Improving efficiency and performance, boosting sustainability with ABB

The steel industry is one of the largest contributors to global carbon emissions, with traditional processes being highly energy-intensive. Modernizing existing facilities is essential for meeting new regulatory requirements and consumer expectations while reducing costs in the long-term. 

Industry Overview  

The iron and steel industry is responsible for around 5% of EU CO2 emissions and 7%-9% of global emissions. The steel sector needs to decarbonize its production processes by more than 50% to comply with EU 2030 and Paris Agreement 2050 climate targets. 

Innovative production methods like Direct Reduced Iron (DRI) and processes like Electric Arc Furnace (EAF) technology are revolutionizing the steel industry. These methods significantly increase efficiency throughout the production process, reducing energy consumption and emissions. DRI-EAF setups are particularly effective in producing cleaner steel while optimizing resource usage. 

New Processes: Direct Reduced Iron and Electric Arc Furnace –EAF 

Move beyond traditional steelmaking methods with Direct Reduced Iron (DRI) and Electric Arc Furnace (EAF) processes. EAF steelmaking offers a more sustainable alternative, transforming scrap metal and DRI into cleaner steel. 

• Low Carbon Production: Utilizes natural gas instead of coal-based coke, significantly lowering emissions. 

• Cleaner Steel: The EAF furnace melts direct reduced iron (DRI) and scrap steel, producing high-quality EAF steel. 

• Enhanced Efficiency: Optimized energy use through advanced motors and variable speed drives (VSDs) for compressors, fans, and pumps. 

Efficiencies throughout the process 

Energy Sources

Where commercially feasible, using hydrogen instead of natural gas in the DRI process can help achieve carbon-free steel production, especially when sourced from renewables. 

Emissions

With the end goal of carbon neutral steel production, process changes can deliver a carbon footprint of steel per kg that's significantly reduced. Embracing Carbon Capture, Utilization & Storage (CCUS) should also be considered as a strategy for decarbonizing steel.

The sustainability of scrap steel is pivotal in the context of the low carbon steel industry. Understanding energy use, emissions, and carbon counting throughout not only the manufacturing process, but the transportation and supply chain too, is essential for maximizing the potential of scrap in steel production. ABB provides state-of-the-art products and solutions to support the transition to greener steel processes, including motors and  variable speed drives that enhance efficiency and reduce emissions. 

The sustainability of scrap  

Recycling scrap metal is crucial for sustainable steel production, reducing energy use, emissions, and supporting carbon counting. 

Reduced Carbon Emissions	Energy Efficiency	Cost Savings
Recycling scrap significantly offsets the emissions associated with producing new steel, contributing to a lower carbon footprint of steel per kg.	The DRI-EAF processes are far more energy-efficient than traditional methods, making them ideal for producing low carbon steel.	By effectively recycling scrap, steel mills can reduce their carbon footprint by up to 60% while saving huge amounts of raw materials such as ore and coal.

Steelmakers must adapt their production processes to incorporate scrap metal, which may involve upgrades or redesigns for EAF steelmaking.