainable steel production routes such as the DR-EAF route is needed to further reduce the carbon emissions. In this study the potential reduction of carbon dioxide emission for the voestalpine Stahl Linz plant is simulated by partially switching the steel production of one BF to a DR-EAF. For the assessment of the theoretical carbon dioxide emission reduction, a digital twin of the voestalpine Stahl Linz site was implemented in its as-is conventional BF-BOF route set up and compared to a theoretical substitution one of voestalpine’s BF by a DR-EAF plant. Therefore, the voestalpine Stahl Linz plant is depicted through the m.simtop metallurgical process modelling library in form of a flowsheet and validated with process data. In a subsequent step the flowsheet was modified by removing one BF and introducing a DR and an EAF to form a hybrid steel plant. For further CO2 reduction the use of coke oven gas at the blast furnace or in the DR process was simulated and the changes in the energy network of the steel plant are investigated.

Joachim von Scheele, Linde plc, Germany

Co-Author:
Pravin Mathur, Linde Inc.

Abstract:
Most of the world steel production takes place in countries that have already committed to achieve net-zero carbon emission goals, and many producers have set carbon neutral goals over the 2030-2050 timeframe. Although the pace of reaching green steel production will vary across different regions of the world based on the individual preconditions, similar pathways could be considered, potentially with geographical dislocation of supply chains. Naturally, direct carbon avoidance solutions like increased scrap use and electrification are the first steps to achieve sustainability and decarbonization. Between the years 2000 and 2010, the world steel production grew by more than 700 Mt/a, and this is resulting in a massive increase in availability of scrap for decades to come, especially in China. Electrification, based on clean power supply, is the route to decarbonize many processes, however, many unit processes in steel production are extremely difficult to electrify. These include processes for iron ore reduction as well as heating processes which use large scale high temperature combustion. For such processes, the main options include use of oxyfuel combustion to achieve increased energy efficiency, introduction of low carbon fuels, and carbon capture. Ultimately, the use of clean hydrogen as a reductant as well as a fuel source is the endgame that steelmakers will adopt when a viable supply of hydrogen becomes available. Accordingly, there is here a general pathway to decarbonization: 1. Oxyfuel combustion for increased energy efficiency 2. Use of low carbon fuels 3. Carbon capture for storage or use 4. Use of clean hydrogen as reductant and fuel This paper discusses and exemplifies proven solutions and technologies ready for implementation along each pathway, including, for example, full-scale use of hydrogen as fuel in electric arc furnaces and reheating (scheduled for 2023), and DRI production using gasified waste and carbon capture.

Klaus Jax, Primetals Technologies Austria, Austria

Co-Author:
Norbert Hübner, Primetals Technologies Austria
Wolfgang Oberaigner, Primetals Technologies Austria

Abstract:
"Continuous product improvement based on steel producers requirements is an essential part of the TPQC success story. But how can TPQC users take advantage of these? This paper describes the latest developments in the area of TPQC. Among the developments are improvements of the Statistical Process Control (SPC) functionality, now supporting an electronic logbook of changes and measures applied to the process, and digital guidance to select the right measures when SPC alarms occur. Other new features comprise extended support for data recording, visualization and evaluation for the liquid steel production and visualization of data for entire campaigns such as tundish sequences. Integration of prescriptive AI models make it possible to online react to process deviations to adapt the next process in order to reach the required product quality targets. TPQC is now available as subscription license to ensure that the system is always at the latest state and steel producers can benefit from the new features of the system and become a lifecycle partner of Primetals Technologies. The paper further explains success stories of projects in which TPQC is interacting with Primetals Technologies' production management system (PMS) and condition monitoring system (ALEX) to maximize the benefits and to make a big step towards the Digital Unity vision of Primetals Technologies. ALEX can provide valuable information about the condition of the production facilities to TPQC via a plug & play interface and such enabling TPQC to even more precisely decide on necessary measures to ensure that the products will meet the required quality. The interaction with the PMS ensures that the product transport and necessary further production steps can automatically be controlled based on on-line quality decisions and remedial measures proposed by TPQC."

Christoph Kirmse, SMS group, Germany

Co-Author:
Pallavi Mohta, SMS group
Ritwick Manatkar, SMS group
Agnieszka Zuber, Macrix Technology Group
Rashmi Murthy, SMS group

Abstract:
During continuous casting longitudinal facial cracks (LFC) can occur due to various root causes. LFCs are difficult to capture during the production process and are visible only in the final stages of a process. Some of the LFCs can open and lead to a breakout. This creates safety and environmental issues due to hot, liquid metal flowing outside the casting machine. It also leads to a loss in production time and potential damage to the equipment. The goal of this paper is the prediction of those breakouts during operations using deep learning models. The deep learning algorithm uses different signals at the mold to calculate a probability of a breakout. When the probability exceeds a threshold value, a breakout alarm will be triggered. Upon detection of an upcoming breakout, suitable countermeasures are suggested to prevent the breakout from happening. Early results suggest a reduction of breakout events of 50%.

Ahmad Rajabi, VDEh-Betriebsforschungsinstitut GmbH, Germany

Abstract:
Growing customer expectations together with increasing availability of relevant information and high flexibility of final product features are taking established Decision Support Systems (DSS) performing automatic release decisions continuously to their limits. Emerging machine-learning technologies could solve this problem, but concepts for their robust industrial application performing high-stakes decisions are missing. This paper aims to report our attempt to improve the automatic quality assessment of steel products by means of a holistic approach combining deep learning technology with sophisticated management of underlying training data to enable the optimal use of all available data sources and simultaneously simplify the configurability and maintainability of previous DSS.

Gerfried Millner, Materials Center Leoben Forschung GmbH, Austria

Co-Author:
Lorenz Romaner, Montanuniversität Leoben
Daniel Scheiber, Materials Center Leoben Forschungs GmbH
Manfred Mücke, Materials Center Leoben Forschungs GmbH

Abstract:
The production of steel coils with scrap material using an electric arc furnace (EAF) results in a very low CO2 emission compared to traditional production in blast furnace followed by basic oxygen steelmaking, but introduces many tramp elements by scrap. The impact of these foreign elements on the mechanical properties is in many cases not entirely understood and predicting the impurity effects on mechanical properties of steel from processing solely with physical models is not feasible. In this work we present a data-driven approach applying AI regression model techniques to predict r-value, tensile strength and other parameters of cold-rolled steel strip produced by voestalpine Stahl GmbH. The data includes a full chemical analysis, as well as many parameters measured during all working steps of the process and the resulting mechanical properties. As a prerequisite for training of AI models, the data needs to be understood, analyzed, checked, and unreasonable data be removed (data cleaning). The result is a machine-readable dataset fit for various modelling tasks. The used models include Random Forest Regression, Support Vector Regression, Artificial Neural Networks and Extreme Gradient Boost. Based on the insights gained, we present strength and limitations of different model types with the available data and number of features. In addition, we are presenting methods to calculate the feature importance and determine the impact of each feature in our models. Furthermore, we discuss possible improvements like introducing prior physical knowledge.

Christoph Nölle, VDEh-Betriebsforschungsinstitut GmbH, Germany

Co-Author:
Asier Arteaga Ayarza, Sidenor Investigación y Desarrollo
Monika Feldges, VDEh-Betriebsforschungsinstitut GmbH
Martin Schlautmann, VDEh-Betriebsforschungsinstitut GmbH
Norbert Holzknecht, VDEh-Betriebsforschungsinstitut GmbH

Abstract:
A concept for estimating the risk of steel long products to develop surface defects during the production is presented, based on an advanced product tracking system and machine learning algorithms. The aim of the risk estimators is to identify products with a high risk for defects as early as possible in the production chain and to support operator decisions on corrective actions or the immediate recycling of a product in order to save resources for the further processing. In our use case, the secondary metallurgy, continuous casting and hot rolling processes are considered of relevance for the surface quality, and besides the raw process data also the results of a set of soft sensors are evaluated, which integrate physical process knowledge into the otherwise data-driven risk estimators to increase the reliability. Some challenges of the approach are discussed, such as difficult product tracking conditions, the need to retrieve aligned data from different sources and the availability of sufficiently broad datasets for training. A digital twin-based software platform for the integration of different data sources, soft sensors and risk sensors is presented, along with a data model based on international standards but adapted to our use case.

Nils Hallmanns, VDEh-Betriebsforschungsinstitut GmbH, Germany

Co-Author:
Roger Lathe, VDEh-Betriebsforschungsinstitut GmbH
Andreas Wolff, VDEh-Betriebsforschungsinstitut GmbH
Detlef Sonnenschein, VDEh-Betriebsforschungsinstitut GmbH
Hagen Krambeer, VDEh-Betriebsforschungsinstitut GmbH
Monika Feldges, VDEh-Betriebsforschungsinstitut GmbH
Alexander Dunavitzer, VDEh-Betriebsforschungsinstitut GmbH

Abstract:
In flat steel production, flatness of steel strips and plates is of paramount significance for a safe and stable process operation and essentially defines final product quality. Although local flatness is controlled successfully during rolling, many steel plants face significant flatness problems for thin and/or high-strength steel products in downstream processes and after production. Especially the automotive industry has increasing demands for thinner and higher-strength steels. But this implies new difficult challenges for the aged plants and machinery run at their physical and technical limits to produce such highly specialized steel products. Additional limits are given in terms of cooling capacity, maximum required strip tension or the required rolling force, but most importantly by roll bending and continuous variable crown. HatFlat investigates cross-process influences on the development of flatness defects. For this purpose it will apply a unique way of combining existing models based on physical laws – so called first-principle models – and state of the art machine learning (ML) approaches. This so-called physics-informed ML approach allows to a) improve the prediction of flatness and flatness deficiencies, b) identify the influential factors of greatest impact on flatness and c) to make proposals for changing the processes (as long as the product quality specifications are not affected) for achieving a better flatness characteristic. The project will also utilize proven Industry 4.0 tools, such as digital product twins for hosting the prediction models. The models developed in HatFlat will be assembled into a holistic assistance tool for flatness prediction. Featuring a strong industrial participation of some of Europe´s biggest steel producing companies, plants allocated along the process chain of steel processing with strip and plate products, two highly reputed steel research institutes and a university, all working together to create one new tool for predicting, understanding and improving flatness.