Green Steel technologies - Race Towards Achieving Netzero
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Oct 17, 2025
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About This Presentation
Green Steel Technology (GST) represents a transformative shift in the steel industry toward sustainability and carbon neutrality. It focuses on reducing or eliminating the use of fossil fuels by adopting cleaner alternatives such as green hydrogen, renewable energy, and increased scrap recycling. By...
Slide Content
1
Green Steel Technologies
(Race Towards Achieving Net Zero)
By
Dr. M. Kalyan Phani
Professor and Head
Metallurgical and Mining Engineering
O.P. Jindal University, Raigarh, India
OPJU-Sohar Lecture SeriesM Kalyan Phani
Green Steel Technologies
(Race Towards Achieving Net Zero)
By
Dr. M. Kalyan Phani
Professor and Head
Metallurgical and Mining Engineering
O.P. Jindal University, Raigarh, India
OPJU-Sohar Lecture SeriesM Kalyan Phani
Contents
➢The threat
➢Why Green Steel (GS)?
➢GS Production methods
➢Hydrogen and its importance
➢Innovations in GS
➢Benefits/Challenges/Limitations of GS
➢Government Initiatives to promote GS production
➢Conclusions
OPJU-Sohar Lecture Series 10M Kalyan Phani
➢The threat
➢Why Green Steel (GS)?
➢GS Production methods
➢Hydrogen and its importance
➢Innovations in GS
➢Benefits/Challenges/Limitations of GS
➢Government Initiatives to promote GS production
➢Conclusions
OPJU-Sohar Lecture Series 10M Kalyan Phani
OPJU-Sohar Lecture Series 11
The Threat
❖Global climate change poses an alarming threat to our planet, with the
concentration of carbon dioxide (CO
2) in the atmosphere reaching 431
parts per million (ppm), the highest in over 800,000 years.
❖UN Emissions gap: 23 GT by 2030 (1 GT = 1 Billion Tonnes)
❖Pledges and Ambitious goals of various countries are being taken.
❖Net Zero pledges: India – 2070, China – 2060, USA and EU - 2050
Urgent Requirements:
Developed countries should bring net zero
GHG by 2075 and net zero emissions by 2050.
Every ton of steel emits on an average 1.85
tons of carbon dioxide, equating to about 8
percent of global carbon dioxide emissions. M Kalyan Phani
The Threat
❖Global climate change poses an alarming threat to our planet, with the
concentration of carbon dioxide (CO
2) in the atmosphere reaching 431
parts per million (ppm), the highest in over 800,000 years.
❖UN Emissions gap: 23 GT by 2030 (1 GT = 1 Billion Tonnes)
❖Pledges and Ambitious goals of various countries are being taken.
❖Net Zero pledges: India – 2070, China – 2060, USA and EU - 2050
Urgent Requirements:
Developed countries should bring net zero
GHG by 2075 and net zero emissions by 2050.
Every ton of steel emits on an average 1.85
tons of carbon dioxide, equating to about 8
percent of global carbon dioxide emissions. M Kalyan Phani
Global Climate Crisis: Paris Agreement
12
In order to limit global warming to 2 degrees Celsius, it is estimated that global greenhouse
gas emissions need to be reduced by 40-70% by 2050 and reach net zero by 2100.
OPJU-Sohar Lecture Series
India produces >3 Billion
Tonnes of GHG
Global Average 7.5 tons
per capita
GHG Emissions trends: GloballyM Kalyan Phani
12
In order to limit global warming to 2 degrees Celsius, it is estimated that global greenhouse
gas emissions need to be reduced by 40-70% by 2050 and reach net zero by 2100.
OPJU-Sohar Lecture Series
India produces >3 Billion
Tonnes of GHG
Global Average 7.5 tons
per capita
GHG Emissions trends: GloballyM Kalyan Phani
What happens when it reaches +2.0 deg C?
13
Needs immediate action on crisis
OPJU-Sohar Lecture Series
Draughts, Deforestation,
Loss of species, Glacier
melting, increase in water
levels, unseasonal issues
in specific areas, impact
on human and ecological
systems……. M Kalyan Phani
13
Needs immediate action on crisis
OPJU-Sohar Lecture Series
Draughts, Deforestation,
Loss of species, Glacier
melting, increase in water
levels, unseasonal issues
in specific areas, impact
on human and ecological
systems……. M Kalyan Phani
Global CO2 emissions: Recent Trends &
2025 Forecasts
OPJU-Sohar Lecture Series 14
Ref: International Energy Agency data (IEA, 2008)
❖In 2024, energy-related CO₂ emissions were
estimated at ~37.8 Gt CO₂, an increase of
~0.8% over 2023.
❖The Global Carbon Budget 2024 data
supports that emissions are still rising, so
2025 is likely to hit or exceed new records
unless aggressive mitigation steps are taken.M Kalyan Phani
2025 Forecasts
OPJU-Sohar Lecture Series 14
Ref: International Energy Agency data (IEA, 2008)
❖In 2024, energy-related CO₂ emissions were
estimated at ~37.8 Gt CO₂, an increase of
~0.8% over 2023.
❖The Global Carbon Budget 2024 data
supports that emissions are still rising, so
2025 is likely to hit or exceed new records
unless aggressive mitigation steps are taken.M Kalyan Phani
Why Steel Industry?
OPJU-Sohar Lecture Series 15
❖Largest Industrial Polluters
❖Heavy Reliance on Fossil Fuels (Coal)
❖Scale and Central Role in the Economy
❖Availability of Proven Green Alternatives
❖Policy and Market PressureM Kalyan Phani
OPJU-Sohar Lecture Series 15
❖Largest Industrial Polluters
❖Heavy Reliance on Fossil Fuels (Coal)
❖Scale and Central Role in the Economy
❖Availability of Proven Green Alternatives
❖Policy and Market PressureM Kalyan Phani
Steel Industry Process
CS<36 in
2
(230 cm
2
)
CS > 100 sq cm
2,
width
2*thickness
CS>Billet CS
16OPJU-Sohar Lecture SeriesM Kalyan Phani
CS<36 in
2
(230 cm
2
)
CS > 100 sq cm
2,
width
2*thickness
CS>Billet CS
16OPJU-Sohar Lecture SeriesM Kalyan Phani
OPJU-Sohar Lecture Series 17M Kalyan Phani
Scope of Emissions
OPJU-Sohar Lecture Series 18
❖Scope 1 – Direct Emissions
❖Emissions from on-site operations and fuel combustion.
❖Includes CO₂ from blast furnaces, coke ovens, and reheating
furnaces.
❖Example: Carbon released from coal and natural gas used in
steelmaking.
Typical share: 70–80% of total steel plant emissions.
❖Scope 2 – Indirect Energy Emissions
❖Emissions from purchased electricity, steam, or heat used in
processes.
❖Arises from power generation units outside the plant
boundary.
❖Example: CO₂ from electricity supplied by coal-based power
plants.
Can be reduced by switching to renewable energy sources.
❖Scope 3 – Value Chain Emissions
❖All other indirect emissions from activities across the value
chain.
❖Includes raw material extraction, transportation, use, and
end-of-life recycling.
❖Example: Mining, shipping of ore, supply of coking coal, and
product disposal.
Represents 20–40% of total life-cycle emissions in steel.
Green steel technologies aim to cut
across all three scopes — by using
hydrogen, renewable electricity, and
circular materials.M Kalyan Phani
OPJU-Sohar Lecture Series 18
❖Scope 1 – Direct Emissions
❖Emissions from on-site operations and fuel combustion.
❖Includes CO₂ from blast furnaces, coke ovens, and reheating
furnaces.
❖Example: Carbon released from coal and natural gas used in
steelmaking.
Typical share: 70–80% of total steel plant emissions.
❖Scope 2 – Indirect Energy Emissions
❖Emissions from purchased electricity, steam, or heat used in
processes.
❖Arises from power generation units outside the plant
boundary.
❖Example: CO₂ from electricity supplied by coal-based power
plants.
Can be reduced by switching to renewable energy sources.
❖Scope 3 – Value Chain Emissions
❖All other indirect emissions from activities across the value
chain.
❖Includes raw material extraction, transportation, use, and
end-of-life recycling.
❖Example: Mining, shipping of ore, supply of coking coal, and
product disposal.
Represents 20–40% of total life-cycle emissions in steel.
Green steel technologies aim to cut
across all three scopes — by using
hydrogen, renewable electricity, and
circular materials.M Kalyan Phani
CO₂ Emissions from Conventional
Steelmaking
OPJU-Sohar Lecture Series 19
➢Coke Production:
➢Transforming coal into coke (by heating at high temperatures)
➢Emits ~0.71 tonnes of CO₂ per tonne of steel produced
➢Blast Furnace Operation:
➢Burning coke in the blast furnace for iron reduction
➢Emits ~1.41 tonnes of CO₂ per tonne of steel
➢Steelmaking Process:
➢Converting molten iron into steel in the basic oxygen furnace
➢Emits ~0.21 tonnes of CO₂ per tonne of steelM Kalyan Phani
Steelmaking
OPJU-Sohar Lecture Series 19
➢Coke Production:
➢Transforming coal into coke (by heating at high temperatures)
➢Emits ~0.71 tonnes of CO₂ per tonne of steel produced
➢Blast Furnace Operation:
➢Burning coke in the blast furnace for iron reduction
➢Emits ~1.41 tonnes of CO₂ per tonne of steel
➢Steelmaking Process:
➢Converting molten iron into steel in the basic oxygen furnace
➢Emits ~0.21 tonnes of CO₂ per tonne of steelM Kalyan Phani
Four Fronts to control Steel’s
Climate Impact
1.Transforming Steel Production Processes
❑Shift from coal-based blast furnaces to cleaner technologies like Hydrogen Direct
Reduction (H-DRI) and Electric Arc Furnaces (EAFs).
❑Focus on reducing carbon emissions in iron-making; the most carbon-intensive step.
2. Increasing Recycled Steel Usage
❑Boost the use of scrap-based steel production using electric arc furnaces.
❑Recycling saves up to 60–70% energy and cuts CO₂ emissions drastically.
3. Using Renewable Energy
❑Use solar, wind, and hydro power for electricity and heat in every production stage.
❑Transition from fossil-based to renewable-powered steel plants.
4. Producing & Consuming Less Steel
❑Optimize design and reuse materials to reduce overall steel demand.
❑Use lightweight materials and innovative designs for lower climate impact.
OPJU-Sohar Lecture Series 20M Kalyan Phani
Climate Impact
1.Transforming Steel Production Processes
❑Shift from coal-based blast furnaces to cleaner technologies like Hydrogen Direct
Reduction (H-DRI) and Electric Arc Furnaces (EAFs).
❑Focus on reducing carbon emissions in iron-making; the most carbon-intensive step.
2. Increasing Recycled Steel Usage
❑Boost the use of scrap-based steel production using electric arc furnaces.
❑Recycling saves up to 60–70% energy and cuts CO₂ emissions drastically.
3. Using Renewable Energy
❑Use solar, wind, and hydro power for electricity and heat in every production stage.
❑Transition from fossil-based to renewable-powered steel plants.
4. Producing & Consuming Less Steel
❑Optimize design and reuse materials to reduce overall steel demand.
❑Use lightweight materials and innovative designs for lower climate impact.
OPJU-Sohar Lecture Series 20M Kalyan Phani
Green Steel
OPJU-Sohar Lecture Series 21M Kalyan Phani
OPJU-Sohar Lecture Series 21M Kalyan Phani
Green Steel and Production methods
22
❖Green Steel isthe manufacturing of steel
without any Carbon emissions and
utilizing newer methods over
conventional.
❖Its fundamental objectives revolve
around the minimization of carbon
emissions, the reduction of energy
consumption, and the advocacy for
resource efficiency.
❖Its importance lies in addressing
environmental issues and promoting
sustainable development.
❖First Developed by Sweden – Hybrit
Technology
Advanced
Manufactur
-ing
Process
Circular
Economy
Principles
Renewable
energy
sources
OPJU-Sohar Lecture Series
Reasons for Requirement: >970 Steel plants in India and Country is about to see a surge in
production capacity and the GHG emissions (mainly CO2 emissions) will double. M Kalyan Phani
22
❖Green Steel isthe manufacturing of steel
without any Carbon emissions and
utilizing newer methods over
conventional.
❖Its fundamental objectives revolve
around the minimization of carbon
emissions, the reduction of energy
consumption, and the advocacy for
resource efficiency.
❖Its importance lies in addressing
environmental issues and promoting
sustainable development.
❖First Developed by Sweden – Hybrit
Technology
Advanced
Manufactur
-ing
Process
Circular
Economy
Principles
Renewable
energy
sources
OPJU-Sohar Lecture Series
Reasons for Requirement: >970 Steel plants in India and Country is about to see a surge in
production capacity and the GHG emissions (mainly CO2 emissions) will double. M Kalyan Phani
Steel Production through Renewable Technologies
23
Solar
•Abundant, inexhaustible, and widely available.
•Solar power in India is booming, and installed capacity of over 70 GW as of 2023.
Wind
•By installing wind turbines near steel manufacturing facilities.
•As of 2023, India's total installed wind capacity exceeded 41.666 GW.
Hydropower
•Utilizing the force of flowing water.
•Nearly 100 hydropower plants with a capacity above 25 MW.
Waste Heat Recovery
✓By converting this heat into useful energy, the industry can improve overall energy
efficiency and reduce its reliance on conventional energy sources.
Biomass and Biogas
•Derived from organic materials and waste.
•Biomass capacity 750 million metric tons (MMT) per year, surplus of230 MMT/year.
OPJU-Sohar Lecture Series
UNIVERSITY OF STEEL TECHNOLOGY
AND MANAGEMENTM Kalyan Phani
23
Solar
•Abundant, inexhaustible, and widely available.
•Solar power in India is booming, and installed capacity of over 70 GW as of 2023.
Wind
•By installing wind turbines near steel manufacturing facilities.
•As of 2023, India's total installed wind capacity exceeded 41.666 GW.
Hydropower
•Utilizing the force of flowing water.
•Nearly 100 hydropower plants with a capacity above 25 MW.
Waste Heat Recovery
✓By converting this heat into useful energy, the industry can improve overall energy
efficiency and reduce its reliance on conventional energy sources.
Biomass and Biogas
•Derived from organic materials and waste.
•Biomass capacity 750 million metric tons (MMT) per year, surplus of230 MMT/year.
OPJU-Sohar Lecture Series
UNIVERSITY OF STEEL TECHNOLOGY
AND MANAGEMENTM Kalyan Phani
Global vs India Trends: Renewable Capacities
24OPJU-Sohar Lecture Series
A net increase in capacities will be seen before 2045M Kalyan Phani
24OPJU-Sohar Lecture Series
A net increase in capacities will be seen before 2045M Kalyan Phani
Steel by Advanced Manufacturing
Direct reduction using natural gas or hydrogen
Melting scrap in Electric Arc Furnace
Induction Heating
Additive Manufacturing (3D Printing)
Industry 4.0 Integration
Sustainable Carbon Capture and Utilization (CCU)
25OPJU-Sohar Lecture SeriesM Kalyan Phani
Direct reduction using natural gas or hydrogen
Melting scrap in Electric Arc Furnace
Induction Heating
Additive Manufacturing (3D Printing)
Industry 4.0 Integration
Sustainable Carbon Capture and Utilization (CCU)
25OPJU-Sohar Lecture SeriesM Kalyan Phani
Hydrogen: Beacon of Hope
•Hydrogen, the lightest and most abundant element in the universe, holds immense promise for
addressing climate change and reducing CO
2 emissions in the steel industry.
26OPJU-Sohar Lecture SeriesM Kalyan Phani
•Hydrogen, the lightest and most abundant element in the universe, holds immense promise for
addressing climate change and reducing CO
2 emissions in the steel industry.
26OPJU-Sohar Lecture SeriesM Kalyan Phani
27
Advantages of Green Hydrogen as
Fuel
➢Energy Efficiency: A hydrogen fuel cell is two to three times more efficient
than an internal combustion engine fueled by gas.
➢Climate change mitigation: The method of producing green hydrogen
does not emit any green house gases.
➢Storage: Hydrogen has the highest energy per mass of any fuel which mean
that higher the density greater the amount of energy one can store.
➢Economically Sustainable: Since electricity and coking coal prices are not
linked, the 20% higher cost of hydrogen-based steelmaking can be removed
when electricity costs drop to around $15–$20 per MWh — a level already
reached by renewable power in several countries such as Brazil, Mexico,
Saudi Arabia, Portugal, and the United States.
OPJU-Sohar Lecture SeriesM Kalyan Phani
Advantages of Green Hydrogen as
Fuel
➢Energy Efficiency: A hydrogen fuel cell is two to three times more efficient
than an internal combustion engine fueled by gas.
➢Climate change mitigation: The method of producing green hydrogen
does not emit any green house gases.
➢Storage: Hydrogen has the highest energy per mass of any fuel which mean
that higher the density greater the amount of energy one can store.
➢Economically Sustainable: Since electricity and coking coal prices are not
linked, the 20% higher cost of hydrogen-based steelmaking can be removed
when electricity costs drop to around $15–$20 per MWh — a level already
reached by renewable power in several countries such as Brazil, Mexico,
Saudi Arabia, Portugal, and the United States.
OPJU-Sohar Lecture SeriesM Kalyan Phani
28
Challenges of Hydrogen usage
➢Hydrogen Supply & Infrastructure: Need reliable and affordable
hydrogen production, storage, and transport systems. Current
hydrogen mostly comes from fossil fuels, limiting emission benefits.
➢Cost Issues: Green hydrogen is still costly. High setup and operating
expenses, along with the need for new or upgraded infrastructure,
make adoption expensive.
➢Safety Concerns: Hydrogen is highly flammable, requiring strict safety
measures for storage, transport, and use.
➢Technological Challenges: Steel plants need major process and
equipment changes to use hydrogen effectively, along with workforce
training and new operating practices.
OPJU-Sohar Lecture SeriesM Kalyan Phani
Challenges of Hydrogen usage
➢Hydrogen Supply & Infrastructure: Need reliable and affordable
hydrogen production, storage, and transport systems. Current
hydrogen mostly comes from fossil fuels, limiting emission benefits.
➢Cost Issues: Green hydrogen is still costly. High setup and operating
expenses, along with the need for new or upgraded infrastructure,
make adoption expensive.
➢Safety Concerns: Hydrogen is highly flammable, requiring strict safety
measures for storage, transport, and use.
➢Technological Challenges: Steel plants need major process and
equipment changes to use hydrogen effectively, along with workforce
training and new operating practices.
OPJU-Sohar Lecture SeriesM Kalyan Phani
OPJU-Sohar Lecture Series 29
❖Lower Reduction Efficiency
❖Endothermic Reaction Nature
❖Temperature Control Issues
❖Hydrogen Injection Optimization
❖Material Compatibility
❖Water Vapor Formation
❖Process Integration
❖Hydrogen Supply and Pressure Requirements
Technical challenges of Hydrogen
in Blast FurnaceM Kalyan Phani
❖Lower Reduction Efficiency
❖Endothermic Reaction Nature
❖Temperature Control Issues
❖Hydrogen Injection Optimization
❖Material Compatibility
❖Water Vapor Formation
❖Process Integration
❖Hydrogen Supply and Pressure Requirements
Technical challenges of Hydrogen
in Blast FurnaceM Kalyan Phani
30
Steel by Circular Economy Principles
OPJU-Sohar Lecture Series
Reduce
Reuse
Remanufacture
Recycle
Circular
Economy
Benefits
Innovations
Resource
Conservati
on
CO
2
Emissions
reduction
Jobs
Improved
Efficiency
Durable
Products
❑Promotes waste reduction and resource optimization
throughout the steel production process
❑Require collaboration and integration across the
entire steel value chain, including raw material
suppliers, steel producers, manufacturers, and
consumers. M Kalyan Phani
Steel by Circular Economy Principles
OPJU-Sohar Lecture Series
Reduce
Reuse
Remanufacture
Recycle
Circular
Economy
Benefits
Innovations
Resource
Conservati
on
CO
2
Emissions
reduction
Jobs
Improved
Efficiency
Durable
Products
❑Promotes waste reduction and resource optimization
throughout the steel production process
❑Require collaboration and integration across the
entire steel value chain, including raw material
suppliers, steel producers, manufacturers, and
consumers. M Kalyan Phani
OPJU-Sohar Lecture Series 31
Circular Economy StrategiesM Kalyan Phani
Circular Economy StrategiesM Kalyan Phani
OPJU-Sohar Lecture Series 32
Benefits of using Scrap in SM
❑Massive CO₂ Reduction
❑Energy Efficiency
❑Resource Conservation
❑Waste Reduction
❑Lower Water Consumption
❑Supports Circular Economy
❑Cost AdvantageM Kalyan Phani
Benefits of using Scrap in SM
❑Massive CO₂ Reduction
❑Energy Efficiency
❑Resource Conservation
❑Waste Reduction
❑Lower Water Consumption
❑Supports Circular Economy
❑Cost AdvantageM Kalyan Phani
33
Innovations
OPJU-Sohar Lecture Series
Green Steel
Innovations
HYBRIT
(SSAB,
Sweden) Smart
Carbon
(Arcelor
Mittal,
United
Kingdom)
ECO
process
(Nippon
Steel,
Japan)
H2Future
Project
(Voestalpine
, Austria)
Steelanol
Project
(Lanzatech,
Belgium)
Salzgitter
Hydrogen
Steelmaking
(Salzgitter
AG,
Germany)
HIsarna
Pilot Plant
(Tata Steel,
Netherland
s)
These examples demonstrate
how companies are
embracing renewable energy,
advanced manufacturing
techniques, and circular
economy principles to achieve
greener steel production. M Kalyan Phani
Innovations
OPJU-Sohar Lecture Series
Green Steel
Innovations
HYBRIT
(SSAB,
Sweden) Smart
Carbon
(Arcelor
Mittal,
United
Kingdom)
ECO
process
(Nippon
Steel,
Japan)
H2Future
Project
(Voestalpine
, Austria)
Steelanol
Project
(Lanzatech,
Belgium)
Salzgitter
Hydrogen
Steelmaking
(Salzgitter
AG,
Germany)
HIsarna
Pilot Plant
(Tata Steel,
Netherland
s)
These examples demonstrate
how companies are
embracing renewable energy,
advanced manufacturing
techniques, and circular
economy principles to achieve
greener steel production. M Kalyan Phani
OPJU-Sohar Lecture Series 34
Global Green Steelmaking Projects
❖HYBRIT Project (Sweden)
oLed by SSAB, LKAB & Vattenfall
oUses green hydrogen for DRI production, replacing fossil fuels.
oAims to achieve near-zero CO₂ emissions in steelmaking.
oChallenges: High green hydrogen cost, large infrastructure needs, renewable energy supply.
❖H2Future Project (Austria)
oLed by Voestalpine and partners.
oProduces DRI using hydrogen from renewable-powered electrolysis.
oActs as a model for low-carbon steel transition.
oChallenges: High green hydrogen cost, Process optimisation
❖ Steelanol Project (Belgium)
oLed by ArcelorMittal, LanzaTech & Primetals.
oConverts steel plant waste gases into bioethanol via CCU and gas fermentation.
oReduces CO₂ emissions and creates valuable biofuels.
oChallenges: Process efficiency, scalability, and economic feasibility.M Kalyan Phani
Global Green Steelmaking Projects
❖HYBRIT Project (Sweden)
oLed by SSAB, LKAB & Vattenfall
oUses green hydrogen for DRI production, replacing fossil fuels.
oAims to achieve near-zero CO₂ emissions in steelmaking.
oChallenges: High green hydrogen cost, large infrastructure needs, renewable energy supply.
❖H2Future Project (Austria)
oLed by Voestalpine and partners.
oProduces DRI using hydrogen from renewable-powered electrolysis.
oActs as a model for low-carbon steel transition.
oChallenges: High green hydrogen cost, Process optimisation
❖ Steelanol Project (Belgium)
oLed by ArcelorMittal, LanzaTech & Primetals.
oConverts steel plant waste gases into bioethanol via CCU and gas fermentation.
oReduces CO₂ emissions and creates valuable biofuels.
oChallenges: Process efficiency, scalability, and economic feasibility.M Kalyan Phani
OPJU-Sohar Lecture Series 35
Traditional steel vs. green steel processM Kalyan Phani
Traditional steel vs. green steel processM Kalyan Phani
36OPJU-Sohar Lecture SeriesM Kalyan Phani
OPJU-Sohar Lecture Series 37
❖Salzgitter Hydrogen Steelmaking (Germany)
oSalzgitter AG developing hydrogen-based DRI and hydrogen injection in blast
furnaces.
oTargets lower carbon emissions and better energy efficiency.
oChallenges: Green hydrogen cost and reliable supply chain.
❖HIsarna Pilot Plant (Netherlands)
oDeveloped by Tata Steel and partners.
oCombines ore smelting and pre-reduction in one step using hydrogen.
oEliminates need for coke, cutting CO₂ emissions significantly.
oChallenges: Process optimization, scale-up, and cost competitiveness.
Global Green Steelmaking Projects Contd.M Kalyan Phani
❖Salzgitter Hydrogen Steelmaking (Germany)
oSalzgitter AG developing hydrogen-based DRI and hydrogen injection in blast
furnaces.
oTargets lower carbon emissions and better energy efficiency.
oChallenges: Green hydrogen cost and reliable supply chain.
❖HIsarna Pilot Plant (Netherlands)
oDeveloped by Tata Steel and partners.
oCombines ore smelting and pre-reduction in one step using hydrogen.
oEliminates need for coke, cutting CO₂ emissions significantly.
oChallenges: Process optimization, scale-up, and cost competitiveness.
Global Green Steelmaking Projects Contd.M Kalyan Phani
Ambitious goals for Green Steel making by 2030
Steel Production
Source
Annual Steel
Production
Green Hydrogen
Required
Electrolyser
Capacity
Required
Total Renewables
Capacity Required
Base Reference 1 Mt 50 kT 0.56 GW 0.7 GW
U.S. 85.8 Mt 4.3 Mt 48 GW 60 GW
Europe 103 Mt 5.2 Mt 58 GW 72 GW
China 1032.8 Mt 51.6 Mt 581 GW 726 GW
Sweden 5 Mt 5 Mt 5 GW 74 GW
U.K 11 Mt 5 Mt 130 GW 110.5 GW
Japan 110 Mt 3 Mt 130 GW 108 GW
India 120 Mt 5 Mt 60-100 GW 500 GW
Global 1951 Mt 97.6 Mt 1,097 GW 1,371 GW
OPJU-Sohar Lecture Series 38
Hydrogen → decarbonization, improved energy efficiency, and enhanced sustainability in steel
production. India is keen to avert 50 MMT per annum of CO2 emissions by 2030.M Kalyan Phani
Steel Production
Source
Annual Steel
Production
Green Hydrogen
Required
Electrolyser
Capacity
Required
Total Renewables
Capacity Required
Base Reference 1 Mt 50 kT 0.56 GW 0.7 GW
U.S. 85.8 Mt 4.3 Mt 48 GW 60 GW
Europe 103 Mt 5.2 Mt 58 GW 72 GW
China 1032.8 Mt 51.6 Mt 581 GW 726 GW
Sweden 5 Mt 5 Mt 5 GW 74 GW
U.K 11 Mt 5 Mt 130 GW 110.5 GW
Japan 110 Mt 3 Mt 130 GW 108 GW
India 120 Mt 5 Mt 60-100 GW 500 GW
Global 1951 Mt 97.6 Mt 1,097 GW 1,371 GW
OPJU-Sohar Lecture Series 38
Hydrogen → decarbonization, improved energy efficiency, and enhanced sustainability in steel
production. India is keen to avert 50 MMT per annum of CO2 emissions by 2030.M Kalyan Phani
Role of Digital & AI Technologies
➢AI Process Optimization
➢Machine learning algorithms optimize people,
processes, and products to boost sustainability
metrics while reducing waste and energy
consumption.
➢Digital Twin Technology
➢Virtual replicas of physical plants enable real-time
monitoring, predictive maintenance, and scenario
testing before implementation.
➢Hydrogen System Integration
➢Advanced modeling improves the efficiency of
hydrogen production, storage, and utilization systems
within steel plants.
OPJU-Sohar Lecture Series 39M Kalyan Phani
➢AI Process Optimization
➢Machine learning algorithms optimize people,
processes, and products to boost sustainability
metrics while reducing waste and energy
consumption.
➢Digital Twin Technology
➢Virtual replicas of physical plants enable real-time
monitoring, predictive maintenance, and scenario
testing before implementation.
➢Hydrogen System Integration
➢Advanced modeling improves the efficiency of
hydrogen production, storage, and utilization systems
within steel plants.
OPJU-Sohar Lecture Series 39M Kalyan Phani
Potential Benefits of GST
❑Reduced Carbon Emissions
❑Resource Conservation
❑Economic Opportunities
❑Enhanced Competitiveness
OPJU-Sohar Lecture Series 40
Challenges and Limitations of GST
❑High Initial Investment
❑Technological Barriers
❑Scale and IntegrationM Kalyan Phani
❑Reduced Carbon Emissions
❑Resource Conservation
❑Economic Opportunities
❑Enhanced Competitiveness
OPJU-Sohar Lecture Series 40
Challenges and Limitations of GST
❑High Initial Investment
❑Technological Barriers
❑Scale and IntegrationM Kalyan Phani
FIVE Barries for Green Steel Adoption
OPJU-Sohar Lecture Series 41M Kalyan Phani
OPJU-Sohar Lecture Series 41M Kalyan Phani
Main Market Players of GS
OPJU-Sohar Lecture Series 42M Kalyan Phani
OPJU-Sohar Lecture Series 42M Kalyan Phani
Public and Private Partnerships: GST
OPJU-Sohar Lecture Series 43M Kalyan Phani
OPJU-Sohar Lecture Series 43M Kalyan Phani
Policy loop for Green Steel Transition
OPJU-Sohar Lecture Series 44M Kalyan Phani
OPJU-Sohar Lecture Series 44M Kalyan Phani
Policy Framework to Support Industrial
Decarbonization
1. Carbon Border Adjustment Mechanism (CBAM)
Purpose: Prevent “carbon leakage” — where steel production moves to countries with weaker climate regulations.
How it works:
–Imposes a carbon price on imported steel based on its embedded emissions.
–Ensures that domestic green steel producers are not undercut by cheaper, high-carbon imports.
Impact:
–Encourages foreign producers to adopt cleaner technologies.
–Levels the playing field for industries investing in decarbonization.
Example: The European Union began implementing CBAM in 2023 for sectors including iron and steel.
2. Carbon Contracts-for-Difference (CCfDs)
Purpose: De-risk investments in low-carbon steelmaking.
How it works:
–The government guarantees a fixed carbon price for green steel producers over a contract period.
–If the market carbon price falls below this level, the government pays the difference; if it rises above, the producer
repays.
Impact:
–Reduces uncertainty in future carbon pricing.
–Encourages companies to invest in new technologies like hydrogen-based steelmaking or CCUS (Carbon Capture,
Utilization, and Storage).
Example: Germany has started pilot CCfDs for industrial decarbonization projects.
OPJU-Sohar Lecture Series 45M Kalyan Phani
Decarbonization
1. Carbon Border Adjustment Mechanism (CBAM)
Purpose: Prevent “carbon leakage” — where steel production moves to countries with weaker climate regulations.
How it works:
–Imposes a carbon price on imported steel based on its embedded emissions.
–Ensures that domestic green steel producers are not undercut by cheaper, high-carbon imports.
Impact:
–Encourages foreign producers to adopt cleaner technologies.
–Levels the playing field for industries investing in decarbonization.
Example: The European Union began implementing CBAM in 2023 for sectors including iron and steel.
2. Carbon Contracts-for-Difference (CCfDs)
Purpose: De-risk investments in low-carbon steelmaking.
How it works:
–The government guarantees a fixed carbon price for green steel producers over a contract period.
–If the market carbon price falls below this level, the government pays the difference; if it rises above, the producer
repays.
Impact:
–Reduces uncertainty in future carbon pricing.
–Encourages companies to invest in new technologies like hydrogen-based steelmaking or CCUS (Carbon Capture,
Utilization, and Storage).
Example: Germany has started pilot CCfDs for industrial decarbonization projects.
OPJU-Sohar Lecture Series 45M Kalyan Phani
Policy Framework to Support Industrial
Decarbonization
3. Green Public Procurement (GPP)
Purpose: Create demand pull for low-carbon steel.
How it works:
–Governments commit to purchasing certified green steel for infrastructure, construction, and public projects.
–This signals long-term market demand, giving confidence to investors and producers.
Impact:
–Helps scale up green steel production.
–Sets sustainability benchmarks for private-sector buyers.
Example: Sweden and Japan have integrated GPP policies into national green industry strategies.
4. Financial Support – Loans and Grants
Purpose: Support the supply side in transitioning toward clean production.
How it works:
–Governments, banks, and climate funds offer low-interest loans, capital grants, and subsidies for:
•Retrofitting existing blast furnaces
•Setting up hydrogen DRI or EAF facilities
•Worker reskilling and technology adaptation
Impact:
–Reduces upfront capital barriers for industries.
–Promotes inclusive and just transition for the workforce.
OPJU-Sohar Lecture Series 46M Kalyan Phani
Decarbonization
3. Green Public Procurement (GPP)
Purpose: Create demand pull for low-carbon steel.
How it works:
–Governments commit to purchasing certified green steel for infrastructure, construction, and public projects.
–This signals long-term market demand, giving confidence to investors and producers.
Impact:
–Helps scale up green steel production.
–Sets sustainability benchmarks for private-sector buyers.
Example: Sweden and Japan have integrated GPP policies into national green industry strategies.
4. Financial Support – Loans and Grants
Purpose: Support the supply side in transitioning toward clean production.
How it works:
–Governments, banks, and climate funds offer low-interest loans, capital grants, and subsidies for:
•Retrofitting existing blast furnaces
•Setting up hydrogen DRI or EAF facilities
•Worker reskilling and technology adaptation
Impact:
–Reduces upfront capital barriers for industries.
–Promotes inclusive and just transition for the workforce.
OPJU-Sohar Lecture Series 46M Kalyan Phani
(Few Investments, Policies and Schemes)
OPJU-Sohar Lecture Series 47
SomeInitiativesbyvariousGovernments
Region Funding amount (2020-2023) Primary initiatives
European Union EUR2bn
Innovation fund, Horizon Europe for hydrogen
steel projects
United States $1.2bn
Inflation Reduction Act, tax credits, research
grants
China $900m
Subsidies for pilot projects in hydrogen and
CCS
Japan $700m
Green Innovation Fund, targeting hydrogen
and CCS
India
₹19000+ Crores Green Hydrogen Mission (hubs, electrolyser
manufacturing incentives)
Australia AUD 1–2bn
Hydrogen Headstart revenue support for large-
scale projects
South Korea KRW 800–900 billion
Hydrogen-DRI pilots, public funding, green
finance lines and R&D grants for low-carbon
steel tech.M Kalyan Phani
OPJU-Sohar Lecture Series 47
SomeInitiativesbyvariousGovernments
Region Funding amount (2020-2023) Primary initiatives
European Union EUR2bn
Innovation fund, Horizon Europe for hydrogen
steel projects
United States $1.2bn
Inflation Reduction Act, tax credits, research
grants
China $900m
Subsidies for pilot projects in hydrogen and
CCS
Japan $700m
Green Innovation Fund, targeting hydrogen
and CCS
India
₹19000+ Crores Green Hydrogen Mission (hubs, electrolyser
manufacturing incentives)
Australia AUD 1–2bn
Hydrogen Headstart revenue support for large-
scale projects
South Korea KRW 800–900 billion
Hydrogen-DRI pilots, public funding, green
finance lines and R&D grants for low-carbon
steel tech.M Kalyan Phani
Private funding in green steel production
Company Investment Focus area
ArcelorMittal $10bn+ Hydrogen-based steel production
H2 Green Steel (Sweden)$3bn Hydrogen-powered plant in Brazil
Tata Steel
(Europe)
$1.25bn Decarbonisation of European plants
Thyssenkrupp $2bn Carbon-neutral production technologies
SSAB (Sweden)
$6bn First fossil-free steel using green hydrogen; replacing
blast furnace with hydrogen DRI.
Bao Steel (China)
$6bn Hydrogen metallurgy, carbon capture, and recycling of
steel scrap at large scale.
Blue Scope Steel
(Australia)
AUD 1.15bn
Pilot hydrogen DRI and EAF retrofits; renewable
energy transition for operations.
POSCO
(South Korea)
$3.4bn Hydrogen reduction ironmaking and large-scale H₂
infrastructure development.
OPJU-Sohar Lecture Series 48M Kalyan Phani
Company Investment Focus area
ArcelorMittal $10bn+ Hydrogen-based steel production
H2 Green Steel (Sweden)$3bn Hydrogen-powered plant in Brazil
Tata Steel
(Europe)
$1.25bn Decarbonisation of European plants
Thyssenkrupp $2bn Carbon-neutral production technologies
SSAB (Sweden)
$6bn First fossil-free steel using green hydrogen; replacing
blast furnace with hydrogen DRI.
Bao Steel (China)
$6bn Hydrogen metallurgy, carbon capture, and recycling of
steel scrap at large scale.
Blue Scope Steel
(Australia)
AUD 1.15bn
Pilot hydrogen DRI and EAF retrofits; renewable
energy transition for operations.
POSCO
(South Korea)
$3.4bn Hydrogen reduction ironmaking and large-scale H₂
infrastructure development.
OPJU-Sohar Lecture Series 48M Kalyan Phani
(Few Investments, Policies and Schemes)
❖Huge Investments of more than Rs. 80,000 Cr for Green Hydrogen
projects and renewable energy.
❖Steel Scrap Recycling Policy, 2019 → reduce the consumption of coal in SM.
❖Ministry of New and Renewable Energy (MNRE) has announced
NationalGreen Hydrogen Mission for green hydrogen production and usage.
❖Motor Vehicles (Registration and Functions of Vehicles Scrapping
Facility)Rules September 2021 → shall increase availability of scrap
❖National Solar Mission launched by MNRE in January 2010 → promotes
the useof solar energy and also helps reduce the emission of steel industry.
❖Perform, Achieve and Trade (PAT) scheme, → under National Mission
forEnhanced Energy Efficiency, incentivizes steel industry to reduce
energyconsumption.
❖Japan’s New Energy and Industrial Technology Development
Organization(NEDO) Model Projects → Energy Efficiency Improvement
have beenimplemented in steel plants.
❖Implementation of Best Available Technologies (BAT) → For improving
energy efficiency & mitigation of GHG emission.And Many more…….
OPJU-Sohar Lecture Series 49
SomeInitiativesbyIndianGovernmentM Kalyan Phani
❖Huge Investments of more than Rs. 80,000 Cr for Green Hydrogen
projects and renewable energy.
❖Steel Scrap Recycling Policy, 2019 → reduce the consumption of coal in SM.
❖Ministry of New and Renewable Energy (MNRE) has announced
NationalGreen Hydrogen Mission for green hydrogen production and usage.
❖Motor Vehicles (Registration and Functions of Vehicles Scrapping
Facility)Rules September 2021 → shall increase availability of scrap
❖National Solar Mission launched by MNRE in January 2010 → promotes
the useof solar energy and also helps reduce the emission of steel industry.
❖Perform, Achieve and Trade (PAT) scheme, → under National Mission
forEnhanced Energy Efficiency, incentivizes steel industry to reduce
energyconsumption.
❖Japan’s New Energy and Industrial Technology Development
Organization(NEDO) Model Projects → Energy Efficiency Improvement
have beenimplemented in steel plants.
❖Implementation of Best Available Technologies (BAT) → For improving
energy efficiency & mitigation of GHG emission.And Many more…….
OPJU-Sohar Lecture Series 49
SomeInitiativesbyIndianGovernmentM Kalyan Phani
50
RelianceIndustries,IOCL,NTPC,AdaniEnterprises,JSW
Energy,ReNewPower,JSPandAcmeSolarhavehuge
planonGreenHydrogen
❑Nitin Gadkari’s Mirai from Toyota Kirloskar (the first green
hydrogen car
❑Indian Railways (IR) are developing a prototype of a hydrogen
fuel-based train at the Northern Railway workshop and prepared
for test run on the Sonipat-Jind section in Haryana.
❑IR planning for run on following Heritage route (narrow guage):
➢Darjeeling Himalayan Railway
➢Nilgiri Mountain Railway
➢Kalka Shimla Railway
➢Marwar- Devgarh Madriya
OPJU-Sohar Lecture Series
SomeInitiativesbyIndianGovernmentM Kalyan Phani
RelianceIndustries,IOCL,NTPC,AdaniEnterprises,JSW
Energy,ReNewPower,JSPandAcmeSolarhavehuge
planonGreenHydrogen
❑Nitin Gadkari’s Mirai from Toyota Kirloskar (the first green
hydrogen car
❑Indian Railways (IR) are developing a prototype of a hydrogen
fuel-based train at the Northern Railway workshop and prepared
for test run on the Sonipat-Jind section in Haryana.
❑IR planning for run on following Heritage route (narrow guage):
➢Darjeeling Himalayan Railway
➢Nilgiri Mountain Railway
➢Kalka Shimla Railway
➢Marwar- Devgarh Madriya
OPJU-Sohar Lecture Series
SomeInitiativesbyIndianGovernmentM Kalyan Phani
The Future
oGreen steel is expected to become cost-competitive with traditional steel as
production scales up, renewable energy costs decline, and supportive
policies drive market transformation.
oThis transition is critical for meeting global climate targets while satisfying
growing demand for sustainable materials in construction, automotive, and
manufacturing sectors.
OPJU-Sohar Lecture Series 51
37.6% 46 Mt 95%
By
2035M Kalyan Phani
oGreen steel is expected to become cost-competitive with traditional steel as
production scales up, renewable energy costs decline, and supportive
policies drive market transformation.
oThis transition is critical for meeting global climate targets while satisfying
growing demand for sustainable materials in construction, automotive, and
manufacturing sectors.
OPJU-Sohar Lecture Series 51
37.6% 46 Mt 95%
By
2035M Kalyan Phani
Conclusions
❑GST serves as a beacon of hope, ready to transform the steel industry into
a model of sustainability and environmental excellence.
❑Hydrogen offers the potential for significant decarbonization, improved
energy efficiency, and enhanced sustainability in steel production.
❑By harnessing the potential of renewable energy sources, pioneering
manufacturing techniques, and embracing circular economy principles,
GST charts a course towards substantial carbon emission reductions,
resource conservation, and economic prosperity.
❑Still the challenges need to be overcome by collaborative endeavours
between steel producers, governments, and stakeholders who hold the
key to unleashing the transformative power of GST and shaping a world
of enduring sustainability.
❑The integration of AI will empower GST, optimizing processes, enhancing
efficiency, and accelerating the steel industry’s transition toward
sustainability and decarbonization.
OPJU-Sohar Lecture Series 52M Kalyan Phani
❑GST serves as a beacon of hope, ready to transform the steel industry into
a model of sustainability and environmental excellence.
❑Hydrogen offers the potential for significant decarbonization, improved
energy efficiency, and enhanced sustainability in steel production.
❑By harnessing the potential of renewable energy sources, pioneering
manufacturing techniques, and embracing circular economy principles,
GST charts a course towards substantial carbon emission reductions,
resource conservation, and economic prosperity.
❑Still the challenges need to be overcome by collaborative endeavours
between steel producers, governments, and stakeholders who hold the
key to unleashing the transformative power of GST and shaping a world
of enduring sustainability.
❑The integration of AI will empower GST, optimizing processes, enhancing
efficiency, and accelerating the steel industry’s transition toward
sustainability and decarbonization.
OPJU-Sohar Lecture Series 52M Kalyan Phani
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