ENERGY & EMISSIONS IN METAL INDUSTRY BRAJENDRA MISHRA, COLORADO SCHOOL OF MINES

CountryRank Change, % China Japan United States Russia India South Korea Germany Ukraine Brazil Italy Total 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 9 th to 5 th position.

Value estimation 2006 Steel 670 B Є/a Aluminium 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 Mt in 75 years Mt in 25 years ~ 0 in 10 years Mt in 10 years Mt in 10 years Mt in last 4 years MARCH IN GLOBAL STEEL CONSUMPTION There was increase in steel consumption during , after a decade of no growth 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 CO 2 per tonne of crude steel globally; t CO 2 in India. EAF steelmaking using recycled scrap generates only 0.68 t CO 2. CO 2 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 CO 2 saved for every tonne aluminium produced by secondary processing. Primary process, t CO 2 CO 2 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 CO 2 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 CO 2 Reduction, 3.52 t Secondary Process, 1.98 t CO 2 EMISSION IN COPPER PROCESSING (t/t)

Recycling process Reduction CO 2 EMISSIONS (t/t product) FOR STEEL, ALUMINIUM, COPPER and PAPER Steel is the least CO 2 generating metal. Paper produces less CO 2, but has limited application.

CHALLENGES FOR INDIAN STEEL INDUSTRY