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steel production

The Enormous Cost Of Steel Corrosion | Earth Wise

February 28, 2023 By EarthWise Leave a Comment

Global steel production has been rising for decades.  Because steel corrodes over time, part of the demand for more steel comes from the need to replace the steel used in construction materials – in everything from bridges to cars – that has become corroded over time.  Studies have estimated that the economic cost of corrosion is an astonishing 3 to 4% of a nation’s gross domestic product.  Globally, this means that steel corrosion costs the world trillions – yes, trillions with a T – of dollars each year.

On top of the staggering economic impact of corrosion, there is the fact that steel production is one of the largest greenhouse gas emitters of any industry, accounting for more than 25% of all manufacturing sector carbon emissions.  In fact, steel manufacturing causes over 10% of total global carbon emissions.  

As a result of regulations placed on the steel industry, technological advances in the steelmaking process have resulted in a 61% reduction in the industry’s energy consumption over the last 50 years.   There are continuing efforts to reduce the energy consumption of steel making and to move away from the use of fossil fuels to produce the needed energy.  But without significant improvements, just the emissions associated with replacing corroded steel could make the goals set by the Paris Climate Agreement unfeasible.

It’s hard to believe that something costing the world trillions of dollars and has a major negative impact on the climate is largely invisible.  Steel corrosion is an enormous societal challenge that has gone under the  radar for decades and therefore has not received anything like the attention it deserves.

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Reducing steel corrosion vital to combating climate change

Photo, posted July 24, 2008, courtesy of Phil Whitehouse via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio

Green Steel | Earth Wise

October 5, 2022 By EarthWise Leave a Comment

Construction using Green Steel

The Inflation Reduction Act provides $369 billion in investments to ramp up renewable energy generation and manufacturing of solar panels, wind turbines, energy storage, and electric vehicles. 

Every megawatt of solar power deployed requires 35 to 45 tons of steel.  Every megawatt of wind power uses 120 to 180 tons of steel.   Estimates are that it will take 1.7 billion tons of steel just to build all the wind turbines needed to reach net zero emissions by 2050.

This is a big problem because steel production accounts for roughly 10% of global carbon emissions and is one of the most carbon-intensive industries in the world.

Making steel is a complex and age-old process that hasn’t changed much over time.  Green steel is steel made with little or no carbon emissions.  There are a few ways to do it.  One is called the direct reduced iron method that uses green hydrogen instead of fossil fuel gas to produce iron and then a renewable-powered electric arc furnace to make the steel. 

Molten Oxide Electrolysis is an alternative green steel approach that doesn’t depend on having a green hydrogen infrastructure.  It uses electrolysis, powered by renewable energy, to separate the bonds of iron ore and produce liquid metal while releasing only oxygen in the process.

Green steel solutions rely on the availability of renewable energy, but the ultimate success of renewable energy will depend on the success of green steel.  The U.S. steel industry will leverage about $6 billion under the Inflation Reduction Act to make progress on it.

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Building tomorrow’s clean energy systems on green steel

Photo, posted October 30, 2008, courtesy of Paul Bica via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio

A Solar-Powered Steel Mill | Earth Wise

November 17, 2021 By EarthWise Leave a Comment

Greening the steel industry

The steel industry is an essential part of modern society.  Economically, the U.S. steel industry produces goods valued at more than $100 billion a year and employs more than 80,000 people.  The steel industry is also a major contributor to greenhouse gas emissions.   On average, 1.85 tons of CO2 are emitted for every ton of steel produced.  Overall, the steel industry generates between 7 and 9% of the direct emissions that come from the global use of fossil fuel.

The industry is determined to reduce its environmental impact.  Steel is 100% recyclable and indeed much of it is recycled.  Over 2 billion tons of steel were produced in 2019. Meanwhile, more than 700 million tons of steel scrap are recycled each year.  Recycling greatly reduces the energy impact of the steel industry.

The industry has also significantly reduced its energy usage over the years using sophisticated energy management systems and energy recovery efforts.  Since 1960, the amount of energy needed to produce a ton of steel has dropped by 60%.  But making steel is still very energy intensive.

Recently, Lightsource bp announced that its 300 megawatt Bighorn Solar project in Colorado will be used to allow EVRAZ’s Pueblo steel mill to be the world’s first steel mill to run almost entirely on solar power.

The solar project, which will be fully online this month, is the largest on-site solar facility in the U.S. dedicated to a single customer.  (The Bighorn Solar project features 750,000 solar panels located on 1,800 acres).

The project demonstrates that even challenging industrial sectors can be decarbonized when companies work together on innovative solutions.

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Colorado steel mill becomes ‘world’s first’ to be run almost entirely on solar

Photo, posted October 16, 2017, courtesy of UC Davis College of Engineering via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

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