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Gulf charts pathway to clean steel production

1 August 2024

 

Steel manufacturing accounts for 7%-9% of global carbon dioxide (CO2) emissions and is considered a hard-to-abate industry. With a forecast for strong growth in global steel production in the coming decades, changes need to be implemented to bring steelmaking in line with the UN Paris Climate Agreement goal of limiting global warming to 1.5 degrees Celsius.

The need for the international steel industry to slash CO2 and greenhouse gas emissions dominated the agenda at UN climate change summit Cop28 in Dubai last December, with about 35 companies and six industry associations, including the World Steel Association, endorsing the Industrial Transition Accelerator. The initiative aims to scale implementation and delivery of decarbonisation in the steel, aluminum, cement, transportation and energy sectors.

There are many levers for steel decarbonisation, including the electrification of heat generation, improving energy efficiency and increasing the utilisation of scrap steel. However, to reach net-zero, further steps are needed to address the emissions associated with coal’s role as a reducing agent in ironmaking. Breakthrough technologies that can accomplish this include hydrogen direct reduction to replace coal; carbon capture, utilisation and storage; and electrolysis-based, or green hydrogen-supported, production processes.

The Middle East and North Africa accounts for just 5% of global steel output. Despite this low market share, however, steelmakers in the region – particularly in the Gulf – have committed billions of dollars to investments in steel projects that could implement most proven clean technologies.

To reach net-zero, further steps are needed to address the emissions associated with coal’s role as a reducing agent in ironmaking

Saudi clean steel projects

Saudi Aramco, the kingdom’s sovereign wealth institution the Public Investment Fund (PIF) and Chinese steel manufacturing conglomerate Baoshan Iron & Steel Company (Baosteel) signed a joint venture agreement in May 2023 to establish an integrated steel plate manufacturing complex in Saudi Arabia’s Ras Al-Khair Industrial City.

The facility is expected to have a production capacity of up to 1.5 million tonnes a year (t/y). It will mainly cater to industrial sectors such as pipelines, shipbuilding, rig manufacturing, offshore platform fabrication and tank and pressure vessel manufacturing, as well as the construction, renewables and marine sectors.

The plant will be equipped with a natural gas-based direct reduced iron (DRI) furnace and an electric arc furnace to reduce CO2 emissions from the steelmaking process by up to 60% compared to a traditional blast furnace. The DRI plant will be compatible with hydrogen without major equipment modifications, potentially reducing CO2 emissions by up to 90% in the future, Aramco says.

The partners have invited contractors to submit engineering, procurement, installation and construction proposals for the project, which are due by 30 July.

Separately, Indian industrial conglomerate Essar Group is advancing its planned $4bn Green Steel Arabia project, which will also be located in Ras Al-Khair. Essar’s integrated steel complex will have a production capacity of 4 million t/y, and a cold rolling capacity of 1 million t/y, along with galvanising and tin plate lines. The complex will also have two DRI plants, each with a production capacity of 2.5 million t/y.

In September 2023, Essar signed a memorandum of understanding (MoU) with Jeddah-based Desert Technologies to develop solar energy solutions to power its Green Steel Arabia project. Under the agreement, Essar and Desert Technologies will look to develop solutions for renewable energy generation – mainly solar photovoltaic power – and storage for the planned complex.

The parties will also explore opportunities for other similar projects in the region, Mumbai-headquartered Essar said at the time.

A third major clean steel project in the kingdom has been announced by Turkish steelmaker Tosyali Holding, which will invest up to $5bn in the venture. Tosyali said in January that it intends to produce steel with the help of green energy sources and will increase its solar energy output 10-fold to 2,500MW, up from the 240MW it currently uses.

Fuat Tosyali, Tosyali’s chairman, said the increase in solar output will be facilitated by a $1.5bn investment, as well as through plans to buy a stake in a hydrogen energy company.

UAE makes strides

Clean steel production efforts in the UAE have been led by Emirates Steel Arkan, the country’s largest steel manufacturer. The company has partnered with Japan's Itochu to develop a low-carbon iron processing plant in Abu Dhabi that will be capable of processing high-grade Brazilian iron ore into reduced iron, which will be sent to Japan.

The proposed plant will be built in collaboration with Japan’s JFE Steel and is expected to produce about 2.5 million metric tonnes a year of reduced iron starting in 2027. CSN Mineracao, a Brazilian company in which Itochu maintains a stake, will supply the iron ore.

Emirates Steel and Abu Dhabi National Energy Company (Taqa) have also started the concept design for an electrolyser plant that they are jointly developing. Powered by renewable energy, the plant will have a hydrogen output capacity of 160MW, which will be used in the production of steel.

Abu Dhabi aims to establish a large-scale steel production hub with an overall capacity of 15 million t/y. This projected capacity will be in addition to Emirates Steel Arkan's existing production level of 3.5 million t/y, according to the firm's group chief projects officer, Hassan Shashaa.

Meanwhile, Dubai-headquartered Liberty Steel signed an MoU in December 2023 with Abu Dhabi’s AD Ports Group to invest in a green iron production facility in Khalifa Economic Zones Abu Dhabi.

Under the MoU, the two companies will explore the establishment of a green iron production facility and related port infrastructure and conveyor system at Khalifa Port in Abu Dhabi. The MoU is part of Liberty’s early-stage concept development to convert its magnetite ore into green iron in the UAE, using gas and transitioning to green hydrogen once it becomes available at scale in the next decade.

Green steel producers [in Oman] could benefit from cheap, locally available green hydrogen feedstock

Oman’s green steel plans

The largest green steel project in Oman is being developed by Vulcan Green Steel (VGS), the steel arm of Vulcan Green, which is owned by India’s Jindal Steel Group. VGS broke ground on the estimated $3bn project in December 2023.

The planned facility, covering 2 square kilometres in the Special Economic Zone at Duqm (Sezad), will have two production lines of 2.5 million t/y each, comprising DRI units, an electric arc furnace and a hot strip mill. 

Set for completion by 2026, the planned facility will primarily utilise green hydrogen to produce 5 million t/y of green steel. This will make it the world’s largest renewable energy-based green steel manufacturing complex once it is commissioned.

Sezad could also host another large-scale green steel project if Japanese steel manufacturer Kobe Steel and Tokyo-based Mitsui & Company are able to achieve the final investment decision on a preliminary agreement they signed in April last year to develop a low-carbon iron metallics project.

The two Japanese firms agreed to conduct a detailed business study in line with the goal of commencing low-carbon dioxide iron metallics production by 2027. The project is expected to produce 5 million t/y of DRI using a process called Midrex, where DRI is produced from iron ores through a natural gas or hydrogen-based shaft furnace.

Green steel producers in the sultanate could benefit from cheap, locally-available green hydrogen feedstock if the Amnah consortium – which won the first land block contract that Hydrogen Oman (Hydrom) auctioned last year – achieves the financial investment decision on its planned project by 2026.

The estimated $6bn-$7bn project will supply green hydrogen to domestic and overseas steel producers, Amnah project director Mark Geilenkirchen told MEED last year.

The planned integrated facility is expected to have a capacity of 220,000 t/y of green hydrogen and will require up to 4.5GW of renewable energy capacity. Unlike other projects in the region that aim almost exclusively to export their green hydrogen derivative products such as ammonia, Amnah is considering converting or using green hydrogen to support sustainable steel production.

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Indrajit Sen

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