1
Compiled by Dr. Joe Herbertson
June 2001
Sustainable Resource Processing
Case Study: Sustainable Ferrous Primary Processing
Sustainable Ironmaking Goals
•50% Reduction in Capital
•Zero Net Greenhouse Emissions
•100% Valued Products from Slags
Off Gas Credits
GGE - t CO2 equiv / t HRC
  0
1.0
2.0
3.0
4.0
Coal Based
    Smelting
Coal Ore
Pellets
 IS
Gas Based
Reduction
Slag Credits
Net CO2
A
B
C
D
E
F
G
H
 Bio-
mass
Code:
Established Technology
A. Conventional BF-BOS
B. DRI/HBI plus EAF
C. Hot Charging to EAF
D. COREX plus BOS
Emerging Technologies
E. Direct Smelting plus BOS
F. FASTMET plus EAF
Conceptual
G. Innovative ‘Kiln Smelter’
H. Charcoal Based Process
Ref. ‘Sustainable Technology: Iron & Steel Perspectives’, J. Herbertson, L.Wibberley, P.Scaife, Triple Bottom Line, ibc, Sydney, Feb. 1999
Innovative ideas were:
•based on new technologies, non-core synergies, process integration, minimal raw materials pre-processing, renewable energy and reductant sources etc
•tested against life cycle analysis and techno-economic modelling
BHP Steel conducted strategic research to explore future industry configurations that could meet ‘sustainable ironmaking’ goals