Resource efficient
steel production
B. De Lamberterie
Secretary General
ESTEP
ESTEP’s main characteristics
• Among the first ETPs created in Europe
• Financially supported by the EU steel industry only
• Focused on topics linked with Societal Challenges
for Europe
• Living Strategic Research Agenda( SRA)
• Wide panel of stakeholders ( Academia, Research
and Technology centers, E .Commission, Member
States representatives, suppliers, clients...)
• Strong involvement in People activities
2meeting with WssTP, september 27 2010
Research Areas to meet the aims of Sustainable Development
6 working groups for the 6 vertical areas
Rational U
se o
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nerg
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Resid
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Att
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eta
in q
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3meeting with WssTP, september 27 2010
B. De Lamberterie
Secretary General
Organisational &
ManagementSupport
Organisation
Steering Committee
M. Wurth (Arcelor Mittal) K.Adams (Corus)
E. Gibellieri (EMF/CCMI)
Support Group
P.Schwab (VoestAlpine) K. P Imlau (TKS)
P.Gimondo ( CSM)
Working Groups
Decision-making level of
the Stakeholders
Management-level
working body
Expert-level
working groups
Profit
Innovation
Partners
Automotive
Partners
Construction
Partners
EnergyPlanet People
Ch.Marique(CRM)
O. Hoffmann
(TKS) T. Hurd(Corus)
P. Gimondo(CSM)
J.P Birat
(ArcelorMittal)R.C Meiler
(TKS)
Mirror GroupMember States
Implementation group/CommunicationB.De Lamberterie /W. Moonen(Corus)
4meeting with WssTP, september 27 2010
The SRA of ESTEP answers the
following challenges
Development of Safe, clean, energy-efficient and cost-effective technologies
Reducing the CO2 emissions directly in steelmaking and indirectly by offering suitable steel solutions
Promoting conservation of resources, recovery of wastes and societal value of materials ( SOVAMAT)
Contributing to the development of Energy sources for the future
Attracting and securing highly skilled people
5meeting with WssTP, september 27 2010
ESTEP’s Roadmap on
sustainable use of resources
6meeting with WssTP, september 27 2010
Resources: issues and R&D areas
Iron ores and scraps
• Optimising the use of lower grade ores
• Recovering Fe units from in-plant residues in
dedicated tools ( field for R&D and demo projects)
– BF and BOF dusts and sludges
– Electric Arc Furnace (EAF) dusts, oily mill scales
• Optimising scrap recycling
– Today 40% of crude steel within EU27 is produced by
the scrap + EAF route
– Still a potential to increase gradually this rate up to 50%
in the next 20 years thanks to larger available quantities
and better control of scrap qualities
7meeting with WssTP, september 27 2010
Resources issues and R&D areas
Resource & Energy efficiency (1)• Resource & Energy efficiency partnership ( REP)
– Energy Intensive Industries ( EIIs) are key actors in today’s
European Economy
– Recently was established informally a R&D network with
material producers ( steel, non ferrous, glass, cement,
chemicals, paper..) and equipments suppliers ( represented
by Eunited) named REP
– Steel industry is in favor to reinforce this REP R&D network,
publishing an position paper ( oct 2010) in order to :
• Exploit the potential of REP in European research, fully integrated
in the Framework Programme ( FP7 and FP8)
• Strengthen the role of REP in the PPP Factory of the Future
• Promote demonstration projects and deploy key enable technologies
• Coordinate skills development within REP
8meeting with WssTP, september 27 2010
Resources issues and R&D areas
Resource & Energy efficiency (2)
• Energy efficiency in the steel industry
– adoption of the SET-Plan methodology, with a single format
of the definition and the follow-up of energy consumptions
– To address both integrated BF/BOF and scraps+EAF plants
– Identification and evaluation of potential gains
• Carbon needs for reduction
• Energy efficiency of the equipments and processes : roadmap
« intelligent steel manufacturing » in the frame of the PPP FoF
• Energy recovery
• Maximizing the use of scraps
• Process yield improvement
• Application of steel products : transport, construction, steel for energy
9meeting with WssTP, september 27 2010
Resources: issues and R&D areas
Ecological services
• Ensure the water supply for the long term– Improvement of water intake, water discharge, close loop
concept, minimization of water use/waste
– EU steelmakers active in the Worldsteel water project
• Monitor and improve the air quality
• Prevention of the noise
• Steel industry very active in the BREFs and
IPPC approach.
• Preservation of the biodiversity and the land
quality & use
• Ecological village : synergy between industries
and communities. 10meeting with WssTP, september 27 2010
Resources: issues and R&D areas
Global warming
• Medium term approach
– Strong link between energy efficiency and GHG issue:
Energy savings induce reduction of CO2 emissions
– Increase scrap recycling : scrap route emits by the factor
5 significantly less CO2 emissions, including carbon for
electricity
• Long term approach: the ULCOS project
– 2 demonstrations projects are planned so far:
• the BF with TGR( Top Gas Recycling) and CCS with 50%
reduction of CO2 emissions
• Hisarna ( direct reduction with pure oxygen ) with 80% reduction
11meeting with WssTP, september 27 2010
Sustainable water management ( 1)
2 main production routes :
-Blast furnace & converter- Scraps + Electric Arc Furnace
12meeting with WssTP, september
27 2010
Sustainable water management ( 3)• EU 27 steel production is around 200mt/year, before
the crisis with 60% by Blast Furnace route and 40%
by scraps+ Electric Arc Furnace Route.
• The BF/BOF (Blast Furnace/ Basic Oxygen furnace)
route is much more demanding in water than the EAF
route.
• For the 120mt/y of crude steel with BF/BOF , the net
consumption of water is between 1 and 5m3/ ton of
steel and average at around 2.5m3/ton of steel.
• Total intake is around 30m3/ton , so total discharge
water is 27.5m3/ton. Some plants are working in
close loop. 13meeting with WssTP, september 27 2010
Sustainable water management ( 4)
• In steelmaking water is used for
– Cooling ( the major part), especially for the Blast
Furnace, the coke cooling, the continuous casters and
the hot rolling.
– Cleaning ( waste gas cleaning) , mainly for Coke Oven
gas and Blast furnace gas
– Steam use
– Other chemical use such as HCL pickling, emulsions
for rolling, degreasing of steel sheet surface etc…
14meeting with WssTP, september 27 2010
Sustainable water management ( 5)
• Within the World Steel Association, a water
management working group was set-up in 2008.
• The purpose is quantified the amounts of water
used, the different treatment methods, the rate of
reuse of treated water, the quality of discharged
water .
• Exchanges on techniques applied and best
practices.
15meeting with WssTP, september 27 2010
Sustainable water management ( 6)
• Topics of interest between ESTEP and WssTP
– Water and energy
– Water sourcing
– Water treatments
– Water related costs
– Water qualities ( depending on the processes)
• Trends for discharged water ( like Chemical Oxygen
demand, Suspended materials)
• Softening optimisation
• Health & Safety ( ie legionella )and environment
• Sludges and brines
- Global water management for industry 16meeting with WssTP, september 27 2010