The low-emission Integrated Steelmaking Process (ISP) aims to: i) Substantially (>50%) reduce CO2 emissions by the steel industry ii) Address salinity affected regions iii) Recover high grade waste heat from molten slags Iv) Reduce to zero the use of fresh water in the cooling of molten slags v) Enable waste (iron making slag) to be converted into a useful product (cement). The concept is based on industrial ecology and if fully implemented will also address other environmental issues e.g. restoring soil and land quality in salinity affected regions and production of bio-based products from renewable sources.

1. Low-emission Integrated Steelmaking Process (ISP)
MINERALS DOWN UNDER NATIONAL RESEARCH FLAGSHIP
Sharif Jahanshahi
Theme Leader – Sustainable Metal Production

2. Presentation by Sharif Jahanshahi, PhD
Overview of SMP Theme |
 Dr. Sharif Jahanshahi has over 30 years
experience in R&D across; high temperature
processing of ferrous and base metals,
thermodynamics and kinetics of high temperature
systems, melt chemistry, process modelling,
simulation and development
 Currently consulting for leading global players in
the metallurgical industry through Meta-Logical
Solutions Pty Ltd.
Website: http://www.metalogical.solutions
Email: sharif@metalogical.solutions

3. Driver 1: GHG Reduction
0
500
1000
1500
2000
2500Copper
Nickel
Lead
Zinc
Alum
inium
Steel
GlobalGHGemissions(MtCO2e/y)
0
10
20
30
40
50
AustralianGHGemissions(MtCO2e/y)
Global Australia
~ 2.2 billion
tonnes of CO2-e
per annum!

4. Driver 2: Salinity
Problem
2M ha of farmland degraded by salinity
(6M ha by 2040)
Solution
Partial revegetation with Mallee trees
Electricity and charcoal from the
biomass
Challenge
Full rehabilitation results in 25Mt/a
biomass – charcoal market?
• Special planting of trees in the Western Australian wheat belt could restore soil
and land quality
• Plantation of over 12,000 ha in WA has taken place recent years
Metallurgical application of the charcoal in smelting (eg ironmaking) could be a
GHG neutral alternative to coal

5. 5
Objectives
The low-emission Integrated Steelmaking Process (ISP) aims to:
– Substantially (>50%) reduce CO2 emissions by the steel industry
– Address salinity affected regions
– Recover high grade waste heat from molten slags
– Reduce to zero the use of fresh water in the cooling of molten slags
– Enable waste (iron making slag) to be converted into a useful product (cement).
The concept is based on industrial ecology and if fully implemented will also
address other environmental issues e.g. restoring soil and land quality in salinity
affected regions and production of bio-based products from renewable sources.

6. 6
What is ISP
• ISP has been under development by CSIRO since 2006
• ISP has 3 key components:
a) Slow Autogenous Pyrolysis (SAP) for conversion of biomass to biochar and
other valuable by-products (bio-oil, bio-energy)
b) Use of Bio-Char (UBC) as fuel and reductant in iron and steel making
processes
c) Dry Slag Granulation (DSG) to recover high grade waste heat and convert slag
into Portland cement substitute.
• ISP development has been supported since 2006 by BlueScope and
OneSteel

7. Our Vision for Future of Australian Industries
Biomass Energy Iron & steel Energy CementSalinity control
Dry
granulation
Cement
making
Agriculture
Bio-fuel
processing
Smelting
TREE PLANTING BIOCHAR HOT SLAG SLAGBIOMASS
Look at the CSIRO, which has been working with BlueScope and OneSteel on a low-carbon
breakthrough program for five years. CSIRO's integrated steel-making process is one of the
few known technologies which can deliver a substantial cut in carbon emissions at minimal
cost to smelters. The estimated value of that knowledge over the next twenty years is $42
billion, assuming just 10 per cent global market penetration. That is the potential we can
unlock in this country.
Senator Kim Carr, Former Minister for Innovation, Industry Science & Research
BIO-OIL

8. Appendix
Overview of SMP Theme |

9. Fuel
Reductant
CO2
+
H2O
Plants,
Algae farm
Solar
Energy
CO
H2
CO2
CO2
H2O
Power plant
Metal & Building
Products
Biomass
(Charcoal)
Ore, fluxes
Concept - Closing the Carbon Loop
By-products
electricity
Bio-oil

10. • ISP has been under development by CSIRO since
2006 in collaboration with the Australian steel
industry.
• The objectives of ISP are to:
− Introduce deep cuts (>50%) in net CO2
emissions by the steel industry
− Recover high grade waste heat from molten
slags
− Reduce fresh water usage in the cooling of
molten slags
− Convert 100s million tonnes/year of waste
(iron making slag) into a high value product
(“green cement”).
Low-emission Integrated Steelmaking Process (ISP)
ISP has 3 components:
a) Slow Autogenous Pyrolysis (SAP)
for conversion of biomass to
biochar and other valuable by-
products (bio-oil, bio-energy)
b) Use of Designer Bio-Char (DBC) as
fuel and reductant in iron and steel
making processes
c) Dry Slag Granulation (DSG) to
recover high grade waste heat and
convert slag into Portland cement
substitute.
Concept
Development
Techno-economic
and LCA
Proof of Concept -
Large Scale Piloting
Demonstration via
Full Scale Plant Trials
2006 2012 20162009