DECARBONISATION OF STEEL MAKING

Latest Context

Hydrogen is a crucial part of the world’s plans to greenify its manufacturing and automobile industries as a fuel whose production and use needn’t emit carbon. Hydrogen can also be used instead of carbon in an important chemical reaction that contributes to 5-7% of the global greenhouse-gas emissions and 11% of carbon dioxide emissions.

What is the Direct Reduction Process by Hydrogens in Steel Making?

• The direct reduction process by hydrogen is a method used in steel making to produce iron from iron ore. The process involves the use of hydrogen gas to reduce iron ore pellets or lump iron ore into metallic iron.
• Iron ore is crushed and screened to obtain particles of the appropriate size for the reduction process. The iron ore is then mixed with a reducing agent, usually natural gas, and passed through a furnace where it is heated to a high temperature.
• Hydrogen gas is then introduced into furnace at temperatures ranging from 600 to 800-degree Celsius, where it reacts with the iron oxide in the iron ore to form water vapor and metallic iron.  
• It is also known as the "green route" for steel production because it reduces the carbon emissions.

                                                           Fe2O3 + 3H2 → 2Fe + 3H2O

Significance:

• Low Carbon Emissions: Hydrogen act as a reducing agent and produces only water vapor as a by-product. It reduces carbon emissions up to 97%.
• Energy Efficiency: The process is more efficient because there is no need for heating and melting huge quantities of iron ore in a furnace.
• High Quality Steel: It produces high-quality of iron that contain low level of impurities.
• Cost-Effective: It reduces the dependence on imported fossil fuels and improving the competitiveness of steel producers and a carbon-constrained world.

Use of Hydrogen in Industries other than Steel Making

• Energy: Hydrogen can be used as a fuel in fuel cells to generate electricity with zero emissions.
• Chemical Production: Hydrogen is used as a feedstock for the production of chemicals such as ammonia, methanol, and hydrogen peroxide.
• Electronics: Hydrogen is used in production of electronic components such as semiconductors, flat panel displays and light-emitting diodes (LEDs).
• Food Process: Hydrogen is used in the food industry to hydrogenate vegetable oils, which converts liquid oils into solid fats.
• Note: National Green Hydrogen Mission (NHEM) is an initiative by the Indian government to incentivise the commercial production of green hydrogen. This mission announced in Union Budget 2021-2022 and aimed at reducing the country’s carbon footprint and promoting the development of a sustainable energy system.

 Status of Steel Production in India

• Production and Consumption: India is 2nd largest producer of crude steel (as of 2021) and also the 2nd largest consumer of finished steel (as of 2021) in world.
• Centres of Steel-Producing in India:  Durgapur (West Bengal), Jamshedpur (Jharkhand), Burnpur (West Bengal), Rourkela (Odisha) and Bokaro (Jharkhand), Bhilai (Chhattisgarh).
• Export: India export steel products in several countries such as US, the UAE, and Nepal.
• Government Policies: National Steel policy launched in 2017 which projects crude steel production of 255 MT, capacity of 300 million tonnes (MT), and a finished steel per capita consumption of 158 Kgs by 2030-31.
• Steel Industry and GHG Emissions: The steel industry is responsible for around 7% of global CO2 emissions according to the International Energy Agency (IEA).
• Pollutants from Steel Industries:

1. Particulate Matter (PM2.5 and PM 10)
2. Oxides of Sulphur
3. Oxides of Nitrogen
4. Carbon Monoxide (CO)
5. Carbon Dioxide (CO2)
6. Solid Waste

• Green Steel: To reduce CO2 in steel industry with promotion of Green Steel by the Ministry of Steel.

Challenges

• High Costs: Hydrogen production and storage can be expensive. Hence, it is costly.
• Availability of Hydrogen: There is a limited supply chain for hydrogen and existing infrastructure needs to be upgraded or developed to support the widespread use of hydrogen in steel production.
• Safety: Hydrogen is highly flammable and requires careful handling and storage.
• Equipment Modification: It need to be modified to accommodate the use of hydrogen, which could involve significant capital investments.

Way Forward

• Investment: Governments and the private sector should increase investment in R&D of green hydrogen production technologies, which can help to reduce the carbon footprint of steel production.
• Foster international cooperation: Collaboration between steel producers, hydrogen producers, governments and research institutions can help to address technical challenges and promote the development of infrastructure.
• Policy: Governments provide policy support through incentives such as grants, tax credits, and loan guarantees to encourage the adoption of this technology.

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