The Bio Steel Cycle – net-zero CO2 emissions steel production

This research critically analyses global data on CO₂ emissions from the iron and steel industry, including related sub-sectors, to propose low-carbon and clean solutions for the sector. The different stages of resource extraction, transformation, and finally steelmaking and finishing have been examined to establish the current state of knowledge regarding CO2 emissions at each stage. A UK-centric PESTEL and SWOT analysis with the view to implementation of a green steel production cycle called Bio Steel Cycle accompany the data.
The “Bio Steel Cycle” framework could be adapted to apply to a range of industrial activities, not only the steel industry. The working title of the study: “CO2 reduction in the steel industry” led to the development of three specific research questions: ‘Which level of CO2 emissions are being produced at which stage of the steel production process?’ and ‘How can CO2 emissions be effectively reduced in steel production?’ and as a consequence ‘Can the newly developed Bio Steel Cycle framework support energy independence?’. The aim of this study was to create a universally applicable model and strategy to reduce CO2 emissions effectively and sustainably in steel production; and to refine the model in line with circular economic principles.

The different stages of the overall steelmaking process have been examined, and a comprehensive overview has been established, based on the blast furnace – basic oxygen furnace route. All emissions identified have been calculated based on the assumption of steelmaking in a 330 metric tonnes capacity furnace.
Verified industry and scientific data, such as parameters and specifications published by Thyssen-Krupp, ArcelorMittal, Voestalpine, Saint Gobain, Tata Steel, Rio Tinto and British Steel played a significant role in fact-finding, alongside peer-reviewed academic publications. Mathematical modeling and software process simulation (Aspen Plus, Simul8 and INOSIM) was used to verify and further analyse the gathered data.
It is my understanding that – theoretically – when attempting to address the three research questions, the implementation of all components within the Bio Steel Cycle, technology and mechanisms currently exist could almost eliminate the currently produced 4,760.61t of CO2 emissions along the whole line of process stages in iron and steel manufacturing. Additionally, a higher degree of energy independence of up to ~90% could be achieved and a stronger incentive to accelerate the efforts to transform the energy market into an industry based on renewable energy technologies seems achievable with the technology currently available.
Although considerable time and resources have been devoted to this study, there are clearly limitations to desktop research. Variability of data collection methods, reference points and research populations among the publications reviewed also made the acceptance of some publications difficult for the purpose of this study. However, some journal articles based on research investigating several hundred steel plants in specific countries, including carbon reports and process simulations, have provided valuable secondary data for verification.
The data contained within the production process simulation software packages are designed to be close to real-life applications but there are some areas where this appears to be lagging recent technical and knowledge advancement in industry and academia. Furthermore, until there are clear instructions, globally, on how to measure, evaluate and report greenhouse gas emissions in any given industry, the reported data provided so far, by industry and academia, requires to be treated with caution.