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¶American
           Iron and Steel
           Institute

            U.S. Steel Industry Progzress in Reducin2 Greenhouse Gas Emissions


Energv and Steelmaking
                                                                                            below,
Due mainly to the inherent requirement for carbon in iron and steel making, as described
                                                                                          60% of
the steel industry is highly dependent on carbon-based energy sources. Approximately
the energy consumed by the steel industry is dei ied directly from coal   and much of the
                                                                                             for
electricity the industry uses is generated at coaljred power plants. Natural g-as accounts
nearly 30% of the industry's energy consumption For electric arc     ftimace (EAF) steelmakers,
                                                                                             about
the main energy source is electricity. For all steel producers, energy purchases represent
 15-20% of the total manufacturing cost, a fact that has provided a strong incentive for the
                                                                                     ongoing
 industry to develop energy-saving opportunities. All major steel companies have
 conservation programs, and the industry has engaged in conservation,    recycling, and economic
 use of energy for over 80 years. As a result of these measures and technological advancements
 in iron and steelmaking, the industry's energy rqie      ntper ton of steel shipped has declined
 steadily. Since 1975 energy usage per ton of s~lsipd        has been reduced by about 45%. As a
                                                                                        1990 to
 consequence, carbon dioxide (C0 2) emissions haedcied correspondingly. From
 2000, U.S. steel industry CO 2 emissions per to of shipped steel declined about 15%

The Role of Carbon in Iron and Steel1making
                                                                                      ore and
Carbon is an essential raw material that servesa a chemical reactant to convert iron
                                                                                    of this
other iron-bearing materials to iron and steelanCOisnuavdbebyruc
                                                                                         rate of
reaction. While some progress has been mad ovrteyast mrv h tlzton
                                                                     fceity        hsics, and
carbon, as discussed 'below, the amount reur isdcae ylw
thermodynamics, and current usage is very cls otertclmnmmlvl.Cnequently,
                                                                                     to reflect the
 any policies or initiatives designed to decreas ste nutycarbon emissions need
                                                                                      manmer as
 fiundamental principle that carbon used as a redcat antbe reduced in the same
 other carbon-based fuels.
                                                                                       made by
 Steel is produced by two methods in the U.S. +emajority (about 53% in 2001) is
                                                                                       70 to 80%
 integrated steelmakers in basic oxygen furnaces (BOFs), which typically use about
                                                                                         in blast
 molten iron and 20 to 30% scrap. Molten iron [used in BOFs is principally produced
 furnaces from iron ore or ore concentrates, wh Ich consist of oxide minerals  containing less than
                                                                                     in the rock
 65% iron. The remainder of the ore consists of oxygen and impurities contained
 formations from which the ore is extracted. In the blast furnace, coke,  produced from coal
                                                                                                Other
 having certain chemical and physical properti s, is typically used as the source of carbon.
 carbon-bearing materials such as coal, coal derivatives, natural gas, or petroleum products can
                                                                                           in a blast
 also be used as a source 'of carbon to supplement a portion of the coke. Iron produced
  furnace usually contains 3 to 4% carbon, which subsequently must be reduced     to less than 1%
carbon in a steelmaking furnace to produce comihercial grade steels. This is accomplished in a
BOF where the molten iron is combined with scr Ip and refined and alloyed to produce the
desired grade of steel.

The main function of coke and other carbon-bear~ing materials vised in the blast furnace is to
provide the source of carbon that serves as the chemical reactant to convert ('reduce') the iron
ore to iron and to sustain the chemical reactions rquired for the process. *Coke also has the
physical characteristics to provide the necessary structural support for the blast furnace burden
and to serve as a porous material so that the redcig gases can pass through the burden
materials. Alternatives to the blast furnace prots such as direct-reduction and direct-smelting
processes, have been developed in recent year adare still evolving. These processes allow for
iron to be produced without the need for coke, but they still require sources of carbon, typically
coal or natural gas, to reduce the iron oxides to iro.

ElA~s account for the remainder of raw steel production in the U.S. (about 47% in 2001). EAFS
use electricity as the primary source of energy tomelt the charged materials, which typically
consists of nearly 100% recycled steel, or scra. Bcause the EAF process is mainly one of
melting scrap as opposed to reducing oxides, ca      ins is not as dominant as in the blast
                                                       role
furnace/BOF process. However, depending on the characteristics of the charged materials, some
carbon may be added to serve as a chemical reductant or may be contained in the charged
materials themselves. Also, carbon is often associated with the generation of electricity used in
the process. Although EAF production has increased incrementally in recent years, the demand
for steel in a growing economy cannot be met Shilely from recycled steel. In fact, some EAM
producers have begun to use iron substitutes to displace some of the scrap.

 Prog~ress Toward Greenhouse Gas Emission Reductions

 Following are a nuinber of examples as to how -energy and correspondinig C0 2 emission
 reductions have been accomplished in the U.S. steel industry.

 The recovery of byproduct gases is common prciei negrated steel plants. The blast furnace
 process generates large amounts of byproduc <atfraegas. Some of this gas is used directly
 to support the blast furnace process by prehetg bls i n regenerative "stoves." The
 remainder is typically utilized in boilers to prouesta       sed to drive the blowers that sustain
 the process and for other uses throughout the pln for other process and heating purposes. Some
 plants also generate electricity from this byproduct fuel, and the steel industry was a pioneer in
  cogeneration using blast furnace gas. In coke ovens, byproduct coke oven gas is also recovered
 for a variety of uses. About 40% is typically UsIed to underfire the ovens themselves and the
 remainder is used for various process and heating purposes throughout the plant. Some
  companies also utilize waste heat from other pijocesses (e.g., slab heating furnaces) to produce
  steam. These uses of byproduct fuels have a significant effect in reducing overall iron and
  steelmaking energy requirements that would otherwise have to be provided by purchased energy
  sources, and in recent years companies have strived to maximize use and minimize flaring of
  these gases.

  Advancements in blast furnace technology begining in the 1950s have resulted in significant
  reductions in the amount of coke required for iron production. These included benieficiation of
and pellets that improved blast furnace
 ion ore and other raw materials and the use of Site
                                                           coke rates, which in turn reduced the
operation anid allowed for the reduction of blast f~race
                                                        pulverized coal injection and natural gas
demand for production of coke in coke ovens. Ueof
                                                     technology alternatives to blast furnace
injection has also reduced coke rates. A number of
                                                       all are dependent on fossil fuel as a source
ironmaking are in various stages of developmen but
of carbon and many are still coal-based.
                                                   on energy consumption. In the 1960s, basic
Steelmaking trends have also had significant imact
                                                                open-hearth furnaces, and open
oxygen steelmaking began to displace the more enryintensive of EAFs increased
                                                         the use
hearths were completely phased out by 1991 In adton,
                                                        1960 to nearly 50% today. The greater
dramatically from less than I10% of overall produtinin
                                                    advances in furnace design and operation
use of EAFs also stimulated numerous technological
intended to improve EAF productivity.
                                                         and steel and corresponding increases in
 The trend toward more continuous processing of iron
                                                        in energy efficiency. The prime example of
 yield has also given rise to significant improvementms
                                                        from nearly 0% in 1960 to about 95%
 this is the increase in continuous casting, which rose
                                                     energy-intensive steps previously associated
 today. Continuous casting has eliminated severa
                                                             continues with the adoption of thin slab,
 with production of intermediate steel shapes. Tattrend
                                                     Continuous casting and other improvements in
  strip, and other near-net-shape casting procese.
                                                           raw steel production and shipments,
  manufacturing efficiency have closed the gap betwen
                                                          ton of steel product. Yields are now near
  which means that less energy is required to prjuea
  95% as compared to about 70% in the 1960s ad 1970s.
                                                            improvements in energy efficiency.
 Numerous other advancements also contribute t~o overall
                                                      flexible and effective instrumentation, on-
 They include: computerized process controls, more
                                                           scrap preheating, more efficient motors,
 line sensors, hot charging, improved furnace insulation,
                                                         refractories, reduced processing delays
 improved, reheat furnace burner technology, im~proved
                                                           and better energy management generally.
 due to improved maintenance and scheduling practices,
                                                         in partnership with the U.S. Department of
 The industry has a major collaborative R&D program
                                                       Program (TRiP). An investment of $26
 Energy entitled the Technology Roadmap Research
                                                        of improved productivity, energy
 million is earmarked for TRiP projects with thel goals
  utilization, and emissions reduction.
                                                              role of recycling in minimizing energy
  Overarching all of these improvements is the dominant
                                                          infrastructure for recycling of iron and steel
  consumption associated with steel production. The
                                                                  of iron and steel scrap in all types of
  scrap has been in place for the past century andI utilization
                                                         for decades. Recycling of automotive steel,
  steelmaking furnaces has been a common practice
                                                          result, steel is the most recycled material in
  for example, is typically on the order of 98%. As a
                                                                  to produce steel from 100% scrap is
  commerce. This is important because the energy required
                                                             virgin iron ore. Although there are
  about one-third of that required to produce stelel from
                                                           be processed in IBOFs and EA-Fs, other
  inherent differences in the amount of scrap th'at can
                                                         overall economic growth that dictates
  factors - such as scrap availability anid quality4 and
                                                            the ability to increase the use of scrap-
  placement of steel into long-term applications - limit
                                                          example, despite dramatic increases in EAF
  based steel production. Over the past 20 year, for
                                                                 from recycled iron and steel sources
   production, the overall percentage of new steel produced
                                                                 contintie to seek ways to recycle iron-
   has ranged from 65-70%. Nevertheless, steel companies
through the work of the Steel Recycling
bearing dusts, sludges, and other materials. Moreover,
                                                            to promote greater public awareness of
Institute, the industry has undertaken significant ~fforts
                                                      through such initiatives as curbside recycling,
steel recycling and expand recycling infrastructie
municipal programs, and appliance take-back programs.
                                                               energy and reducing related
Finally, steel products play a significant role in cnserving basis. For example:
                                                     a life-cycle
greenhouse gases, particularly when evaluated on
                                                       allowed for production of more energy-
  *Advancements in so-called "electrical steels' have         and transformers.
    efficient electrical equipment such as motors capacitors,
                                                              and lighter than conventional high
   *Advanced and Ultra High Strength Steels are stronger
                                                             in cars and trucks and allow automotive
    strength steels. These new steels are now bigused
                                                            design high-mileage steel vehicles,
    designers to maximize structural efficiencye n thus
                                                                   to retain their recyclability. This is
    which are not only affordable and recyclal btcontinue
                                                               safety demanded by consumers. The
     all accomplished while retaining the driver and family
                                                        Concepts (ULSAB-AVC) program, a
     Ultra Light Steel Auto Body - Advanced VeIhicle
                                                               worked with Porsche Engineering to
     consortium of domestic and international steelmakers,
                                                                   and environmentally responsible.
     develop a vehicle that was safe, affordable, .itel-efficient,
                                                                  around the world with a design
     The results of this program provided auto m~anufacturers
                                                           for a five-passenger sedan with 52 mpg
     utilizing these new Advanced High Strength Steels
                                                 7
                                                                projected 2004 safety requirements
     (gas) and 68 mpg (diesel) performance, whi le meeting
                                                              vehicles. U.S. and international
      and costing no more to manufacture than present-day
                                                                 designs into their current production
      automakers are beginning to incorporate ULSAIB-AVC
                                                                 and emissions reductions. The DOE
      vehicles, which will accelerate improved f~leconomy
                                                            to the manufacture of Advanced High
      TRIP program noted above contributes significantly
      Strength Steels.

                                                            allows for more energy-efficient homes
    *The use of steel framing for residential construction
                                                          other-wise be harvested for construction of
      and preserves carbon-absorbing forests tha would
      wood-framed houses.




                                                     '4

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Document from American Iron and Steel Institute

  • 1. ¶American Iron and Steel Institute U.S. Steel Industry Progzress in Reducin2 Greenhouse Gas Emissions Energv and Steelmaking below, Due mainly to the inherent requirement for carbon in iron and steel making, as described 60% of the steel industry is highly dependent on carbon-based energy sources. Approximately the energy consumed by the steel industry is dei ied directly from coal and much of the for electricity the industry uses is generated at coaljred power plants. Natural g-as accounts nearly 30% of the industry's energy consumption For electric arc ftimace (EAF) steelmakers, about the main energy source is electricity. For all steel producers, energy purchases represent 15-20% of the total manufacturing cost, a fact that has provided a strong incentive for the ongoing industry to develop energy-saving opportunities. All major steel companies have conservation programs, and the industry has engaged in conservation, recycling, and economic use of energy for over 80 years. As a result of these measures and technological advancements in iron and steelmaking, the industry's energy rqie ntper ton of steel shipped has declined steadily. Since 1975 energy usage per ton of s~lsipd has been reduced by about 45%. As a 1990 to consequence, carbon dioxide (C0 2) emissions haedcied correspondingly. From 2000, U.S. steel industry CO 2 emissions per to of shipped steel declined about 15% The Role of Carbon in Iron and Steel1making ore and Carbon is an essential raw material that servesa a chemical reactant to convert iron of this other iron-bearing materials to iron and steelanCOisnuavdbebyruc rate of reaction. While some progress has been mad ovrteyast mrv h tlzton fceity hsics, and carbon, as discussed 'below, the amount reur isdcae ylw thermodynamics, and current usage is very cls otertclmnmmlvl.Cnequently, to reflect the any policies or initiatives designed to decreas ste nutycarbon emissions need manmer as fiundamental principle that carbon used as a redcat antbe reduced in the same other carbon-based fuels. made by Steel is produced by two methods in the U.S. +emajority (about 53% in 2001) is 70 to 80% integrated steelmakers in basic oxygen furnaces (BOFs), which typically use about in blast molten iron and 20 to 30% scrap. Molten iron [used in BOFs is principally produced furnaces from iron ore or ore concentrates, wh Ich consist of oxide minerals containing less than in the rock 65% iron. The remainder of the ore consists of oxygen and impurities contained formations from which the ore is extracted. In the blast furnace, coke, produced from coal Other having certain chemical and physical properti s, is typically used as the source of carbon. carbon-bearing materials such as coal, coal derivatives, natural gas, or petroleum products can in a blast also be used as a source 'of carbon to supplement a portion of the coke. Iron produced furnace usually contains 3 to 4% carbon, which subsequently must be reduced to less than 1%
  • 2. carbon in a steelmaking furnace to produce comihercial grade steels. This is accomplished in a BOF where the molten iron is combined with scr Ip and refined and alloyed to produce the desired grade of steel. The main function of coke and other carbon-bear~ing materials vised in the blast furnace is to provide the source of carbon that serves as the chemical reactant to convert ('reduce') the iron ore to iron and to sustain the chemical reactions rquired for the process. *Coke also has the physical characteristics to provide the necessary structural support for the blast furnace burden and to serve as a porous material so that the redcig gases can pass through the burden materials. Alternatives to the blast furnace prots such as direct-reduction and direct-smelting processes, have been developed in recent year adare still evolving. These processes allow for iron to be produced without the need for coke, but they still require sources of carbon, typically coal or natural gas, to reduce the iron oxides to iro. ElA~s account for the remainder of raw steel production in the U.S. (about 47% in 2001). EAFS use electricity as the primary source of energy tomelt the charged materials, which typically consists of nearly 100% recycled steel, or scra. Bcause the EAF process is mainly one of melting scrap as opposed to reducing oxides, ca ins is not as dominant as in the blast role furnace/BOF process. However, depending on the characteristics of the charged materials, some carbon may be added to serve as a chemical reductant or may be contained in the charged materials themselves. Also, carbon is often associated with the generation of electricity used in the process. Although EAF production has increased incrementally in recent years, the demand for steel in a growing economy cannot be met Shilely from recycled steel. In fact, some EAM producers have begun to use iron substitutes to displace some of the scrap. Prog~ress Toward Greenhouse Gas Emission Reductions Following are a nuinber of examples as to how -energy and correspondinig C0 2 emission reductions have been accomplished in the U.S. steel industry. The recovery of byproduct gases is common prciei negrated steel plants. The blast furnace process generates large amounts of byproduc <atfraegas. Some of this gas is used directly to support the blast furnace process by prehetg bls i n regenerative "stoves." The remainder is typically utilized in boilers to prouesta sed to drive the blowers that sustain the process and for other uses throughout the pln for other process and heating purposes. Some plants also generate electricity from this byproduct fuel, and the steel industry was a pioneer in cogeneration using blast furnace gas. In coke ovens, byproduct coke oven gas is also recovered for a variety of uses. About 40% is typically UsIed to underfire the ovens themselves and the remainder is used for various process and heating purposes throughout the plant. Some companies also utilize waste heat from other pijocesses (e.g., slab heating furnaces) to produce steam. These uses of byproduct fuels have a significant effect in reducing overall iron and steelmaking energy requirements that would otherwise have to be provided by purchased energy sources, and in recent years companies have strived to maximize use and minimize flaring of these gases. Advancements in blast furnace technology begining in the 1950s have resulted in significant reductions in the amount of coke required for iron production. These included benieficiation of
  • 3. and pellets that improved blast furnace ion ore and other raw materials and the use of Site coke rates, which in turn reduced the operation anid allowed for the reduction of blast f~race pulverized coal injection and natural gas demand for production of coke in coke ovens. Ueof technology alternatives to blast furnace injection has also reduced coke rates. A number of all are dependent on fossil fuel as a source ironmaking are in various stages of developmen but of carbon and many are still coal-based. on energy consumption. In the 1960s, basic Steelmaking trends have also had significant imact open-hearth furnaces, and open oxygen steelmaking began to displace the more enryintensive of EAFs increased the use hearths were completely phased out by 1991 In adton, 1960 to nearly 50% today. The greater dramatically from less than I10% of overall produtinin advances in furnace design and operation use of EAFs also stimulated numerous technological intended to improve EAF productivity. and steel and corresponding increases in The trend toward more continuous processing of iron in energy efficiency. The prime example of yield has also given rise to significant improvementms from nearly 0% in 1960 to about 95% this is the increase in continuous casting, which rose energy-intensive steps previously associated today. Continuous casting has eliminated severa continues with the adoption of thin slab, with production of intermediate steel shapes. Tattrend Continuous casting and other improvements in strip, and other near-net-shape casting procese. raw steel production and shipments, manufacturing efficiency have closed the gap betwen ton of steel product. Yields are now near which means that less energy is required to prjuea 95% as compared to about 70% in the 1960s ad 1970s. improvements in energy efficiency. Numerous other advancements also contribute t~o overall flexible and effective instrumentation, on- They include: computerized process controls, more scrap preheating, more efficient motors, line sensors, hot charging, improved furnace insulation, refractories, reduced processing delays improved, reheat furnace burner technology, im~proved and better energy management generally. due to improved maintenance and scheduling practices, in partnership with the U.S. Department of The industry has a major collaborative R&D program Program (TRiP). An investment of $26 Energy entitled the Technology Roadmap Research of improved productivity, energy million is earmarked for TRiP projects with thel goals utilization, and emissions reduction. role of recycling in minimizing energy Overarching all of these improvements is the dominant infrastructure for recycling of iron and steel consumption associated with steel production. The of iron and steel scrap in all types of scrap has been in place for the past century andI utilization for decades. Recycling of automotive steel, steelmaking furnaces has been a common practice result, steel is the most recycled material in for example, is typically on the order of 98%. As a to produce steel from 100% scrap is commerce. This is important because the energy required virgin iron ore. Although there are about one-third of that required to produce stelel from be processed in IBOFs and EA-Fs, other inherent differences in the amount of scrap th'at can overall economic growth that dictates factors - such as scrap availability anid quality4 and the ability to increase the use of scrap- placement of steel into long-term applications - limit example, despite dramatic increases in EAF based steel production. Over the past 20 year, for from recycled iron and steel sources production, the overall percentage of new steel produced contintie to seek ways to recycle iron- has ranged from 65-70%. Nevertheless, steel companies
  • 4. through the work of the Steel Recycling bearing dusts, sludges, and other materials. Moreover, to promote greater public awareness of Institute, the industry has undertaken significant ~fforts through such initiatives as curbside recycling, steel recycling and expand recycling infrastructie municipal programs, and appliance take-back programs. energy and reducing related Finally, steel products play a significant role in cnserving basis. For example: a life-cycle greenhouse gases, particularly when evaluated on allowed for production of more energy- *Advancements in so-called "electrical steels' have and transformers. efficient electrical equipment such as motors capacitors, and lighter than conventional high *Advanced and Ultra High Strength Steels are stronger in cars and trucks and allow automotive strength steels. These new steels are now bigused design high-mileage steel vehicles, designers to maximize structural efficiencye n thus to retain their recyclability. This is which are not only affordable and recyclal btcontinue safety demanded by consumers. The all accomplished while retaining the driver and family Concepts (ULSAB-AVC) program, a Ultra Light Steel Auto Body - Advanced VeIhicle worked with Porsche Engineering to consortium of domestic and international steelmakers, and environmentally responsible. develop a vehicle that was safe, affordable, .itel-efficient, around the world with a design The results of this program provided auto m~anufacturers for a five-passenger sedan with 52 mpg utilizing these new Advanced High Strength Steels 7 projected 2004 safety requirements (gas) and 68 mpg (diesel) performance, whi le meeting vehicles. U.S. and international and costing no more to manufacture than present-day designs into their current production automakers are beginning to incorporate ULSAIB-AVC and emissions reductions. The DOE vehicles, which will accelerate improved f~leconomy to the manufacture of Advanced High TRIP program noted above contributes significantly Strength Steels. allows for more energy-efficient homes *The use of steel framing for residential construction other-wise be harvested for construction of and preserves carbon-absorbing forests tha would wood-framed houses. '4