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electric arc furnace

Less coal for making steel

September 5, 2024 By EarthWise Leave a Comment

Using less coal in steel production

Steel is primarily produced using one of two methods:  blast furnaces or electric arc furnaces.  The first blast furnaces were built in the 14th century.  Making steel in a blast furnace starts by melting the raw materials of iron ore, limestone, and coal at very high temperatures.  The resultant reactions ultimately lead to two products:  iron saturated with carbon and carbon dioxide.  A second furnace reacts the liquid iron with oxygen to remove the carbon and results in steel along with even more carbon dioxide.

Making steel using an electric arc furnace is considerably less emissions-intensive and more sustainable.  So-called circular steel making powered by electric arc furnaces uses electricity to melt scrap and other input materials and turn them into high-quality steel.  Of course, to really minimize the emissions associated with steelmaking, the arc furnaces need to get their power from renewable energy sources. 

The global steel industry is turning away from polluting coal-fired blast furnaces and towards electric arc furnaces, which now account for roughly half of all planned new steelmaking capacity. This represents real progress towards a green steel transition.

By the end of this decade, electric arc furnaces will account for more than a third of steelmaking.  However, there are still plenty of new coal-based steel furnaces being built.  So even as electric arc furnaces account for a greater share of steelmaking, these new coal furnaces will still drive emissions upward.   Environmental advocates argue that what the steel industry needs is to make clean development a true priority and back away from coal-based developments.

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Steelmakers Increasingly Forgoing Coal, Building Electric

Photo, posted July 16, 2018, courtesy of Daniel Steelman via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio

Recycling cement

June 21, 2024 By EarthWise Leave a Comment

Recycling concrete may have a future

Concrete is the second-most-used material on the planet.  Only water is used more.  Producing concrete is responsible for 7.5% of human-produced carbon dioxide emissions.  So, finding a cost-effective way to reduce these emissions is a major challenge in the face of ever-growing global demand for concrete.

Researchers at Cambridge University have found that used cement is an effective substitute for lime flux, which is an essential material used in steel recycling that results in a waste product called slag.  When lime is replaced with used cement, the end product instead is recycled cement that can be used to make new concrete.

The process does not add any significant costs to concrete or steel production and significantly reduces the emissions associated with both.

Concrete is made from sand, gravel, water, and cement.  Cement is made by a process called clinkering, in which limestone and other materials are heated to 2,600 degrees Fahrenheit.  The process converts the materials into cement but releases large amounts of CO2 as limestone decarbonates into lime. 

Cambridge researchers found that using cement clinker and iron oxide instead of lime works well in steel recycling.  Crushing old concrete and taking out the sand and stone results in a cement that is reactivated by the recycling furnace to produce a material with excellent properties. 

Recent tests by the Materials Processing Institute showed that recycled cement can be produced at scale in an electric arc furnace.  Ultimately, this method could produce zero emission cement if the electricity for the furnace comes from renewable sources.

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Cement recycling method could help solve one of the world’s biggest climate challenges

Photo, posted July 18, 2011, courtesy of Kenta Mabuchi via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio

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