The steel industry is in a dilemma: with almost 10% of global CO2 emissions, it is one of the biggest emitters of greenhouse gases. At the same time, demand for steel is increasing worldwide, especially in emerging economies that are continuing to expand their infrastructure. As part of the European Green Deal, the EU has set the goal of becoming climate-neutral by 2050. This objective requires considerable adjustments in the steel industry. The way to achieve a more climate-friendly production is through so-called “green steel”, whose production should drastically reduce emissions. But how can the corresponding challenges be overcome?
“Green steel” refers to a production method in which CO2 emissions are significantly reduced compared to conventional steel production. While the conventional production of one ton of steel releases up to ten tons of CO2, this amount is to be reduced to one ton of CO2 per ton of steel in the future. A completely carbon-free steel production is not yet possible, but various technological approaches can significantly improve the environmental footprint of the steel industry.
The transition to a more environmentally friendly production process is achieved through a number of measures. Particularly important in this regard is the recycling of scrap and the increased use of electric arc furnaces (EAF), which are gradually replacing conventional blast furnaces. At the same time, the use of renewable energies such as wind and solar power plays a key role. These technologies offer enormous potential for reducing energy consumption and emissions.
The recycling of metal waste is an important milestone on the road to a circular economy. A very high proportion of steel can be melted down and recycled, which not only conserves resources but also reduces emissions. However, the quality of recycled steel varies and the availability of recyclable material is limited. Therefore, it will still be necessary to cover part of the future demand for steel from iron ore.
Increased use of electric arc furnaces
Electric arc furnaces (EAF) offer a more environmentally friendly alternative to the conventional blast furnace. By using electricity - ideally from renewable sources - instead of coal, CO2 emissions can be significantly reduced. A further advantage is, that this type of furnace is particularly suitable for recycling metal waste. However, electric arc furnaces will need to increase in size and performance in order to achieve the production volumes of conventional blast furnaces. Achieving this will be technically challenging and will require advances in furnace technology in order to achieve higher temperatures and shorter production times.
Larger furnaces and various raw materials bring with them new technical challenges. On the one hand, the increased weight requires larger and more robust systems; on the other, fluctuating fill levels and raw material qualities must be precisely monitored and controlled to ensure consistent production quality. A stable and efficient production process depends heavily on the precise control of the furnace load level. If the liquid crude steel sump is too extensive or the load levels in the furnace are too low, the ambitious production quantities cannot be achieved. This is where modern measuring and control systems come into play, which enable a precise monitoring of the furnace weight. This technology plays a key role in optimizing operations and avoiding the waste of materials.
One problem with the utilization of metallic waste is its divergence in purity. Scrap can contain various contaminants that can negatively affect the characteristics of the newly melted end product. Therefore, strict quality controls are necessary to ensure that the recycled steel meets the same standards as steel made from iron ore. Modern refining techniques can help improve product quality and compensate for fluctuations.
Advances in weighing technology with integrated condition monitoring
Electric arc furnaces are increasingly equipped with precise weighing cells that enable a continuous monitoring of the furnace weight. These systems are crucial for increasing efficiency and optimizing energy use. Innovative condition monitoring features of the weighing technology also allow for real-time analysis of the operating conditions and corrective adjustments to be made before costly production downtime or inefficiencies occur. The monitoring techniques also make for a more efficient use of energy and a further reduction of carbon emissions.
In addition to the recycling of metallic waste, refined raw materials such as Direct Reduced Iron (DRI) and Hot Briquetted Iron (HBI) also offer potential for green steel production. These materials, which are obtained from iron ore, are of consistently high quality and can therefore compensate for the quality fluctuations in recycled steel. The possibility of replacing natural gas, which is currently used for the production of DRI, with green hydrogen is particularly promising. This can further reduce emissions in steel production, as the production of refined raw materials requires a large amount of energy.
Conclusion: green steel is on the rise
The demand for green steel is growing. Political frameworks such as subsidies and incentives for carbon reduction are promoting the shift towards more environmentally friendly production methods. From a technical perspective, the industry is facing an evolution in which proven processes such as the use of electric arc furnaces must be further developed.
Companies like Qlar are very experienced with these technologies. The established and reliable systems are continuously being enhanced to meet the increased process requirements and the growing demand for green steel. Steel producers are already starting to retrofit their plants to take advantage of the environmental and economic benefits of green steel production. Despite some technical challenges, the transition to climate-friendly steel production is clearly ahead of us.
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