Innovative Strategies for Decarbonizing Steel Production to Combat Climate Change

Sydney Rose Johnson, a graduate student at MIT, has not yet visited the steel mills of central India or the vast steel plants of the American Midwest. However, over the past year, she has gained an extensive understanding of steel production.

Decarbonizing Steel Production: A Critical Challenge

As a fourth-year dual-degree MBA and PhD candidate in chemical engineering and a graduate research assistant with the MIT Energy Initiative (MITEI), Johnson is dedicated to finding ways to minimize carbon dioxide (CO2) emissions from industrial processes in hard-to-abate sectors, including steel.

Steel is a fundamental material found in virtually all infrastructure and transportation systems—ranging from buildings and bridges to cars and mass transit. Despite its critical role, the methods of steel production have seen little evolution since the Iron Age, with some plants in the U.S. and India operating continuously for over a century.

The World Economic Forum projects that steel demand will rise by 30 percent by 2050 due to population growth and economic development in regions such as China, India, Africa, and Southeast Asia.

As one of the largest contributors to global CO2 emissions, the steel industry produced an average of 1.89 tons of CO2 for every ton of steel made in 2020, accounting for about 8 percent of total global emissions, according to the World Steel Association.

Innovative Modeling and Pathways

To tackle this significant environmental challenge, Johnson emphasizes the necessity of combining innovative technical strategies with substantial financial investments to achieve meaningful reductions in these emissions.

Her thesis focuses on modeling and evaluating decarbonization pathways for steel production. By analyzing data from academic and industry sources, she creates models that assess emissions, costs, and energy consumption at the plant level.

Johnson states, “I optimize steel production pathways using emission targets and industry commitments while considering costs.” Given the projected growth of India’s steel industry, she conducts case studies predicting outcomes for over a thousand factories with a combined capacity of 154 million metric tons.

In her analysis for the U.S., she explores the impacts of the Inflation Reduction Act (IRA) credits introduced in 2022, which incentivize efforts to lower carbon emissions in the steel sector.

“If we start today, what would a cost-effective production scenario look like in the years ahead?” she asks. She investigates how various factors would influence achieving a 50 percent reduction in emissions from 2005 levels by 2030.

“Despite challenges, there are pathways forward,” she concludes. “Understanding where the industry stands has been an enlightening journey.”

Early Inspirations and Educational Journey

Raised in Marietta, Georgia, her early exposure to industrial processes came through her father, a chemical engineer in logistics for an aerospace firm. During high school, she interned with chemical engineers working on product stability issues.

At Kennesaw Mountain High School, where she participated in a STEM magnet program, Johnson dedicated a semester to an internship focused on researching chemical solutions at Kemira Chemicals—a company specializing in water-intensive industries.

“I aimed to comprehend why a polymer product was unstable,” she recalls. This experience honed her problem-solving skills and solidified her desire to pursue engineering.

At Stanford University, Johnson explored various applications of chemical engineering, including biotechnology and energy systems. The diversity of fields sparked her intrigue in finding innovative solutions.

At MIT, her focus shifted toward addressing climate change through technological advancements in industries like steel.

Passion for Sustainable Technology and Industry Impact

“I’m passionate about the intersection of technology, global communities, and policy,” she explains. “My goal is to find solutions that benefit under-resourced populations while addressing environmental challenges.”

“Initially, I didn’t envision working within the steel industry when considering climate change mitigation,” she admits. However, recognizing steel’s critical role in infrastructure development has underscored its importance in the climate conversation.

Although many steel mills are aging, some remain highly energy-efficient. Nonetheless, these facilities still produce substantial emissions due to their high-temperature operations.

“Reducing emissions is crucial for creating a cleaner environment,” Johnson emphasizes. She highlights that pollutants such as nitrogen oxides and sulfur oxides also pose health risks near production facilities.

Technological Innovations and Future Prospects

The International Energy Agency’s roadmap suggests that modern technologies or alternative fuels can improve sustainability in the iron and steel sector. These alternatives include clean hydrogen and biomass.

“Using MITEI’s SESAME modeling tool, I analyze various decarbonization strategies,” Johnson notes. She examines options such as switching to hydrogen fuel or integrating carbon-capture technologies, evaluating their potential effectiveness.

“The feasibility of these strategies often hinges on upstream emissions,” she points out. While charcoal from biomass appeared promising, her models revealed limitations in its emission reduction effectiveness during processing.

“The industry’s shift toward recycling scrap into new steel products and adopting emission-reducing technologies is encouraging,” Johnson observes. “Though low-carbon steel can be significantly more expensive than traditional methods, the environmental benefits justify the transition costs.”

“After graduation, I plan to continue working in energy,” Johnson shares. “I hope to leverage my engineering and business expertise to mitigate climate change, possibly through clean technology startups or policy initiatives.”

“Connecting private and public sectors is vital for implementing environmental improvements that can benefit diverse populations.”