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Boston Metal looks to disrupt and decarbonise steel and iron ore industries

Boston Metal is looking to decarbonise the steel-making sector at the same time as helping iron ore producers with their Scope 3 emissions dilemma.

The concept of ‘green steel’ has been widely discussed over the last few years, with LKAB, SSAB and Vattenfall’s HYBRIT project being the most cited case study, thanks to both its advanced stage of development – it has already produced fossil-free steel on a trial basis – and its revolutionary way of introducing hydrogen in place of coke as the iron ore reduction method in the steel-making process.

SSAB and LKAB are leveraging HYBRIT to completely transform their production processes: SSAB is building new hydrogen-based steel making facilities able to match its current base of 8.8 Mt/y of steel by 2030 and LKAB is moving from iron ore pellet production to direct reduced iron (DRI) in line with this.

Tadeu Carneiro, Chairman & CEO of Boston Metal

The ambitions of such a project are impressive, but can such a green steel-making process be applied to the circa-1,900 Mt of steel currently being produced for the world market?

The answer is no, according to Tadeu Carneiro, Chairman & CEO of Boston Metal.

He expands on this: “There are four ways of reducing iron oxides into a metal for steel-making. One is through the use of carbon; another way is through using another metal as a reductant, which is currently not feasible; the third one is with hydrogen, which is possible – as HYBRIT has shown – but is limited to premium iron ores; and the last is through our solution.”

The solution in question is – like HYBRIT – a green option, but – unlike HYBRIT – is applicable to all iron ores, regardless of grade, according to Carneiro.

Boston Metal’s process, which it calls Molten Oxide Electrolysis (MOE), works by adding iron ore to an electrolytic cell and passing electricity through said cell. The electricity both breaks the bonds of the iron oxides present, as well as heats up the whole batch within the cell, creating molten iron that sinks to the bottom of the cell ready for collection (tapping).

During the bond breaking and heating process, MOE produces oxygen as a by-product, with the resultant oxides forming the electolyte and remaining in said electrolyte (floating above the liquid iron).

“Because it is molten, the iron gets separated from the electrolyte and sits in the bottom of the cell,” Carneiro said. “As the molten iron is heavier than the electrolyte, the impurities float to the top and can be tapped separately.”

So, not only do companies using MOE get a molten iron product, they also get a slag by-product that can be used in various applications in the construction industry – all without using coking coal or coke.

“In traditional blast furnace-based steel making, you have to pelletise or sinter the iron ore, you need to process coking coal into coke and you then have to mix the two in the blast furnace and blow air to get pig iron,” Carneiro explained. “This pig iron contains around 4% carbon, which needs to be burnt off through, typically, a process in the basic oxygen furnace to get molten iron.”

Boston Metal’s MOE process gets to this same point using just iron ore and electricity, according to Carneiro.

“All of this is replaced by a battery of cells that, when assembled in significant numbers, can compete with blast furnaces in terms of molten iron capacity,” he said.

Carneiro expanded on what he meant by ‘significant numbers’, offering up an example of 300 MOE modules assembled in two lines of 150 able to produce 1 Mt of steel.

And all of this is in an incremental capital expenditure range within the millions of dollars, instead of the billions of dollars often required to build a traditional steel-making plant.

This puts a green process in the reach of not only steel-makers but iron ore producers, according to Carneiro.

“If you have green electricity at an iron ore mine, you can bring the cells there, melt the iron and ship a metallic product to steel-makers,” Carneiro said.

This pure iron product can be remelted elsewhere and processed into flat and long steel products for the automotive and construction industries.

“This represents a higher value-added product for iron ore miners, enabling them to ship a product that is 40% lighter in terms of weight,” Carneiro explained.

Finding a ‘green’ end-user that brings down a miners’ Scope 3 emissions while holding a molten iron ore product is a lot easier than finding one when shipping iron fines, concentrate or sinter: hence the reason why iron ore miners’ Scope 3 emission goals appear a lot less ambitious than the Scope 1 and 2 targets within their control.

It is no wonder BHP and Vale have been early backers of Boston Metal.

It sounds too good to be true, and there is a reason for that.

From speaking to Carneiro, the company could start producing molten iron through the chosen method today – not at a scale the steel-industry would yet consider commercial, but at a pilot scale at least.

For the commercial process to be considered green, the company would need renewable electricity to do this; and lots of it.

Carneiro doesn’t shy away from this, explaining that MOE will require 4 MWh of electricity per tonne of steel to work at such a scale. This is the equivalent of up to 500 MW for a 1 Mt/y molten iron plant.

The incumbent process Carneiro and his US-based team are looking to take market share from requires 5.5-6 MWh of energy per tonne of steel, while the electric arc furnace (EAF) method of making steel – which uses predominantly scrap metal – has a much smaller electricity requirement.

“If you had 2 billion tonnes of scrap to be melted, the EAF route is the best way to make steel, hands down,” Carneiro admits. “The problem is you don’t have such scrap availability and, in order to increase supply, you would need lots more steel coming from iron ore.”

For reference, the HYBRIT process is expected to require 600 MW of hydrogen electrolyser capacity to 2025 to get LKAB to the 1.3 Mt/y sponge iron (DRI) mark.

Yet, scrap steel is not the only thing in short supply currently. Green electricity is far from abundant, with only the likes of Quebec (hydro power capacity) and some Nordic countries having a plentiful supply – a fact Carneiro acknowledges.

“If you don’t believe that green electricity will be available, abundant, reliable and cheap in the future, you can forget about the MOE process,” he said. “But then you also have to forget about a lot of other processes that are set to use green electricity and the massive amounts of investment the green energy space is seeing on an annual basis.

“Society has decided to go electric and to go electric in a green way, so it is only reasonable to expect that, in the future, electricity will be all of this.”

Carneiro is planning for such a transition, with his company in the process of commissioning a full-size industrial MOE cell at its Woburn, Massachusetts headquarters. This could be ready as early as next month.

It follows a trial of a pilot cell at Brazil-based ferroniobium producer CBMM’s production plant in Araxá, Brazil, where the technology was able to use the same process to turn niobium ore into high-value ferroniobium-based products.

“We were able to prove out the process with CBMM on a smaller scale, which has given us the confidence to make a much bigger cell.”

The company plans to use this bigger cell and, through a subsidiary in Brazil, take advantage of other opportunities to extract value from mining waste using the MOE technology. This could see Boston Metal assemble a battery of MOE cells to manufacture some 5,000-10,000 t of high value-added metals.

While this is deemed ‘pilot scale’ for steel producers, it is sizeable for those producing high value-added products such as niobium, vanadium, tantalum, chrome and others, Carneiro said. And the project will only aide the company’s steel-making ambitions.

“By developing the cell for these high value-added metals, we are finding lots of the answers for the steel-sized cells as well,” he said.

Such groundwork today is preparing the company for a time when steel-makers and iron ore miners have assessed the green electricity landscape and are ready to invest in such technology.

“All the leading steel-making companies have made pledges to be carbon neutral by the 2050s,” Carneiro said. “This means they need to phase out carbon reduction by the mid- to late-2030s. By this point in time, we will be ready to offer our solution on a commercial scale, allowing them to take advantage of the abundance of iron ores – low and high grade – around the world.”

BHP and Tata Steel to partner on low carbon iron and steelmaking tech

BHP has signed a Memorandum of Understanding (MoU) with India’s Tata Steel, one of the world’s largest steelmakers, with the intention to jointly study and explore low carbon iron and steelmaking technology.

Under the partnership, BHP and Tata Steel intend to collaborate on ways to reduce the emission intensity of the blast furnace steel route, via two priority areas – the use of biomass as a source of energy, and the application of carbon capture and utilisation (CCU) in steel production. The partnership aims to help both companies progress toward their respective climate change goals, and support India’s ambitions to be carbon neutral, BHP said.

The technologies explored in this partnership can potentially reduce emission intensity of integrated steel mills by up to 30%. Importantly these projects demonstrate how abatements applied to the blast furnace iron-making process, which contributes to more than 60% of India’s steel production, can materially reduce the carbon intensity of existing capacity.

Beyond these projects, BHP and Tata Steel have committed to a robust ongoing knowledge exchange that will see both parties explore further collaborations, ecosystems and business opportunities in the steel value chain, and the research and innovation sectors in both India and Australia.

BHP’s Chief Commercial Officer, Vandita Pant, said: “The partnership with Tata Steel highlights the importance of collaborations in being able to successfully identify and implement emission reduction technologies in steelmaking, including by developing abatements that can apply to the existing blast furnace process to incrementally reduce its carbon emissions intensity.”

She also highlighted how BHP can contribute to Tata Steel’s, and the broader steel industry’s role in helping to achieve India’s ambitions to be carbon neutral, particularly as India is expected to see robust steel demand growth over the next three decades, underpinned by a growing population and rising urbanisation.

“India has invested heavily in the blast furnace route for steel production, and crude steel output was 118 Mt last year,” she said. “It is, therefore, critical to innovate and demonstrate pathways to reduce emissions from the blast furnace, while alternative steel pathways emerge and low carbon energy systems scale-up.

“A greener steel industry will be integral for India’s growth and decarbonisation journey, and we intend to work hard with Tata Steel to enable this development and hopefully set a benchmark for others in the industry to emulate and learn from. Finding pathways to net zero for steelmaking is challenging and complex but we believe that by working with industry leaders like Tata Steel, together, we will find solutions more quickly to help reduce carbon emissions in steel production.”

Speaking on the partnership, Tata Steel’s Vice President, Group Strategic Procurement, Rajiv Mukerji, said: “The steel sector will play a critical role in achieving India’s net-zero commitment. Tata Steel is already working on several pilot projects focussed on the development of deep decarbonisation technologies such as CCU, hydrogen-based steelmaking, use of biomass and other alternate ironmaking routes. We believe strategic collaborations are vital in paving the way for innovations to accelerate the deployment of breakthrough technologies at scale and therefore this partnership with BHP is an important step for us.”

Tata Steel and BHP have been heavily involved in establishing partnerships with like-minded industry leaders in reducing emissions in steelmaking. BHP has, in recent years, partnered with global majors POSCO, China Baowu, JFE Steel and HBIS Group to explore greenhouse gas emissions reduction from steelmaking. The combined output of the five steel companies across Asia – in China, India, Japan and South Korea – equates to around 13% of reported global steel production, BHP says.

Rio Tinto to provide Salzgitter with iron ore for hydrogen direct reduction steelmaking trials

Rio Tinto and the Salzgitter Group have signed a Memorandum of Understanding (MoU) to work together towards carbon-free steelmaking by studying optimisation of Rio Tinto’s high-quality Canadian and Australian iron ore products for use in Salzgitter’s SALCOS® green steel project in Germany.

Under the MoU, the two companies will explore optimisation of iron ore pellets, lump and fines for use in hydrogen direct reduction steelmaking. The two companies will also explore the potential for greenhouse gas emission certification across the steel value chain.

Rio Tinto produces iron ore pellets and concentrate at Iron Ore Company of Canada and iron ore lump and fines in Western Australia’s Pilbara region. The partnership will focus on the potential use of these products in the SALCOS – Salzgitter Low CO2 Steelmaking – program, which is targeting virtually carbon-free steel production, starting step-by-step in 2025 using hydrogen direct reduction.

Rio Tinto Chief Commercial Officer, Alf Barrios, said: “We welcome the chance to work with Salzgitter on ways to accelerate green steelmaking, in keeping with our commitment to reduce emissions across the steel value chain.

“Salzgitter has one of the world’s most advanced green steelmaking projects. Rio Tinto is excited at the opportunity of supplying our product and combining our technical expertise with that of Salzgitter to help advance the SALCOS project.”

Salzgitter Flachstahl GmbH Chairman of the Management Board, Ulrich Grethe, said: “With this alliance, we want to combine the knowledge of both companies to make further progress with low-carbon steel production.

“In this context, the Salzgitter Group is relying on strong partners, as set out in our ‘Salzgitter AG 2030’ Group strategy, in line with its motto of ‘Partnering for Circular Solutions’.”

The agreement follows a similar technical cooperation pact signed with LKAB last week, which could see the Europe-based iron ore miner supply high-quality iron ore pellets to Salzgitter for its SALCOS project.

Rio Tinto says it is committed to reaching net zero emissions by 2050 and is targeting a 15% reduction in Scope 1 & 2 emissions by 2025 (from a 2018 baseline) and a 50% reduction by 2030. Rio Tinto’s approach to addressing Scope 3 emissions is to engage with its customers on climate change and work with them to develop the technologies to decarbonise.

Under the SALCOS program, Salzgitter’s carbon-based blast furnace route will gradually be replaced from the middle of this decade by direct reduction plants, initially operated by natural gas and then with a steadily increasing proportion of hydrogen.

Fortescue’s Forrest opens up about iron ore miner’s ‘green steel’ ambitions

Fortescue Metals Group Chairman and founder, Dr Andrew Forrest (pictured), has revealed the iron ore miner has plans to build Australia’s first “green steel” pilot plant this year.

A commercial plant, powered entirely by wind and solar, could be constructed in the next few years he said in the first Australian Broadcasting Corporation (ABC) Boyer Lecture for 2021, entitled: ‘Oil vs Water: Confessions of a Carbon Emitter’.

In a wide-ranging talk, he acknowledge that Fortescue was trialling both known methods of making “zero-carbon-steel” without the use of coal in Australia: replacing coal in the furnace with ‘green hydrogen’ and adding carbon separately to strengthen the steel, and “zap[ping] the ore with renewable electricity”.

On the development of such an industry, Forrest said: “We could look at losing our coal industry as a national disaster – yet, I’ve always believed, out of every setback, is the seed of equal or greater opportunity.

“We produce over 40% of the world’s iron ore. And our potential green energy and hydrogen resources are immeasurable.

“If Australia were to capture just 10% of the world’s steel market, we could generate well over 40,000 jobs – more than what’s required to replace every job in the coal industry.”

Fortescue, through its Fortescue Future Industries company, has been signing agreements to leverage hydro-electric power and geothermal energy to become one of the “world’s largest green energy and product businesses”, Forrest said.

“We’re now undertaking feasibility studies that could lead to some 300 GW of power – more than four times what Australia can produce,” he explained.

Forrest also mentioned some of the decarbonisation work Fortescue is currently working on.

Back in December, Fortescue Chief Operating Officer, Greg Lilleyman, announced the company was working on developing an in-house, non-diesel 240 t haul truck prototype that will test both battery-electric and fuel-cell electric drivetrain technology in the Pilbara of Western Australia.

Seemingly referencing this project, Forrest said: “By the end of the decade, our trucks will run on renewable energy. Imagine that: a fleet of vehicles that produces nothing more than steam as exhaust.”

He also said the company was aiming to develop “green iron ore trains” powered by either renewable electricity or “green ammonia”.

Looking at the company’s shipping operations, he said 2021 would see the company “begin to settle designs” that allow its ships to run on “zero-pollution, green ammonia”.

He added: “And we’re willing to share that knowledge, to help our competitors go green too – including Vale, one of the largest mining companies in the world.”

BHP and China Baowu take on steel industry GHG emission reduction challenge

BHP has signed a memorandum of understanding (MoU) with leading steel producer, China Baowu, with the intention, it says, to invest up to $35 million and share technical knowledge to help address the challenge of reducing greenhouse gas emissions facing the global steel industry.

The five-year partnership will focus on the development of low carbon technologies and pathways capable of emission intensity reduction in integrated steelmaking, according to BHP. Under the MoU, the deployment of carbon capture, utilisation and storage in the steel sector will also be investigated at one of China Baowu’s production bases.

BHP’s investment will be funded under the $400 million Climate Investment Program, set up last year to coordinate and prioritise projects, partnerships, R&D and venture investments to reduce Scope 1, 2 and 3 emissions, offsets and support development of technologies with the highest potential to impact change.

BHP Chief Executive Officer, Mike Henry (pictured left), said the companies would collaborate on technical solutions to use low carbon fuel sources such as hydrogen injection in the blast furnace, and explore other low emission options in support of China Baowu and the steel industry’s low carbon transformation and green development goals.

“This MoU further strengthens our longstanding relationship with China Baowu and reflects our joint determination and commitment to help reduce emissions in line with the Paris Agreement goals,” Henry said.

“BHP will invest in supporting the development of low emissions technologies, promote product stewardship and partner with others to enhance the global policy and market response to climate change. Our investments are focused on actions that can create real change in emissions.”

In September, BHP awarded a tender for world’s first LNG-fuelled Newcastlemax bulk carrier to carry iron ore between Western Australia and China, which will reduce emissions by more than 30% per voyage.

In October 2019, China Baowu, meanwhile, announced the establishment of a Low Carbon Metallurgy Innovation Centre and plans to establish a Global Low Carbon Metallurgy Innovation Alliance.

China Baowu Chairman, Chen Derong, said the MoU with BHP will further enhance and broaden the existing strategic partnership between the companies, and establish a model of joint industrial efforts to promote technological innovation and a sustainable transition to a lower carbon world.

“At the UN General Assembly, President Xi Jinping delivered an important speech that outlined China’s low carbon transformation and development,” Chen Derong said. “Low carbon transition and green development represent a major disruption to the traditional steelmaking value chain.

“As a leading company in the sector, China Baowu will take an active role in implementing low carbon technologies, working together with upstream and downstream partners.

“The global steel industry needs an open platform to jointly explore low carbon technology and roadmaps, as well as showcase to the world the efforts to reshape the steelmaking value chain.”

Consistent with the ambitions of China Baowu and BHP to drive efficiency and address emissions across the global steel industry, both companies will work together to establish a China Baowu-BHP Low Carbon Metallurgy Knowledge Sharing Center, to link complementary research and share low carbon and green development knowledge with domestic and international steel industry stakeholders, the two companies said.