Dr Paul Brooks, director environment and climate change, Corus - at the CBI Climate Change Summit, Tuesday 2 December 2008

1. Presentation to CBI Climate Change Summit
Using Technology to Reduce Carbon
Intensity in Production/Manufacturing
Dr Paul Brooks, Director Environment & Climate Change, Corus
December 2008
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2. Presentation
(1) Corus/Tata Steel Group overview
(2) Climate change & the steel industry
(3) Tata Steel Group climate change strategy
– Vision
– Short to medium term energy efficiency
improvements & CO2 emission reductions
– Longer term breakthough technology developments
– Sustainable solutions (product & market
development)
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3. Corus
Overview
• 2nd largest European steel producer
• Annual turnover c £12bn
• Approximately 42,000 employees worldwide
• Major manufacturing sites in UK, Netherlands, Germany,
France and Belgium
• Sales offices and service centres in over 40 countries
• Supplier to many of the most demanding markets worldwide
including construction, automotive, packaging, mechanical
engineering and other markets worldwide
• Corus was acquired by Tata Steel in 2007 and is now part of
Tata Steel Group, which is the 6th largest global steel producer.
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4. Tata Steel Group
Global reach
Western Europe
Teesside 3mt Steel making operations
Rotherham 1mt Sales offices
Scunthorpe 4.5mt
Mining assets & projects
Port Talbot 5mt
Scandinavia
CIS
IJmuiden Western
Europe
7mt North America CEE
China
Turkey India
Japan
Western Orissa
Africa
SE Asia
Oman
(limestone)
South East Asia Ivory Coast
Latin America
(iron ore)
Mozambique
South Africa (coal)
New Zealand
Jamshedpur
5mt
Tata Steel Thailand
1mt
Orissa
Natsteel
1mt
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5. Fit for the Future
New products
Rails for record-breaking Polymer coated steel for new Ultra high performance
high speed TGV trains can concepts steels for Airbus
Steel plate for the pioneering MagiZinc – award-winning Ympress S700 – strongest in
Talisman Beatrice wind farm coating with 4 times corrosion the Ympress range of high
off east coast of Scotland protection strength, low-alloy steels
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6. Our Vision
The Tata Steel Group vision is to be the world steel industry
benchmark for value creation and corporate citizenship.
Value Creation + Corporate Citizenship
Our People
• The vision translates into a number of ambitious five year goals
which are measurable and tangible
• A performance culture supports the vision and goals.
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7. Our Vision
Goals for 2012
Value Creation:
- Increase our return on invested
capital (ROIC) to 30%
Safety:
- Reduce our lost time injury frequency
(LTIF) to 0.4
Environment:
- Reduce CO² emissions to <1.7 tonnes
per tonne of liquid steel
Employer of choice:
- Rank top quartile across all industries.
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8. Steel Industry & Climate Change
Sectoral (worldsteel) action plan
Reporting and targeting
 Common reporting methodology
 Third party endorsement
 Regional emission reduction targets
Technology
 Technology transfer / Asia-Pacific Partnership
 Breakthrough programme / ULCOS project
Off-setting with steel solutions
 Automotive
 Construction
 Energy
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9. TSG Climate Change Strategy
Vision
Climate change is one of the most pressing issues the world faces today.
In response to this challenge, Tata Steel Group will be part of the solution
and will achieve a leading position within the steel industry* whilst creating
value through:
• continuing to improve its current processes, reducing emissions to
<1.7 t CO2/t steel by 2012 and to <1.5 t CO2/t steel by 2020**
• investing in breakthrough technologies
• developing new products and services to reduce environmental impact over
the product lifecycle, offsetting emissions in manufacture
• actively engaging its workforce
• further developing its pro-active role in global steel sector initiatives.
* Target percentile for 2020 to be determined following publication of IISI global benchmarking data
** Equivalent to a reduction of at least 20% compared to 1990 9

10. Tata Steel Group Vision 2012
Specific CO2 emissions
Tata Steel Group (consolidated, weighted average, integrated sites only)
Gap 0.17
Gap 0.37
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11. Climate Change Strategy
Corus emission reduction action plan - 2012
Latest Key initiatives / examples
view
 BOS gas recovery @ Port Talbot
 Ladle furnace @ IJmuiden
Large capex 800  Back pressure valves @ Port Talbot
 Possible partial switch to pellet feed
 Increased scrap ratio
Burden
optimisation
800  Reduced slag volume
 Increased coal injection
 Yield improvements
Small capex,
house keeping
400  Lighting efficiency
 Variable speed drives
2012 target
Total
0 500 1000 1500 2000 2500
Kt CO2
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12. Investment in Energy Efficiency &
CO2 Emission Reductions
Transmissi
on &
Distribution
System
MARGM MARGAM C
ABoiler 3 MARAM B
Power Boiler 6
Mitchell Boiler
Boiler 5 Plants Boiler 7
BOS Plant Gas Recovery at Port Talbot (an investment of ~£60m)
• Increases on-site generation from 61MW to 76MW; reduces electricity & natural gas imports
• Reduces CO2 emissions by 290,000 t/year; reduces particulate emissions by ~40 t/year.
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13. Support Provided
Energy optimisation platform
Objective
To provide a platform for energy managers & experts to
share & learn from each other in order to help to deliver energy
efficiency improvements/emission reductions at site level.
Working Model
- Initially focussing on steelmaking sites, including Jamshedpur,
expanding later to include others
- Rotating venues, including site visits, meeting 6 times each year
- Process specific energy/emissions issues to be picked up by relevant
PITs, horizontal/common issues to be addressed by EOP
- Practical focus, covering large capital schemes plus smaller
initiatives.
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14. Support Provided
Energy/CO2 task team
Overall Objective - To provide expertise & resource, where necessary, to
help business units/sites contribute to the TSG climate change strategy
targets of <1.7 tonnes CO2 per tonne of steel by 2012 and <1.5 tonnes CO2
per tonne of steel by 2020.
Specific Objectives - To work with energy managers & engineers across
the company to:
(i) establish/confirm baseline energy use/CO2 footprints for
each manufacturing site;
(ii) identify energy efficiency and CO2 emission reduction
opportunities;
(iii) quantify the improvement potential for each site, leading to site specific
improvement targets;
(iv) develop proposals to the point where decisions on investments can be
taken by business unit management;
(v) help to deliver energy efficiency improvements/emission
reductions through site specific improvement plans.
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15. Support Provided
Monitoring & benchmarking
RD&T, in close cooperation with each steelmaking site. are currently
developing a monitoring and benchmarking system (‘MoniCA’) for CO2
emissions
The objectives of this system are:
• to monitor CO2 emissions per site and facility with time
• to compare CO2 emissions of similar facilities
• to help to identify opportunities for CO2 emission reduction
• to improve awareness on CO2 emissions at various levels
• to benchmark the position of Corus sites in the world
First phase (2008-2009): Reporting for steelmaking sites
Second phase: Expansion to other sites
First phase plan:
• December 2008: Data collection and reporting systems tested, and
‘MoniCA’ ready for implementation
• March 2009: Monitoring and benchmarking system implemented.
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16. Support Provided
Energy workshops
Objectives
-Inform and educate key stakeholders in :-
• The energy & climate change challenge.
• Energy flows/balance for an integrated site & individual plants. (‘As Is – To Be’)
Scope
• Best Practise Energy Efficiency Technology. Scunthorpe Site
-Coke-making
-Sinter
COAL
-Blast Furnaces
COAL 12.785
OIL
+
BREEZE
-Steelmaking
0.022
COKE 1.723 -Hot Mills
1.361
COKE OVENS 0.252
COAL 3.750
BENZOLE 0.136
COKE 9.750
TAR 0.406 2.085
0.034
MISC LOSSES 0.031
0.083
1.573 BLAST FURNACES
1.827
1.868 5.024 0.036
SALES 0.142
SINTER PLANT COAL
NATURAL PLANT
PROPANE 0.024 0.396 0.320
GAS
0.079 MISC 0.151
LOSSES
0.176 OIL 0.147
BOS/
CONCAST 0.925 0.607
MISC
0.019 0.748 PROPANE 0.005
LOSSES POWER PLANT
SALES 0.001
Deliverables BF GAS BREEZE / NUTS
ROLLING 1.974 CONSUMERS
0.321
Target Audience
STEAM MILLS
-Detailed action plans
CO GAS
SALES 0.021 -Manufacturing Managers
BOS GAS ELECTRICITY
0.802 CONSUMERS -Energy Specialists
Timetable
- December 08 16

17. Climate Change Strategy
Breakthrough technology development
Ultra Low CO2 Steelmaking
A groundbreaking €59m part EU funded multi-phased R&D
project, advanced by 48 European companies and institutes,
to identify and develop breakthrough technologies that could
enable a significant (~50%) reduction in CO2 emissions from
ore-based steel production by 2050.
Example: Blast furnace gas
capture & recycling
•MEFOS / LKAB (Sweden)
•Pilot blast furnace (Ø 1.2m) CO2
•Top gas recycle
•Operation of CO2 capture (VPSA)
•8 M€
•Successful 1st campaign in 2007 CO
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18. ULCOS
Other breakthrough technologies
ISARNA
• A combination of new ironmaking technologies
(joint work with HISMELT)
• Coal preheating and partial pyrolysis in a reactor
• Melting cyclone for ore melting
• Smelter vessel for final ore reduction and iron
production
Alkaline Electrolysis
• Process operates at only 110oC
• Negatively charged oxygen ions migrate to the
anode - the oxygen is then captured.
• Remaining particles migrate to the cathode
where they undergo reduction resulting in
deposition of iron metal.
Advanced Direct Reduction
• Natural gas is treated with reactor off gases to
produce reducing gases which are injected in the direct
reduction vessel.
• The temperature in the vessel is below that needed
to melt the iron but high enough to initiate the
reduction of the iron ore.
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19. ULCOS II
From R&D to demonstration
• Likely to focus on:
- Top gas recycling blast furnace (plus
carbon capture & storage, possibly at
Scunthorpe linked to depleted North Sea
gas fields via a pipeline network being
developed by a Yorkshire & Humberside
consortium, of which Corus is a member
- Smelting reduction (ISARNA)
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20. Climate Change
Sustainable solutions
Automotive
•High strength steels/advanced high strength steels
•Low friction engineering steels for gearboxes/
engines
Construction
•Light-framed steel housing
•Carbon neutral housing, sustainable construction,
flood defence
Power
•Offshore/onshore wind turbines
•Photovoltaic coatings, which have the potential,
based on the surface area of coated steel cladding
currently sold, of generating significant quantities of
electricity.
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21. Life Cycle CO2 Emissions
Use phase dominates
CO2 vehicles/buildings/food packaging/motors/turbines
Material Assembly Use Phase End of Life
Manufacture Construction
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22. Steel Solutions
New steel
products
AHSS in automotive
Electrical steels in transformers
Electrical steels in motors
Shipping Rail
Fracture split con-rods
Composite floors
Cladding panels
Light steel framing
Colorcoat
Solar roofs
Parapets
Food cans
Pipelines Displacing
New & growing
Wind turbine Bridges Slag for alternatives
markets
towers cement 22

23. Automotive
Advanced High Strength Steel
(New Steel Products)
• 25% weight savings vs mild steel
• 1kg AHSS saves 8kg CO2 over life cycle
• Potential saving for all cars
= 156 million tonnes of CO2
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24. Thank you for your attention.
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