Climate MRV for Africa – Phase 2

Development of National GHG Inventory

Iron & Steel (IPPU)

Project of the European Commission

DG Clima Action EuropeAid/136245/DH/SER/MULTI

Amr Osama Abdel-Aziz, Assen Gasharov, Mike Bess

and Laura Lahti

Team Leader and Key Experts

April 2017

Lead partner

Global Iron & Steel Production and Trend

Uses of Steel

Construction: columns, beams, cables, etc.

Transport: vehicle parts, etc.

Energy infrastructure: oil & gas wells and platform

components, power turbines, transmission towers, etc.

Packaging: Food and beverage packaging, etc.

In the home: Cutlery, appliances, casings

And others…

Source: wikipedia, Georg Jensen

Iron & Steel Production and Global GHG

Emissions

Source: Taras Berezowsky, MetalMiner (2013); ASN Ecofys 2013

Process emissions

(mainly from coke)

contribute

significantly to

overall iron & steel

emissions

About 4.8% of total

emissions

worldwide, including

sectors 1 & 2 (2010)

Essentials of Iron Production

Source: Jindal Trading , Metalloinvest

Two main methods:

Blast furnace ➤ pig iron

Direct reduction ➤ direct reduced iron or “sponge

iron”

Iron Production: Blast Furnace

Source: American Iron & Steel Institute, United States Steel Corporation

400 deg C

1800 deg C

Also: sinter,

pellets

Iron Production: Direct Reduction

Source: midrex.com, steelmaking.wordpress.com

900 deg C

Essentials of Steel Production

Source: http://www.stahlseite.de/ Stahlseite Industrial Photography

Two main methods:

Basic Oxygen

Steelmaking

Furnace: relies

mainly on pig iron

Electric Arc

Furnace: relies

mainly on scrap steel

Open hearth process is

disappearing

Steel Production: Basic Oxygen Furnace

Source: Encyclopaedia Britannica, https://www.britannica.com/technology/basic-oxygen-

furnace, Stahlseite Industrial Photography

Process is “basic” due to the role of

bases as a flux, e.g. MgO, CaO

Steel Production: Electric Arc Furnace

Source: INTECO; Gajic, Savic-Gajic, Savic, Georgieva & Di Gennaro. Energy, Vol. 108

(01/08/16)

Emissions Sources from Iron

& Steel Production

Energy use (Energy, Sector 1)

Production of metallurgical coke for use in

the blast furnace (Category 1A)

The CO2 emissions from all fuels burned

to heat this process (e.g. coke oven gas,

blast furnace gas, others) are considered

as energy emissions

Emissions Sources: Coking Coal for Iron

& Steel – IPCC 2006 Subcategory 1.A.2a

Emissions Sources from Iron

& Steel Production

CO2 and CH4 emissions from a variety of sources (IPPU,

Sector 2, Sub-Sector 2.C.1)

Emissions from sintering and pelletizing are considered

IPPU

Oxidation of coke and other inputs (e.g. lime)

Emissions from the blast furnace process are IPPU

Oxidation of coke and other inputs. Chemical reactions:

Coke: Iron ore:

Emissions Sources from Iron

& Steel: IPPC 2006, Subcategory 2.C.1.

Emissions Sources from Iron

& Steel Production

Sintering is a process with significant emissions in an integrated

steel mill.

Source: EMEP/EEA emission inventory guidebook (2013), Iron and Steel

Production

Source: Greenhouse Gas Emissions From Major Industrial Sources

(2000), Iron and Steel Production

Source: Greenhouse Gas Emissions From Major Industrial

Sources (2000), Iron and Steel Production

Emissions Sources from Iron

& Steel Production

Natural gas or coal may be used as fuel for pelletisation plants.

In pelletisation plants located onsite at an integrated iron and steel

facility, coke oven gas may be used as a fuel.

Source: Kobelco (2010), KOBELCO Pelletizing Process

Emissions Sources from Iron

& Steel Production

Direct reduced iron

Use of natural gas (as

reformed gas), coke

breeze, coke as

reducing agents

Source: steelmaking.wordpress.com

Emissions Sources from Iron

& Steel Production

Basic oxygen furnace

Use of limestone,

dolomite as reducing

agents

Source: Encyclopaedia Britannica, https://www.britannica.com/technology/basic-oxygen-

furnace,

Emissions Sources from Iron

& Steel Production

Electric arc furnace

Consumption of the

carbon electrodes

Emissions Potential for the Category

The emission factor per tonne of steel produced varies

greatly by technology

Basic oxygen furnace (includes iron making):

1.46 tCO2/tonne steel

Electric arc furnace (steelmaking only):

0.08 tCO2/tonne steel

Open hearth furnace (includes iron making):

1.72 tCO2/tonne steel

Source: Default EF from IPCC 2006 Vol. 3, Ch. 4, Table. 4.1

Decision Tree for Iron & Steel CO2

Emissions IPCC 2006

Source: IPCC 2006 Vol. 3, Ch. 4, Fig. 4.7

Decision Tree for Iron & Steel CH4

Emissions IPCC 2006

Source: IPCC 2006 Vol. 3, Ch. 4, Fig. 4.8

Tier 1 Method

IPCC 2006: Tier 1 Method for CO2 emissions

from Iron and Steel production

Based on multiplying production data by default emission factors

Emissions per unit of steel production vary widely depending on the

method of steel production.

It is good practice to determine the share of steel produced in different

types of steelmaking processes, calculate emissions for each process,

and then sum the estimates.

Source: IPCC 2006 Vol. 3, Ch. 4, Eq 4.4

Where:

IPCC 2006: Tier 1 Method for CO2 emissions

from Direct Reduced Iron production

Source: IPCC 2006 Vol. 3, Ch. 4, Eq 4.6

IPCC 2006: Tier 1 Method for CO2

emissions from Sinter Production

Where:

It is good practice to estimate separately the emissions from sinter production

and pellet production, using the equations provided.

Source: IPCC 2006 Vol. 3, Ch. 4, Eq 4.7

IPCC 2006: Tier 1 Method for CO2

emissions from Pellet Production

Where:

Source: IPCC 2006 Vol. 3, Ch. 4, Eq 4.8

Tier 1 Method Emission Factors

Source: IPCC 2006

Vol. 3, Ch. 4, Table

4.1

Tier 1 Activity Data

Production data at the national level, from government entities, trade associations, individual plants, or etc.

Pig iron not processed to steel

Direct reduced iron

Sinter

Pellets

Metallurgical coke

Steel production, by method (BOF vs. EAF)

Tier 1 CH4 Emissions Method

Source: IPCC 2006 Vol. 3, Ch. 4, Eq 4.12-4.14

Tier 1 CH4 Emissions Factors

Source: IPCC 2006 Vol. 3, Ch. 4, Table 4. 2

IPCC 2006: Tier 2 Method for CO2 emissions

from Iron and Steel production

Source: IPCC 2006 Vol. 3, Ch. 4, Eq. 4.9

Appropriate if there are national data on amounts of

process materials for iron & steel production

IPCC 2006: Tier 2 Method for CO2 emissions

from Iron and Steel production

Source: IPCC 2006 Vol. 3, Ch. 4, Eq. 4.9

IPCC 2006: Tier 2 Method for CO2 emissions

from Direct Reduced Iron Production

Tier 2 method based on:

fuel consumption

fuel carbon content.

Emissions from DRI production are derived from combusting fuel, coke breeze,

metallurgical coke or other carbonaceous materials, and are to be reported as

IPPU emissions. Source: IPCC 2006 Vol. 3, Ch. 4, Eq 4.11

Tier 2 Method Emission Factor

Source: IPCC 2006 Vol. 3, Ch. 4, Table 4.3

Tier 2 Activity Data & Sources

If a key category, then Tier 2 is preferred

over Tier 1

Data on amount of inputs of limestone,

dolomite, and carbon electrodes may be

available from government entities or trade

associations, but it may be necessary to

receive information from individual plants

Default carbon contents from the

Guidelines may be applied, or plant-specific

carbon contents, if available

IPCC 2006: Tier 3 Method

The Tier 3 emission estimate uses plant specific

data:

Plant-specific mass balance approach (for CO2

emissions), and

Direct emissions monitoring data (mainly for CH4

emissions)

It must address the use and offsite-transfer of all

process materials listed in Tier 2

Uncertainty in Iron & Steel Emissions

Estimates

Source of uncertainty Range How to mitigate

Tier 1

•Default emission factors

•National production data

•±25%

•±10%

N/A

Tier 2

•Material-Specific Default Carbon

Contents

•National Reducing Agent & Process

Materials Data

•±10%

•±10%

•Use site-specific

carbon contents

Tier 3

•Company-Derived Process Materials

Data

•Company-Specific Measured CO2 and

CH4 Data

•Company-Specific Emission Factors

•±5%

•±5%

•±5%

N/A

Based on: IPCC 2006 Vol. 3, Ch. 4, Table 4.4

Special Considerations for Iron & Steel

Emissions Estimates

Special care should be taken to avoid double-counting or

omissions of CO2 from the use of coke, especially in integrated

production facilities

Limestone or Dolomite used as carbonate fluxes in iron and

steelmaking, should be accounted for as part of the iron & steel

inventory emissions

QA/QC for Iron & Steel Emissions

Check site-specific emission factors and carbon contents

against IPCC defaults

Review consistency of activity data between sites / plants

Make use of expert reviews, for example by main industrial

trade organizations

Cross check against emissions reported in category 1A for

double-counting or omissions of emissions from coke, coal,

natural gas, and etc. used as reducing agents in iron &

steelmaking

Reporting Considerations for Iron &

Steel Emissions

Link reporting with emissions reported in category 1A, to

demonstrate there is no double-counting of emissions from

coke or coal used as reducing agents in iron & steel

production

Thank you!

Amr Osama Abdel-Aziz, Assen Gasharov, Mike Bess and Laura Lahti