AIST Decarbonization Subcommittee Webinar #8 – Ironing Out Carbon: The EAF & DRI Revolution

26 November 2024 • Zoom • 9–10 a.m. EDT

About the Program

The electric arc furnace (EAF) process is a low-carbon and proven steelmaking technology. However, EAF operations are not exempt from further reducing their carbon emissions. Depending on raw material quality and steel product portfolio, purer iron sources than scrap are necessary while keeping the carbon emissions as low as possible. As such, the “DRI Revolution” offers some solutions to further reducing carbon emissions. This webinar will cover a few of the challenges and consequences of EAF steelmaking with direct reduced iron feed in comparison to scrap-based operations.

Registration Fees

US$0 for AIST members, U$50 for non-members.

Available Sponsorships

Event Sponsor – 1 available US$3,500

Name recognition for specific webinar on upcoming webinar calendar.
Sponsor logo and hyperlink included in electronic promotions.
Sponsor logo and hyperlink on specific webinar page.
Sponsor can provide a message (2–3 sentences) for host to read during opening webinar remarks.
Verbal recognition by host at end of webinar.
Recognition in thank-you message to all participants when the webinar ends.
Sponsor will receive a list of all webinar participants (name, company, country).
Three AIST memberships for non-members only.

Moderators

Michelle Vachon, Environmental Manager, Big River Steel – A U. S. Steel Co.
Michelle Vachon joined Big River Steel – A U. S. Steel Co. in 2016 as the environmental manager and in 2023 became the first divisional manager of sustainability for both of Big River’s steelmaking plants in Osceola, Ark., USA (BR1 and BR2). Her current role includes responsibility for the operational side of Big River Steel’s sustainability program and ResponsibleSteel™ Site and Product Certification systems, with a focus on environmental, social and governance issues, such as piloting the purchase of carbon offsets and renewable energy credits for a German automaker and decarbonization research and development. She also represents Big River Steel on the U. S. Steel Sustainability Leadership Steering Team and U. S. Steel Tactical GHG Reduction Task Force. Prior to being named environmental manager, Vachon consulted for Big River Steel’s chief compliance officer from 2014 to 2016, but also for academic institutions, the private manufacturing and non-profit sectors, with a focus on brownfield remediation, redevelopment and site selection for large industrial redevelopment projects. Vachon earned her bachelor’s degree from the University of Michigan in Dearborn, Mich., where she majored in environmental studies. She also earned two master’s of science degrees in environmental science and bioregional planning and sustainable communities from the University of Idaho.

Kyle Vanover, General Manager, Metallurgist, Steel Dynamics Inc. – Flat Roll Group Butler Division
Kyle Vanover is a metallurgist with 14 years of experience at Steel Dynamics Inc. He earned his master's degree in engineering from Purdue University and has worked in various departments, including the electric arc furnaces, ladle metallurgy furnace, caster, and hot rolling mill. Vanover is known for his technical expertise, analytical skills and creative problem-solving abilities.

Presentation 1: Stegra: Large-Scale Production of Green Hydrogen, Iron and Steel, Denis Hennessy, Head of Steel, Stegra

Presentation Abstract: Stegra is an industrial impact scale-up in the process of building its first plant for large-scale production of green hydrogen, green iron and green steel. The company was founded in 2020 as H2 Green Steel and changed its name to Stegra in 2024 to reflect its purpose to decarbonize hard-to-abate industry, starting with steel. Stegra’s flagship plant is being built in Boden, northern Sweden, and its headquarters are in Stockholm.

Presenter Bio: Denis Hennessy is head of Steel at Stegra, formerly H2greenSteel. He graduated with a degree in chemical engineering at University of Toronto and continued his education at McMaster University. His previous experience includes:
- Stelco (Lake Erie Works and Hilton Works)
- Severstal (now Steel Dynamics Inc. – Flat Roll Group Columbus Division)
- Big River Steel (now part of United States Steel Corporation)

Hennessy worked in melting, casting, rolling, galvanizing, technical service, product development, engineering and construction.

Presentation 2: The Challenges of DRI Utilization as a Decarburization Lever for the Steel Industry, Jeremy Jones, Founding Partner and President, Continuous Improvement Experts (CIX)

Abstract: Production and utilization of direct reduced iron (DRI)/hot briquetted iron (HBI) has grown considerably in the past 10–20 years. Due to their extremely low levels of copper, ore-based materials (OBMs) can be utilized to dilute copper levels in recycled scrap to achieve acceptable copper levels in steel products. Hydrogen-based DRI is key to achieving decarburization targets in the future. However, the availability of high-grade iron ore to support this transition is in question. The iron and steel industry is about to hit a crisis, due to rising scrap residual levels and declining generation of prompt scrap. OBMs play a critical role in enabling maximization of scrap recycle. Steel industry sustainability depends on finding the correct balance between DRI and scrap. Ultimately, metallics quality is integral to controlling carbon footprint, improving circularity and providing a sustainable steel industry.

Presenter Bio: Jeremy Jones was born in Tonbridge, England, and emigrated to Canada in 1966. He grew up in Ottawa, Ont., Canada, and attended Queen’s University in Kingston, Ont., Canada, earning a B.S. degree in chemical engineering in 1983 followed by an M.S. degree in chemical engineering in 1985.

He is a founding partner and president of Continuous Improvement Experts (CIX). Previously he held senior positions at Transfield Services, Tenova, WorleyParsons, Nupro Corp., Bechtel Corp., Florida Steel and Hatch Associates.

Jones is frequently invited as a keynote speaker/instructor for international steel conferences. He is the primary author of the EAF steelmaking chapter for the updated Steelmaking Volume of The Making Shaping and Treating of Steel. He is a frequent contributor to AIST conferences, frequent session chairman at annual convention, and author of over 100 technical papers and articles.

In May 2023, he was made an honorary member of the American Institute of Mining, Metallurgical and Petroleum Engineers (AIME) for his “commitment to the advancement and education related to international electric steelmaking.” Jones is an AIST Distinguished Member and Fellow and recipient of the John Bell Award for advancing EAF technologies. He is also a Fellow of the International Iron Metallics Association (IIMA). Jones has carried out assignments for clients in over 100 countries. He is the past chairman of the AIST Electric Steelmaking Technology Committee and the past chairman of the WorldSteel EAF Technology Committee. He also chaired the Continuing Education Committee, the Energy and Environment Committee and the Advanced Technology Committee at the Iron & Steel Society, a predecessor of AIST. Jones is one of the original instructors of AIST’s EAF training seminar.

His steelmaking experience spans direct reduction, smelting reduction, EAF steelmaking, blast furnace operations, basic oxygen furnace operations, ladle metallurgy, vacuum treatment and casting operations for all grades of steel. Previous assignments have spanned the fields of project management, project negotiations, process engineering, process control engineering, process simulation and optimization, environmental engineering, industrial engineering, and management consulting.