National Technology Day — why India’s steel industry need to adopt better technologies to address CO2 emissions
Summary
As technology advances, there are reasons to be hopeful that we can find ways to reduce carbon emissions in steel production. However, existing solutions are either in their early stages of development or face specific challenges that require significant investment and cooperation from both government and industry, observes Tata Steel’s Rajiv Mangal in his exclusive column on the occasion of the National Technology Day.
The steel industry is currently facing a crucial moment in its history. It must address the urgent need to reduce its carbon footprint while keeping up with the growing global demand for steel. As one of the largest sources of industrial carbon emissions, accounting for roughly 7-9% of global CO2 emissions, the steel sector plays a vital role in the fight against climate change.
India aims to achieve its net zero emissions target by 2070. According to India’s steel ministry, the domestic steel manufacturing industry emits 2.2-2.7 tCO2/tcs (tonnes of CO2 per tonne of crude steel produced) against a global average of 1.8-2 tCO2/tcs. India is the second largest crude steel producer globally, with 161 million tonnes of installed capacity and 122 million tonnes of production per annum.
As technology advances, there are reasons to be hopeful that we can find ways to reduce carbon emissions in steel production. However, existing solutions are either in their early stages of development or face specific challenges that require significant investment and cooperation from both government and industry.
Green hydrogen is a promising solution. However, the cost of producing green hydrogen is too high for Indian steel companies, making it economically unfeasible. To make green steel competitive, green hydrogen must be around $1-2/kg. Secondly, there are technological limitations, as only up to 15% of coking coal in blast furnaces can be replaced by green hydrogen. Lastly, there are engineering challenges to integrate hydrogen injection systems into older blast furnaces.
The discourse around carbon capture, utilisation, and storage (CCUS) has recently intensified. According to the World Steel Association, CCUS technologies can be retrofitted into existing systems to cut carbon emissions, projected to reach 8 billion tonnes by 2050. For instance, Tata Steel has commissioned a 5 tonnes per day carbon capture plant, in collaboration with a UK-based startup, in Jamshedpur.
However, some challenges are bottlenecks to its large-scale adoption, not limited to the steel industry. While the high cost of carbon capture is the major challenge, its utilisation post-capturing is the other concern. Even though mineralisation is among the most feasible ways to use it, its carbon uptake is very low. Conversion to ethanol and methanol requires green hydrogen, which poses other questions about commercial viability, availability, scale, etc.
The other routes are either capex intensive or are low on the maturity scale. Though economically viable, storage requires specific geological strata devoid of cracks to avoid future leakage. Sea basin is an option but is not logistically feasible for all companies.
Steel manufacturers are also experimenting with coke oven gas. The EASyMelt (Electric-Assisted Syngas smelter) technology, developed by Germany’s SMS Group, is a cutting-edge metallurgical solution to decarbonise steelmaking. It utilises blast furnace top gas recycling for syngas production by reforming the coke oven gas.
Coke oven gas injection is another technologically feasible route; however, its main challenge is scalability. Of the coal used to generate coke, only about 15% is released as coke oven gas, making a minimal contribution to the steel industry’s decarbonisation targets.
The stamped charging of coals, developed in Europe and adopted in China and India, allows the use of highly volatile poor coking coals and soft and semi-soft coals without impairing coke quality. Apart from these, through polymerisation technology, the amount of non-coking coals in traditional steelmaking can potentially increase by about 10%. The shear crushing method helps increase the use of cheaper or less preferred coals. The microwave coke oven technology can potentially make coke totally from non-coking coals.
Internationally, the Japanese steel industry has also made some breakthroughs. The Super COURSE 50 technique, developed by Japanese steelmakers, reduces carbon dioxide emissions by using heated hydrogen, which has the potential to reduce blast furnace CO2 emissions by up to 30%. It uses by-product gas generated in integrated steel mills that are currently used in furnaces.
SCOPE 21 (Super Coke Oven for Productivity and Environment Enhancement toward 21st Century) is a high-end coke-making process developed by the Japanese steel industry. It aims to replace their ageing top-charge coke ovens. SCOPE21 is claimed to use up to 50% semi-soft, weak, and non-coking coals.
Indian steelmakers are adding the electric arc furnace route of steelmaking to their manufacturing portfolio. The technology is familiar; however, the main challenge around its adoption has been the availability of low-cost green electricity and steel scrap. As part of its carbon emission reduction strategy, Tata Steel is building its first electric arc furnace-based low-emissions steel plant in India at Ludhiana. It has also signed a 25-year agreement with Tata Power to source renewable power, potentially reducing its carbon emissions by 50 million tons.
The steel industry will need a bouquet of solutions, posing an exciting opportunity to transform itself. With the help of cutting-edge technology, we can reduce emissions, improve efficiency, and promote sustainability. Collaboration is critical to achieving these goals, and by working together, we can chart a clear path towards a bright and resilient future. Let’s embrace innovation and collective efforts to build a greener, more sustainable steel industry that will benefit future generations. The possibilities are endless, and I’m excited to see what we can achieve together!
—The author, Rajiv Mangal, is Vice President, Safety, Health & Sustainability, at Tata Steel. The views expressed are personal.
Elon Musk forms several ‘X Holdings’ companies to fund potential Twitter buyout
3 Mins Read
Thursday’s filing dispelled some doubts, though Musk still has work to do. He and his advisers will spend the coming days vetting potential investors for the equity portion of his offer, according to people familiar with the matter