The presentation highlights two innovative data-driven models designed to improve the efficiency of the steelmaking process.
The first model focuses on predicting the optimal amount of calcium additions during ladle refining by analyzing the characteristics of non-metallic inclusions. The model, which has been trained on a robust data set including more than 5,000 heats and rigorously tested with 1,200 heats, has demonstrated its practical impact by reducing submerged inlet nozzle clogging by approximately 30% when implemented in a steel plant.
The second model takes a proactive approach by predicting the probability of clogging during continuous casting, taking advantage of knowledge of steel chemistry and closure bar positions. This model, trained with data from 150 casts and validated with 100 casts, proved its effectiveness in real conditions, contributing to a remarkable 5% improvement in castability during tests conducted at the steel plant's R&D facility.
The author argues that these data-driven models are valuable tools for online process monitoring and optimization in the steel industry. However, the success of these models is closely linked to the quality of the input data. In addition, the author stresses the continuing importance of operator knowledge, and emphasizes their role in addressing complex issues that the models may not cover.
In summary, while the potential of data-driven models to improve steelmaking processes is clear, the author advocates a balanced approach. They state that the integration of these models with operator expertise is paramount, especially when addressing nuanced challenges that are beyond the scope of automated algorithms. The author also stresses the need for extensive industrial validation before widespread adoption of such models. In addition, the quality of the data collection infrastructure is a determining factor influencing the accuracy and performance of these data-driven tools. This nuanced perspective underscores the need for harmonious collaboration between human expertise and cutting-edge technological advances in the quest for optimized steelmaking processes.
The analysis of Industry 5.0 reveals a paradigm shift that complements its predecessor, Industry 4.0, with particular emphasis on human-centered, sustainable and resilient practices. This forward-looking perspective underscores the need for social innovation, advocating the seamless integration of societal priorities into technological advances.
At the heart of Industry 5.0 are transformative technologies aimed at improving human-machine interaction, promoting energy efficiency and harnessing artificial intelligence. Unlike its precursor, Industry 4.0, Industry 5.0 presents a distinctive framework that harmonizes competitiveness with sustainability. It not only recognizes the importance of technological governance, but also empowers workers through the judicious use of digital tools, establishing a balanced dynamic between technological progress and human well-being.
A key hallmark of Industry 5.0 is its commitment to fostering a transition to more sustainable applications of technology. This orientation is exemplified through European initiatives such as ESSA and COCOP. ESSA takes a holistic approach in formulating a long-term competency strategy for the steel industry, aligning itself with an ecosystem perspective. COCOP, on the other hand, participates in a co-creation process involving engineers and workers to develop a tool for monitoring steel plants. This collaborative approach not only facilitates technological development, but also integrates social innovation, improving both efficiency and acceptance.
The ROBOHARSH project is a tangible demonstration of Industry 5.0 principles in action. This project illustrates the evolving nature of workers' tasks, moving from manual to robot-facilitated supervised functions. The human-robot interface, a central component of ROBOHARSH, is designed to relieve operators of heavy and hazardous tasks, thus contributing to a safer and more ergonomic work environment.
In essence, Industry 5.0 emerges as a transformative force in production that prioritizes human well-being, sustainability and resilience. The integration of societal priorities into technological development is not just a theoretical concept, but is actively demonstrated through European projects employing co-creation strategies and capacity building initiatives. Industry 5.0 is set to redefine the landscape of industrial practices, promoting a harmonious coexistence between technology and humanity.
Artificial intelligence (AI) is at the forefront of the digital transformation of the steel industry, playing a key role in driving various business outcomes, such as operational excellence, a connected workforce, improved asset and process performance, and sustainability.
In the realm of foundry operations, AI and big data analytics emerge as transformative forces, enabling autonomous and optimized processes. Applications such as automatic crane scheduling, ladle tracking and thermal prediction models are critical to achieving benefits such as increased energy efficiency, increased productivity and improved overall quality. This is an important step towards achieving operational excellence in the steel production process.
Beyond operational improvements, AI becomes a key player in advancing sustainability efforts within the steel industry. AI-driven load planning and forecasting help to avoid risks in energy demand and supply, reduce energy costs, and minimize environmentally harmful practices such as gas flaring. This underscores the potential of AI to align business operations with sustainable practices.
However, the implementation of AI in the steel industry is not without its difficulties. Issues such as data quality, the paucity of training data, and the overriding need for explanation and confidence on the part of operators pose practical hurdles. Addressing these challenges is essential to successfully integrating AI technologies.
In summary, while AI and digital technologies offer a plethora of opportunities for the steel industry, pragmatic challenges need to be overcome to ensure successful implementation and value realization. A strategic focus on business outcomes, along with the use of standardized solutions and continuous monitoring, emerge as crucial enablers for scaling AI initiatives. Careful consideration of these factors positions the steel industry to leverage AI for a transformative and sustainable future.
Digitization involves the use of digital technologies to reshape business models, creating new revenue streams and value-generating opportunities that go beyond the mere digitization of analog information.
Central to this transformative process is digital transformation, a strategic application of digital technologies aimed at fundamentally improving both business operations and customer experiences. Achieving digital transformation requires organizational changes in processes and culture to take full advantage of digital capabilities.
Crucial digital technologies such as machine vision, edge computing, big data analytics and artificial intelligence are identified as enablers of this transformative journey. The importance of data preparation is emphasized, with data scientists devoting considerable effort to this fundamental step in data-driven solutions.
One aspect worth mentioning is the need for "clean data", i.e. relevant, filtered and converted data. This type of data forms the basis for calculating meaningful metrics and effectively using artificial intelligence in digital transformation efforts.
The incorporation of a state-of-the-art digital system for data collection and preparation is highlighted, showing its multifunctional advantages in areas such as predictive maintenance, quality control and asset management.
Although digital transformation is based on existing technologies, true innovation arises from the synergistic combination of these technologies. Cultivating a "digital mindset" and collaborating with subject matter experts become essential components to take advantage of the full spectrum of possibilities that digital transformation opens up.
In short, digital transformation is more than technology adoption; it requires comprehensive changes in processes, culture and mindset to fully realize its benefits. The foundation of data-driven solutions and artificial intelligence lies in meticulous data preparation and the cultivation of a "clean data" environment. The journey to digital transformation requires not only the adoption of new technologies, but a holistic reorientation of organizational practices and perspectives.
The steel industry is currently undergoing a profound technological shift towards Industry 4.0 and 5.0, embracing automation, robotics and digitalization to improve sustainability, agility, resilience and human-centricity. Polytec plays a crucial role in this transformation by developing customized turnkey robotic solutions tailored to specific steelmaking processes. This not only ensures operator safety by removing people from hazardous areas, but also fosters a safer working environment.
Polytec's innovative solutions include an automatic sampling robot for the electric arc furnace, designed to measure the temperature of the steel inside the furnace. This innovative technology reduces operator exposure to extreme conditions from 4-6 times per hour to only 0.8-1.2 times per hour. In addition, an automatic EBT maintenance robot for the electric arc furnace effectively cleans and lances the EBT when it is clogged, minimizing operator exposure from 0.4-0.8 times per hour to only 0.1-0.2 times per hour.
In addition, Polytec's multi-tool robot for the continuous casting machine handles operations such as cover handling and oxygen lancing, significantly reducing the number of operators needed in the casting area. In addition, its automatic ladle slide gate maintenance system reduces human intervention and minimizes exposure to hot metal splashes.
In short, Polytec advocates a human-centered approach that prioritizes quality of life and sustainability as key factors for the future of the steel industry. Its overall goal is to empower workers through technology, facilitating their transition from field operators to machine supervisors and contributing to a safer, more efficient and sustainable steel production landscape.
The discourse on architecture in the Industry 4.0 arena has reached a critical point, prompting a re-evaluation of conventional structures and the introduction of a revolutionary paradigm known as Unified Namespace.
The author makes a compelling case against architectures rooted in the traditional Purdue model, emphasizing their inherent flaws that doom them to failure. Point-to-point connections, the cornerstone of this model, are found to be unscalable, stifle innovation, burden organizations with technology debt, and foster data gaps that hinder operational efficiency.
In response to these challenges, the proposed solution is the Unified Namespace, a cutting-edge approach that meticulously organizes real-time data into thematic categories aligned with the business structure. This innovative architecture acts as a centralized data hub, offering seamless accessibility through a single, standardized interface. It operates on a publish/subscribe model, employs a central intermediary and adopts open protocols such as MQTT.
To illustrate the practical application of the Unified Namespace, the author provides a compelling example in the context of a steel company. Here, disparate applications, ranging from manufacturing execution systems (MES) and supply chain management (SCM) to radio frequency identification (RFID) and quality control, are seamlessly integrated. This demonstrates the adaptability and versatility of the unified namespace.
The advantages of this paradigm shift are manifold. First, it streamlines the integration process, significantly reducing the associated costs. Second, it improves organizational agility, enabling companies to respond dynamically to changing needs and challenges. In addition, the scalability of the Unified Namespace is an outstanding feature: by facilitating communication through a central intermediary rather than direct connections, it can effortlessly accommodate connections to millions of nodes without compromising efficiency.
In essence, the Unified Namespace is not merely a technology solution, but a transformative force poised to reshape the Industry 4.0 landscape, offering a blueprint for improved connectivity, efficiency and adaptability in the rapidly evolving digital age.
Fraunhofer, a leading German research institute, champions smart maintenance practices through its innovative Smart Maintenance Community, emphasizing the transformative impact of new technologies and digitalization in optimizing maintenance processes. Smart maintenance serves as a powerful catalyst to help companies achieve their sustainability and resilience goals through several key mechanisms:
1. Predictive maintenance: Leveraging advanced analytics and predictive algorithms, intelligent maintenance enables proactive identification of potential equipment failures. This foresight enables companies to address problems before they escalate, minimizing downtime, reducing energy consumption and extending asset life. As a result, the approach improves sustainability by curbing resource waste and strengthening operational resilience.
2. Energy efficiency: Smart maintenance practices incorporate real-time monitoring and data-driven insights to optimize energy consumption in industrial processes. By identifying inefficiencies and implementing targeted maintenance interventions, companies can significantly reduce energy consumption. This not only contributes to environmental sustainability, but also aligns with resilience goals by ensuring reliable and efficient operation even under challenging conditions.
3. Resource optimization: By integrating sensors and IoT devices, smart maintenance facilitates accurate tracking of resource utilization. This data-driven approach enables companies to optimize material allocation, reducing waste and improving overall resource efficiency. The result is a more sustainable and resilient operating framework.
4. Improved equipment reliability: Intelligent maintenance practices improve the reliability of industrial equipment by detecting potential problems in real time. By minimizing unexpected breakdowns and interruptions, companies can ensure a smoother and more continuous production process. This increased reliability aligns with sustainability goals by reducing the need for emergency repairs and minimizing the environmental impact associated with unplanned downtime.
5. Data-driven decision making: Adopting smart maintenance fosters a culture of data-driven decision making. By harnessing the power of data analytics, companies can gain valuable insights into their operations, identify areas for improvement, and make informed decisions that align with sustainability goals. This data-centric approach improves overall resilience by enabling rapid and adaptive responses to changing challenges.
In essence, Fraunhofer's Smart Maintenance Community advocates a holistic integration of smart maintenance practices as a strategic pathway for companies to achieve their sustainability and resilience goals. By embracing technological advances and digitalization in maintenance processes, organizations can not only improve operational efficiency, but also contribute significantly to a more sustainable and resilient industrial landscape.
The Internet of Things (IoT) is a transformative force that reshapes user experiences and redefines value propositions by connecting physical objects to the Internet, facilitating data collection and sharing. This connectivity enables businesses to improve efficiency, make informed decisions, save costs and dynamically adapt to evolving demand.
While traditional IoT applications such as predictive maintenance and inventory management offer substantial benefits, the text argues that IoT goes beyond these functionalities to unlock new dimensions of business innovation. It asserts that IoT can pave the way for new business models that not only strengthen customer relationships, but also increase revenue. A prime example is the connected product-as-a-service model, which delivers tailored offerings, cost efficiencies and generates recurring revenue and services. This model not only differentiates companies in the marketplace, but also fosters deeper customer connections and facilitates new customer acquisition.
From the customer's perspective, IoT-based offerings translate into lower upfront investment costs, ongoing cost savings, and improved maintenance and uptime. The text delves into various business models for IoT, ranging from subscription and pay-per-use to asset sharing, asset tracking, data-driven and service-based models. It highlights that the underlying objective of most IoT business models is to generate revenue or reduce costs for the enterprise.
In conclusion, the transformative potential of the Internet of Things (IoT) to revolutionize user experiences and value propositions is clear. Beyond traditional applications such as predictive maintenance, IoT opens the door to innovative business models, such as connected product as a service, fostering deeper customer engagement and revenue growth. From the customer's point of view, the benefits are manifold: lower upfront costs, ongoing savings and greater operational efficiencies. Success in the IoT landscape depends on factors such as making a compelling business case, leveraging data effectively, fostering collaboration, ensuring strong security measures, embracing innovation, leveraging existing solutions and building strategic partnerships. Embracing these key success factors is essential for organizations that want to navigate the IoT landscape and unlock its full potential to reshape user experiences and drive value.
The problem of hydrogen uptake in steel production, particularly in the casting tundish lining, poses a challenge, as hydrogen can adversely affect steel quality and properties, with multiple sources contributing to its presence, including slag formers, alloying materials, coating powders, casting tundish mixing, climate and outgassing treatments.
Different distributor coating mixes are used, covering dry-setting, slurry-spraying and cold-setting varieties, with special emphasis on optimizing slurry-spraying mixes to lower hydrogen potential; laboratory tests were conducted to determine the ideal proportions of binder content, dispersing agent, cellulose fibers and water demand, with the objective of achieving the lowest hydrogen potential while maintaining favorable mixing properties.
Pilot tests used two different mixes optimized for slurry gunning, which were applied to a model casting tundish and evaluated for drying behavior, preheating performance and bulk density; one of the mixes demonstrated superior drying speed and lower steam generation during casting. Subsequent field tests in a steel plant confirmed the effectiveness of the inorganic binder blend, characterized by a lower water content, showing better performance and lower hydrogen uptake. In essence, reducing the water content in the tundish coating mix means a potential 10% decrease in hydrogen content, with additional measures such as drying and preheating offering other avenues for hydrogen reduction.
Acerinox Europe and DTA's MELCARTA project to develop autonomous heavy load transport solutions for the steel sector using technologies such as artificial intelligence, robotics and connectivity. It aims to optimize industrial processes and improve productivity by researching technologies to handle, transport and store stainless steel rolled coils in an integrated way.
To integrate the AGVs with the factory management systems, they developed redundant location systems using LiDAR, GPS, obstacle detection systems and cooperative communication systems. Prototype AGVs capable of transporting coils of more than 20 tons indoors and outdoors were successfully tested, traveling along factory roads and avoiding obstacles and people. This is an improvement over the manual vehicles currently in use.
The 21st Century Management Debate is a comprehensive exploration of the multifaceted responsibilities and principles that define successful leadership in the contemporary business landscape.
At its core, effective management transcends immediate results and entails a dual commitment: nurturing a company's present success and strategically safeguarding its future. This holistic approach places particular emphasis on the well-being and development of the people who are the driving force of the organization.
A key point stressed in the speech is the imperative for companies to recognize their inherent fragility. Lessons learned from the failures of other companies serve as a reminder of the need for constant awareness and adaptability.
A company's ability to synchronize with the changing needs of its customers is paramount. Striking a balance between maintaining consistency and proactively staying ahead of the curve is a delicate but crucial management task.
The concept of capturing the future is introduced as more than just strategic planning, emphasizing the importance of adaptability and a continuous learning mindset. Companies are encouraged to discern which aspects will remain unchanged, which require adaptation and which need transformation in the next decade.
Executive roles are described as a nuanced combination, requiring leaders to be both stewards of existing business operations and pioneers in exploring new opportunities, an approach described as "ambidextrous."
Innovation is heralded as an inescapable and challenging pursuit, with a clear warning that the real risk lies in stagnation. The call for innovation goes beyond profitability and emphasizes the need for environmentally sustainable, socially positive and ethically viable breakthroughs.
The text advocates a "humanistic management" ethic, which places people at the epicenter of organizational considerations. Effective leadership involves fostering talent and adaptability, emphasizing collaborative ecosystems over individual egos.
Leadership, in this paradigm, is a service-oriented role, requiring a delicate blend of vision, example, ambition and humility. A company's growth is intrinsically linked to its contribution to the growth of customers, professions, shareholders and society at large.
Authenticity is heralded as an antidote to mediocrity, and the quest to build a legacy is positioned as the differentiating factor between a company and a mere commercial entity. This holistic view of 21st century management encompasses a holistic vision that goes beyond profit margins, conceiving organizations as dynamic entities intrinsically connected to their people, their communities and the broader global context.
Green hydrogen, derived from renewable sources, plays a fundamental role in industrial decarbonization, especially in sectors that are difficult to eliminate, such as the chemical, steel and transport sectors. Iberdrola, a promoter of green hydrogen, is putting forward a comprehensive strategy with short-, medium- and long-term objectives, aiming to install 3 gigawatts of electrolyzers and produce 350,000 tons of green hydrogen per year by 2030. With a broad global portfolio and partnerships such as Cummins, Iberdrola has already completed two projects by 2022, demonstrating tangible progress. Beyond hydrogen, Iberdrola foresees the production of green derivatives such as ammonia, methanol and steel, highlighting the commitment to diversify customers and add value across the green hydrogen value chain, positioning itself as a leader in sustainable industrial transformation.
Hydrogen, especially when it comes from renewable sources, is a key element in the overall goal of industrial decarbonization. This is especially pronounced in hard-to-abandon industrial sectors, where the adoption of green hydrogen - generated from renewables - is recognized as a transformative measure. Green hydrogen derivatives, such as green ammonia, green methanol and green steel, present unique opportunities not only to mitigate emissions, but also to increase overall value within these sectors.
Iberdrola, a leading advocate of green hydrogen, places it at the core of the decarbonization of energy-intensive industries such as chemicals, steel and transportation. Its strategic vision encompasses short-, medium- and long-term goals, highlighting the multiple opportunities offered by the greening of these industries. Iberdrola is committed to achieving important goals, such as installing 3 gigawatts of electrolyzers and producing 350,000 tons of green hydrogen per year by 2030.
With a broad portfolio spanning eight countries, Iberdrola is actively driving green hydrogen projects, signaling a global commitment to sustainable industrial transformation. Collaborating with industry leaders such as Cummins for the procurement of electrolyzers and successfully completing two projects in 2022, Iberdrola has translated its green hydrogen ambitions into tangible achievements.
Beyond the immediate focus on green hydrogen, Iberdrola envisions a cascading impact through the production of derivatives such as green ammonia, methanol and steel. These derivatives represent the natural progression after establishing green hydrogen as a viable reality. The strategy not only aligns with decarbonization goals, but also underscores the commitment to diversify customers and add value throughout the green hydrogen value chain.
In essence, Iberdrola's holistic approach illustrates how green hydrogen, derived from renewable sources, serves as a lynchpin for decarbonizing challenging industrial sectors. Its ambitious goals, strategic alliances and tangible projects underscore its commitment to leadership in advancing the green hydrogen value chain and its contribution to sustainable industrial practices.
The potential impact of hydrogen in mitigating carbon emissions in the steel industry is crucial, considering that a significant portion, around 70%, of current steel production relies on coal, a process known for its significant production of carbon dioxide. The speech presents four viable pathways to decarbonize steel production: transitioning to hydrogen, intensifying recycling efforts, implementing carbon capture and storage, and adopting direct electrification.
In the field of steel production, hydrogen is emerging as a promising alternative to coal, serving as both a fuel and a reducing agent in the steelmaking process. This change can significantly reduce carbon dioxide emissions during the iron reduction phase. Some leading methodologies, such as HYL DRI and MIDREX, use hydrogen as a reducing agent, resulting in increased efficiency, reduced emissions and the production of superior quality steel.
However, the economic viability of hydrogen in the steel industry depends on two critical factors: a reduction in the cost of hydrogen production and an increase in carbon taxes. The steel industry must undergo substantial transformations to meet upcoming carbon emission targets. The incorporation of hydrogen as a fuel and as a reducing agent is emerging as a key component of its overall decarbonization strategies.
Hydrogen can revolutionize the steel industry's decarbonization efforts by replacing coal as a fuel and reducing agent. To realize this large-scale shift, it is imperative to address the challenges of reducing hydrogen production costs and raising coal prices.
More than ten million tons of carbon dioxide are reduced each year in Europe using blast furnace slag in cement production. However, the steel industry is moving towards more sustainable production methods, such as direct reduction and electric arc furnaces. This will change the composition of the slags produced, making them less suitable as hydraulic materials without further treatment.
An upcoming EU-funded research project called InSGeP will investigate different types of slag from various steel production processes. The aim of the project is to develop slags that can be used as construction materials to reduce environmental impact. With steel companies planning to close their first blast furnaces by 2025, there is not much time left for the slag development process to enable the transition of the steel industry to carbon neutral production by 2030.
SMS Group emerges as a leading provider of state-of-the-art digital scrap yard management solutions, offering a complete suite of integrated products tailored to meet the evolving needs of the steel industry. The range of digital solutions encompasses various facets of scrap yard operations:
Autonomous digital plant operation: SMS Group facilitates autonomous operation within the digital realm, streamlining plant processes and improving operational efficiency.
2. Real-time crane and movement tracking: The system provides real-time tracking of scrap movement and crane positions, providing a dynamic and up-to-date view of operations.
3.Camera-based scrap sorting: Using advanced camera technology, the solution enables real-time scrap sorting, improving sorting and categorization accuracy.
4. 3D scanning for raw material measurement: The integration of 3D scanning technology enables accurate measurement of raw materials, providing valuable information on inventory and volume metrics.
5. Incorporation of artificial intelligence extends to predicting foreign elements, such as copper content, and optimizing charge blends, contributing to improved efficiency and profitability.
6. SMS Group presents a cohesive ecosystem that seamlessly integrates various digital tools and solutions, fostering a holistic and interconnected approach to scrap yard management.
These digital solutions directly address important challenges faced by the industry, such as inaccuracies in scrap inventory, labor-intensive scrap quality inspection and collection processes, and variations in scrap quality. Real-time tracking of scrap movement and crane positions, along with automatic scrap sorting based on machine learning, contributes to a more agile and accurate operational workflow.
In addition, the incorporation of 3D scanning technology ensures accurate measurement and monitoring of scrap piles, mitigating challenges associated with inaccurate inventory information. Hybrid AI models not only predict tramp items, but also optimize load mixes, demonstrating a commitment to efficiency and resource optimization.
The effectiveness of SMS Group's AI-based models is corroborated by case studies, which show significant improvements in the accuracy of stray item prediction and the potential for substantial cost savings through load mix optimization. In essence, SMS Group's digital solutions are a testament to innovation in the steel industry, providing a forward-thinking and technologically advanced approach to scrap yard management.
Nippon Gases is an integral member of a major Japanese industrial gases conglomerate with a remarkable century-long legacy of European and global operations. Their extensive European network spans 13 countries, positioning them as a key player in the supply of gases and technology solutions to diverse industries such as food and beverage, metal production and manufacturing.
A leader in the commercial liquid CO2 sector in Europe, Nippon Gases excels in the production of more than 1 million tons of CO2 per year through 12 strategically located plants. In particular, its liquid CO2 sources differ from their fossil counterparts, coming from ammonia and ethanol plants. Nippon Gases' fleet of three specialized CO2 vessels is responsible for transporting this liquid CO2.
In the field of carbon capture and storage projects, Nippon Gases assumes a key role as a technology partner, leveraging its extensive experience and advanced CO2 recovery technology. The Northern Lights project in Norway, currently the most advanced CO2 sequestration initiative in Europe, exemplifies Nippon Gases' commitment to advancing sustainable solutions.
Positioning itself as a catalyst for environmental responsibility, Nippon Gases aligns its strategic vision with the goal of contributing to a carbon-neutral world. This commitment is manifested through a strategic shift towards innovative technologies such as CO2 recovery, oxygen production and hydrogen production. By focusing on these solutions, Nippon Gases helps industries such as steel, glass and aluminum to actively reduce their emissions, thus playing a key role in the global quest for a sustainable, low-carbon future.
Navigating the intricacies of material selection and corrosion control in carbon capture and storage (CCS) systems proves to be a multifaceted challenge. Chief among these complexities is the diverse nature of carbon dioxide, stemming from its origins in different capture sources and technologies. This diversity results in different levels of impurities and compositions in the carbon dioxide stream, introducing elements such as water, hydrogen sulfide and nitrogen oxides. These impurities not only modify the properties of carbon dioxide, but also pose potential corrosion risks.
The second challenge arises from the diverse operating conditions required to transport and store carbon dioxide. The gas must be managed at different pressures and temperatures, presenting a spectrum of states, such as supercritical fluid, dense fluid or liquid. Each state significantly influences the behavior of carbon dioxide and, consequently, its corrosion potential.
The third layer of complexity concerns corrosion threats arising from impurities and the variety of conditions encountered. The third layer of complexity concerns corrosion threats arising from impurities and the variety of conditions encountered, requiring complicated testing and material selection processes, compounded by the difficulty of reproducing high-pressure conditions and managing impurities accurately during laboratory testing. Uncertainties around test duration and performance requirements add an additional layer of complexity to this challenge.
Fundamental to this equation is material selection, where the choice of alloys is paramount. In carbon dioxide transport and injection applications, different alloys have different performances, especially in terms of corrosion resistance and maintenance of mechanical properties, especially in low temperature conditions.
In the face of these challenges, Tubacex is strategically positioned as a leading manufacturer, focusing on the supply of seamless tubular solutions in corrosion resistant alloys. This strategic approach is essential to address the complex demands associated with carbon dioxide transport applications within CCS systems.
In conclusion, the pressing need for standardization of material requirements and testing procedures, which is essential for the widespread deployment of carbon capture and storage systems, is evident. The challenges articulated in this intricate landscape underscore the need for comprehensive solutions, both in terms of materials innovation and industry-wide standardization efforts.
A Japanese company with more than 100 years of experience, Taiyo Nippon Sanso operates more than 130 air separation units in 31 countries.
With steel production accounting for 7-9% of global CO2 emissions, reducing CO2 emissions from the steel industry is key to tackling climate change. The BF process emits about 1.9 tons of CO2 per ton of steel, while the EAF process emits about 0.3 tons.
A high-temperature gas generator was developed by Taiyo Nippon Sanso to preheat oxygen blast furnace shafts. It generates hot gasses with a temperature of 900 degrees Celsius by burning blast furnace gas with oxygen. Computational fluid dynamics modeling was used to scale up the design of the generator to handle a variety of fuel qualities and pressures.
The examination of the role of ferroalloys such as nickel, molybdenum, and niobium in the context of sustainable steel production for the transition to a green economy underscores critical considerations in the ongoing battle against carbon emissions. Several key points emerge from this discussion:
Steel, despite its relatively low carbon footprint, contributes significantly to global CO2 emissions due to its immense production volume, accounting for 6-8% of the total. The adoption of high-strength alloys offers a strategic avenue to diminish steel intensity, thereby mitigating its environmental impact.
Renewable energy technologies, particularly steel-intensive applications like wind turbines, present a dual challenge: addressing the carbon footprint of both the steel and renewable energy industries. This intersection highlights the crucial role that materials and alloys can play in achieving sustainability goals.
The text outlines supply constraints associated with ferroalloys, particularly emphasizing the dependence on a limited number of countries for essential metals like niobium. Additionally, challenges in scaling up production sustainably pose significant hurdles to meeting the growing demand for these critical components.
Mining and processing operations for these metals contribute to carbon emissions, presenting a paradox in the pursuit of sustainability. Integrated producers, exemplified by CBMM in the case of niobium, have proactively taken steps to reduce their carbon footprint, showing a commitment to environmental responsibility within the industry.
Despite the carbon footprint associated with ferroalloy production, the text emphasizes a crucial counterbalancing factor. These alloys play a pivotal role in enabling the creation of high-strength steel grades, facilitating weight reduction in applications and thereby curbing CO2 emissions through optimized material usage.
In conclusion, the challenges inherent in ferroalloy production are acknowledged, yet their indispensable role in curbing the carbon footprint of steel for the green transition is evident. The strategic application of high-strength grades, made possible by these alloys, stands as a linchpin in achieving sustainability goals by minimizing material usage. However, the text also underscores the imperative for establishing more sustainable and secure supply chains for these critical metals, underscoring the necessity of a holistic approach to sustainability in the steel industry.
Sweden's exports will increase as a result of H2 Green Steel building a new European industry leader in green steel production. Using hydrogen, renewable energy, and scrap, they aim to produce 5 million tons of steel every year while reducing carbon emissions by 95%. The company has raised around 1.8 billion Euros from investors who share its environmental values. Furthermore, they have around 1 million tons of pre-sold steel volumes through binding agreements with customers like BMW, Ikea, and Volvo.
The company plans to gradually increase production, starting commercial operations in 2025 and reaching full capacity of 5 million tons by 2028. Key parts of the production process are supplied by SMS Group, Midrex, and Thyssenkrupp.
Achieving zero carbon requires new technologies and processes, which is a challenge for the company. Nevertheless, the company strives to continually reduce its carbon footprint by exploring new alloy designs and green chemistries. Additionally, they hope to help lower emissions in other industries beyond steel production.
SSAB is steadfast in its commitment to evolve into a fully fossil-free steel company through its pioneering HYBRIT initiative. The current carbon emissions from SSAB's blast furnaces, ranging from 2 to 4 million tons annually, underscore the urgency of transformative measures. To meet the ambitious target of a 90% reduction in carbon intensity by 2050, SSAB recognizes the imperative for a metallurgical paradigm shift beyond incremental advancements.
The HYBRIT technology emerges as a groundbreaking solution, employing hydrogen in lieu of coal for the direct reduction of iron ore. This innovative approach results in the production of water instead of carbon dioxide. The process encompasses direct reduction utilizing hydrogen, electric arc furnace melting, and secondary steelmaking. The HYBRIT integrated Research and Development program meticulously tests this revolutionary process across lab, pilot, and demonstration scales. Encouragingly, successful pilot trials have demonstrated the production of high-quality hydrogen direct reduced iron.
SSAB's comprehensive transformation plan envisions the construction of new electric arc furnaces and "mini mills" to replace existing coal-based plants. The inaugural electric arc furnace is slated for completion in Oxelösund by 2026, with additional mini mills planned for Luleå and Raahe around 2030. In a strategic collaboration, SSAB is partnering with customers who share their ambition for an entirely fossil-free value chain. The overarching goal is a seamless transition to a fully sustainable steel portfolio, featuring SSAB Fossil-free steel derived from iron ore alongside SSAB Zero, a recycled scrap-based steel. This concerted effort underscores SSAB's commitment to leading the charge toward a greener and more sustainable future in the steel industry.
Steel production, while essential to various industries, poses environmental challenges due to its resource-intensive nature and emissions generation. Sustainable steel production is pursued through the development of resource-minimizing technologies, increased steel recycling, low-carbon steel production methods using hydrogen, and industry initiatives that embrace sustainability and circular economy principles. These efforts pave the way for a greener steel industry and a more sustainable future.
The steel industry is heading towards the next industrial revolution with Steel Tech 2023. New technological pathways are needed to significantly reduce carbon emissions in the steel sector. Several avenues are being explored, such as circular economy, smart carbon use, direct carbon avoidance and process integration with carbon capture and use. This also involves the use of hydrogen, electricity and biological conversion of carbon gases such as CO and CO2. All this is intended to move industry towards Industry 5.0, a more sustainable, resilient and human-centered industry, as envisaged by the European Commission.