ENERGY & EMISSIONS IN METAL INDUSTRY

BRAJENDRA MISHRA, COLORADO SCHOOL OF MINES

Country Rank 2007 2006 Change, %

China 1  489.0  422.7   15.7Japan 2  120.2  116.2    3.4

United States 3   97.2   98.6   -1.4Russia 4   72.2   70.8    2.0India 5   53.1   49.5    7.3

South Korea 6   51.4   48.5    6.0Germany 7   48.5   47.2    2.8Ukraine 8   42.8   40.9    4.7Brazil 9   33.8   30.9    9.3Italy 10   32.0   31.6    1.2Total 1343.1 1245

CHANGE IN STEEL PRODUCTION (Mt) 2006/2007

Over the last fours years, India has increased production from 32.6 Mt to 53.1 Mt – a sizeable increase, and displaced South Korea and Germany to move from 9th to 5th position.

595

13 0.24 27

1240

40.8 0.73

230*

0

200

400

600

800

1000

1200

1400

Steel Aluminium Magnesium Plastics

Mt 1970 2006

Value estimation 2006Steel 670 B Є/aAluminium 80 Billion Є/a Magnesium 18 Billion Є/a Plastics 262 Billion Є/a

*2005

STEEL BEATS OTHER MATERIALS Production and Value 1970 / 2006 (Mt / Bil Eu)

Year Change

1873-1948 +100 Mt in 75 years

1948-1973 +400 Mt in 25 years

1973-1983 ~ 0 in 10 years

1983-1993 +115 Mt in 10 years

1993-2003 +230 Mt in 10 years

2003-2007 +379 Mt in last 4 years

MARCH IN GLOBAL STEEL CONSUMPTION

There was increase in steel consumption during 1983-2003, after a decade of no growth.

2003-2007 has witnessed hitherto unmatched increase.

CRUDE STEEL PRODUCTION: CHINA / INDIA

TYPICAL COST BREAK UP OF HOT METAL

Coke is the major cost component; yet is in short supply/expensive.

Reduction, 0.86 t

Recycling 0.68 t

Primary process, 1.54 t

Steel – excellent material in terms of sustainability – can be infinitely recycled without loss of quality. Steel from ore produces 1.54 t CO2 per tonne of crude steel

globally; 2.4-2.6 t CO2 in India.

EAF steelmaking using recycled scrap generates only 0.68 t CO2.

CO2 EMISSION IN STEEL PROCESSING (t per tcs)

After steel, aluminium is the most widely used metal. In 2006, out of 34 Mt aluminium produced worldwide, 23% was secondary aluminium. Aluminium scrap processing leads to some loss of quality, but energy is only 5% of primary production. Hence, 9.87 t of CO2 saved for every tonne aluminium produced by secondary processing.

Primary process, 10.60 t CO2

CO2 EMISSION IN ALUMINIUM PROCESSING (t/t)

Globally 35% of 17 Mt copper produced each year is from recycling of copper scrap. The secondary process saves 3.5 tonnes CO2 per tonne of copper produced – 36% improvement compared to the primary route, There is 5% material loss and some difference in quality between primary and secondary copper.

Primary process, 5.5 t CO2 Reduction,

3.52 t

Secondary Process, 1.98 t

CO2 EMISSION IN COPPER PROCESSING (t/t)

Recycling process

Reduction

CO2 EMISSIONS (t/t product) FOR STEEL, ALUMINIUM, COPPER and PAPER

Steel is the least CO2 generating metal. Paper produces less CO2, but has limited application.

CHALLENGES FOR INDIAN STEEL INDUSTRY