Hazer Group has extended its non-binding Memorandum of Understanding (MOU) with Japanese trading giant Mitsui & Co, Ltd (Tokyo, Japan), pushing forward joint efforts to explore potential markets for Hazer’s low-emissions graphite. 

The agreement, which builds on the original MOU announced on 16 November 2022, will now continue for another year, with automatic renewals unless terminated by either party, as revealed in an ASX announcement. 

The partnership leverages Mitsui’s extensive global network to evaluate the applications of Hazer’s graphite in steel manufacturing, chemicals, and other sectors. 

Hazer has already conducted positive market analysis, identifying promising segments for its graphite, including iron and steel production, thermal energy storage, and water purification.

“We are excited to be extending our strategic partnership with Mitsui,” said Hazer’s CEO and Managing Director, Glenn Corrie. 

“Hazer’s technology is unique in that it produces both low-cost, clean hydrogen as well as a low-emissions graphite product.”

Initial investigations have pointed to a variety of applications for Hazer’s graphite:

• Steel Manufacturing: Hazer’s graphite demonstrates suitability for both traditional blast furnaces and emerging green-steel processes, owing to its structured composition and iron inclusion.
• Thermal Energy Storage: Its excellent thermal conductivity and stability make it an efficient medium for heat transfer.
• Water Purification: Hazer’s graphite has shown potential for enhanced PFAS removal, a growing environmental concern.
• Construction Materials: The graphite is also being evaluated for asphalt, bitumen, and concrete production.

According to Corrie, the collaboration with Mitsui helps Hazer access challenging markets and critical industries where decarbonisation solutions are in high demand. 

“In light of increased global awareness around the vulnerability of critical mineral supply chains, this is a clear value differentiator for Hazer’s technology in the methane pyrolysis space,” he added.

As part of the extended agreement, the two companies will move forward with further product evaluation and larger sample testing from Hazer’s Commercial Demonstration Plant (CDP). 

Both companies will also engage with potential buyers to establish volumes, pricing frameworks, and potential offtake agreements.

“Through this important partnership with Mitsui, we have jointly identified markets that offer a good fit for our graphite, and discussions are ongoing to establish volume, pricing ranges, and potential offtake opportunities,” Corrie explained.

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InfraBuild, an Australian recycling firm, has advanced its sustainability efforts by installing a relocatable two-storey office complex made from shipping containers at its vast one-million-square-metre facility in Mayfield, Newcastle.

Developed by Modulate Group, this innovative project highlights InfraBuild’s dedication to eco-friendly practices and demonstrates the viability of steel as a sustainable and long-lasting building material.

The 225-square-metre office development, bathed in natural light, was custom-built to meet the needs of InfraBuild’s recycling staff. 

As Australia’s only fully vertically-integrated steel manufacturer, InfraBuild leads the charge in material circularity, using electric arc furnaces to transform high-quality scrap steel into new products, diverting waste from landfills and contributing to the global circular economy.

David Bowden, National Project Operations Manager at InfraBuild Recycling, praised the design, noting that it aligns with the company’s sustainability goals while offering practical benefits.

“We believe the very tough but very comfortable relocatable steel building we refined and customised shows what can be achieved within the scope of well-designed container-based steel buildings,” Bowden said.

The structure consists of eight 20-foot and two 40-foot shipping containers, customised to create a spacious, functional workspace with built-in insulation and integrated utilities. 

Key sustainability features include efficient water management, climate control systems, and the ability to be disassembled and relocated as needed, offering long-term flexibility for InfraBuild’s operations.

The office complex includes:

• Top-floor open layout: A large boardroom and manager’s office feature sliding glass doors and panoramic windows, providing expansive views of the worksite.
• Ground-floor offices: Seven private offices are connected by a wide hallway, with a foyer and additional workspaces.
• Well-equipped kitchen: Includes modern Polytec® joinery, a breakfast bar, and a ZIP hot and cold filtration system. An additional kitchenette maximises space at the end of the hallway.
• Bathrooms: Two bathrooms fitted with R10 sheet vinyl surfaces for easy cleaning and durability.
• Staircase and roof design: A galvanised steel staircase with custom handrails connects the two floors. The cyclone-rated roof and water management system, including gutters and downpipes, ensure efficient rainwater conservation.
• Climate control: Three external AC units power 16 interior head units, ensuring a comfortable environment throughout the structure.

Bowden highlighted the office’s resilience, noting it was built to endure the challenges of a demanding industrial site.

“The strength is built into it, so it can comfortably accommodate hard-working crews with all their gear, without having to worry too much about damage. Even if the exterior of the building got a bump from site machinery, it is built to take the knocks without spilling insulation or fracturing services,” he said.

For more details on the project, visit Modulate Group or learn about InfraBuild’s operations at InfraBuild.

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Over the past decade, more than 1,850 workers have lost their lives to traumatic injuries in Australian workplaces. Even more alarming, over 1.1 million workers have filed serious compensation claims for injuries resulting in more than a week of lost work time. That is approximately one in every 12 workers facing significant workplace injuries.

These numbers paint a grim picture of workplace safety across Australian industries, with steel manufacturing being particularly high-risk. However, a technological revolution is on the horizon, promising to dramatically reshape the safety landscape of Australia’s steel manufacturing sector.

As Australia’s steel industry grapples with the dual pressures of global competition and stringent safety standards, many experts have pointed to artificial intelligence and robotics as the compelling solution. It is not just about boosting productivity but fundamentally transforming how Australia approaches safety in one of its most vital yet hazardous sectors.

This is the argument Professor Cori Stewart, founder and CEO of Advanced Robotics for Manufacturing (ARM) Hub, presented at the recent Finding Your Productivity Edge with Robots and AI.

The role of AI in boosting safety

While automation is crucial, AI’s role in enhancing safety at steel mills extends far beyond replacing human workers in dangerous tasks. AI systems are being deployed to predict potential hazards, optimize processes, and create a more proactive approach to safety management.

Pointing to Australian successes in AI and robotics, Professor Stewart cited Boeing Australia’s delivery of the Ghost Bat autonomous warfighting aircraft and the automation of more than 700 Caterpillar, Komatsu and Hitachi haulage trucks in the Pilbara mines.

These achievements demonstrate Australia’s capacity to develop and implement advanced AI and robotics solutions in complex, high-risk environments.

Looking to the future, Professor Stewart advocates for a holistic approach to implementing AI and robotics in the steel industry.

“Often we hear about companies creating downstream value (how they create jobs or attract vocational education training (VET) educated staff or low skilled workers), and we also need to ask different questions about how to create upstream value using highly skilled jobs, jobs that may not even exist yet but will soon; indeed it means companies investing more in high-value skills and high-value products than they are likely to now.” 

This vision calls for steel manufacturers to invest not just in the technologies themselves, but in the high-value skills and products that will drive the industry forward. It suggests a future where safety, productivity, and innovation are all linked and powered by AI and robotics.

Shaping tomorrow’s Australian steel production

Undoubtedly, AI and robotics are set to become cornerstone technologies in tomorrow’s workplace safety. Many industry leaders hope that this means safer work environments and more innovative workplaces. The challenge now lies in embracing this change. This means investing in the necessary skills and infrastructure while ensuring that the safety and well-being of workers remain at the forefront.

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BlueScope Steel Limited has announced the release of its FY2024 Sustainability Report, outlining its progress and future plans towards creating a more sustainable and environmentally friendly steel manufacturing process. 

The report highlights significant achievements in reducing greenhouse gas (GHG) emissions, promoting responsible supply chain practices, and fostering a safe, inclusive workplace.

Sustainability leadership and global recognition

BlueScope has received global recognition for its sustainability efforts, being named a worldsteel 2024 Sustainability Champion. 

It also secured ResponsibleSteel site certification for its Phu My facility in Vietnam, marking a notable achievement in the Southeast Asian steel industry.

BlueScope’s CEO, Mark Vassella, emphasised the company’s commitment to environmental stewardship and community development across the 15 countries where it operates.

Emission reduction milestones

According to the report, in New Zealand, BlueScope’s Glenbrook site is undergoing a transformative upgrade with the construction of an electric arc furnace (EAF). 

This project, in partnership with the New Zealand government, is expected to reduce the site’s Scope 1 and 2 GHG emissions by 55 per cent. BlueScope’s Delta, Ohio steel mill in North America has contributed to a 12 per cent reduction in steelmaking emissions intensity since 2018.

In Australia, BlueScope is exploring lower-emission ironmaking technologies, including the use of natural gas and hydrogen. These developments could reduce GHG emissions by as much as 85 per cent, marking a step towards BlueScope’s long-term goal of achieving net-zero emissions by 2050.

Community and workplace safety initiatives

Safety remains a top priority for BlueScope, with the company reporting several key safety initiatives in 2024. A global “Refocus on Safety” program was launched to address safety risks in high-risk activities, including the cleaning of live equipment. 

However, BlueScope reported four incidents in FY2024 that resulted in permanent incapacities, underscoring the continued importance of safety innovations.

BlueScope also emphasised its efforts to foster an inclusive workplace. The company maintained its target gender balance for its Board and Executive Leadership Team (ELT), with women representing 25 per cent of its workforce globally. 

In New Zealand, BlueScope received the Inclusive Workplace award at the Diversity Awards NZ for its progress in gender equity and inclusivity.

Collaboration for a sustainable future

To further its decarbonization goals, BlueScope has partnered with leading Australian iron ore producers Rio Tinto and BHP to investigate the feasibility of Australia’s first ironmaking electric smelting furnace (ESF). 

This collaboration could help pave the way for near-zero GHG emissions in steel production, utilizing renewable energy and direct reduced iron (DRI) technology.

Additionally, BlueScope continues to prioritise circularity within its operations, focusing on the durability, reuse, and recyclability of steel products. 

The company said it is working closely with universities, industry partners, and customers to address sustainability challenges, from designing longer-lasting products to reducing the carbon footprint of steel across its lifecycle.

For more information about BlueScope Steel’s sustainability initiatives and to view the full report, visit bluescope.com.

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Despite being a cornerstone of Australia’s economy, the country’s steel manufacturing industry is currently facing a critical juncture amid intense global competition.

Professor Cori Stewart, CEO of the Advanced Robotics for Manufacturing (ARM) Hub, says the country’s productivity is at a 60-year all-time low, with the steel manufacturing industry at the epicentre of these challenges.

Australia’s manufacturing landscape today, particularly steel manufacturing, is a mix of traditional practices and emerging technologies. And while it continues to produce high-quality products, the entire sector still finds itself grappling with a multitude of issues, such as rising energy costs, environmental regulations, and an ever-increasing need for efficiency.

Professor Stewart says these challenges mean companies need to move beyond “business as usual” and adopt innovative strategies to be globally competitive. According to her, the answer lies in fully embracing the critical role of artificial intelligence (AI) and automation in Australia’s steel manufacturing sector.

Driving competitiveness and growth

It goes without saying that AI and automation are no longer just buzzwords in manufacturing. They are not just merely enhancing existing processes, but revolutionising the entire landscape. AI-driven systems can optimise production schedules, predict maintenance needs, and enhance quality control, leading to significant cost savings and increased productivity. Automation, on the other hand, eliminates the need for humans to handle dangerous or repetitive tasks, enhancing worker safety and freeing up human resources for more complex, value-added activities

“In the highly competitive steel industry, AI and automation is helping Australia realise business growth and competitiveness, commercialise research and development, address skills shortages, and compete in an economy that is rapidly decarbonising,” says Stewart.

Capitalising on green energy demand

The transition to a low-carbon economy presents both challenges and opportunities for the Australian steel industry.

According to the ARM Hub executive, the continuous growth in the manufacturing industry, particularly in steel production, was likely because of the global shift towards sustainable practices. However, she argued that the industry must embrace technological advancements to fully capitalise on these opportunities.

Addressing productivity challenges

Aside from Australia’s productivity levels being a cause of concern, manufacturers are also facing a low adoption rate of robotics. Out of 38 developed countries, Australia ranks 35th in robot population density in the sector. This represents a substantial gap in technological integration that puts Australian manufacturers at a significant disadvantage compared to their global counterparts.

Such lag in robotics adoption has far-reaching implications. Manufacturers in countries with higher robot density can benefit from increased productivity, improved quality control, and enhanced operational efficiency.

These advantages translate into lower production costs, faster throughput and rollout to market, and greater flexibility in meeting customer demands – all crucial factors in the highly competitive global steel market.

Creating upstream value in Australian manufacturing

Citing success stories in Australia’s AI and robotics integration, Stewart pointed to Boeing Australia’s delivery of the Ghost Bat autonomous warfighting aircraft and the automation of more than 700 Caterpillar, Komatsu, and Hitachi haulage trucks in the Pilbara mines.

“This is the kind of high-value, highly skilled industry Australia needs. We need it to back our steel industry and therefore we need to nurture our local tech capability.”

Looking to the future, Stewart advocates for a shift in focus towards creating upstream value in manufacturing, especially in steel production.

“Often we hear about companies creating downstream value (how they create jobs or attract vocational education training (VET) educated staff or low skilled workers) and we also need to ask different questions about how to create upstream value using highly skilled jobs, jobs that may not even exist yet but will soon; indeed it means companies investing more in high-value skills and high-value products than they are likely to now.”

All for a competitive edge

As a cornerstone of Australia’s manufacturing industry, the steel sector’s performance serves as a barometer for the overall health of Australia’s manufacturing capabilities. The integration of AI and robotics is not just an option; it is a necessity for its survival and growth in an increasingly competitive global market.

To address this crucial topic, leaders of the Australian steel industry will gather at the upcoming Australian Steel Convention 2024 in Brisbane from 8 to 10 September 2024. A highlight of the convention will be Professor Cori Stewart’s presentation titled “Finding Your Productivity Edge with Robots and AI.” For more information, visit steel.org.au.

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The Australian Steel Institute (ASI), the peak body for the local steel industry, is urgently seeking state and federal government intervention to support local steel fabricators and manufacturers. 

This follows a recent survey revealing the domestic market is being seriously undercut by a surge of cheap imported steel, the organisation said in a news release. 

An ASI survey conducted in July 2024 found that 86 per cent of local steel fabricators and manufacturers had reduced profit margins due to cheap imported fabricated steel, which is priced between 15 per cent and 50 per cent lower than locally produced steel. 

This price disparity suggests that subsidies from the country of origin and/or dumping—selling goods at below market value to gain market share—are major contributors to the problem. 

ASI noted that such practices breach international trade rules and place local businesses at a severe disadvantage.

Mark Cain, CEO of ASI, highlighted the detrimental effects on east coast fabrication businesses, particularly those reliant on the portal frame market for structural steel, as well as other steel product manufacturers. 

He noted that impacted businesses are reporting a loss of viability due to decreased profit margins, reduced revenue from lower volumes and capacity utilisation, and increased costs.

The survey revealed that nearly half of the respondents are restructuring to remain viable. The brunt of the impact is being borne by small and medium-sized businesses, each employing between 20 and 200 Australians, providing skilled employment in their local regions. 

Approximately 80 per cent of surveyed businesses are operating at less than 80 per cent capacity utilisation, a critical benchmark for breakeven profitability in manufacturing. 

Alarmingly, the report revealed that one-fifth of businesses reported operating at below 50 per cent of production capacity.

The survey adds to reports received by ASI from its members over the past year, painting a grim picture of businesses laying off long-term, skilled staff due to significantly diminished orders. 

“The ASI is engaging with state and federal governments to bring this problem to their attention, explain the damage being done to strategically important local industries, and identify possible actions to provide relief to our members,” Cain said.

A general manager of a long-established NSW steel fabrication business, who participated in the survey, emphasised the disruption caused by the influx of unsustainably priced steel imports. 

“We estimate that over the past 18 months, almost $300 million worth of steel has been imported into Sydney alone,” he said. “This money is going offshore, directly affecting the Australian market and local jobs.” 

The general manager added, “The downturn in local work impacts not only our business but the entire steel industry. It is disheartening to see the repercussions, especially for our dedicated workshop team.”

Another Sydney steel product manufacturer, who preferred to remain anonymous, called for a more proactive government approach to investigate potential dumping. 

He noted that governments need to investigate whether products are being dumped in Australia at greatly reduced prices by countries struggling to find outlets in their own markets due to a downturn in demand.

According to ASI, the outcomes of these investigations are expected to be made public in the coming months.

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The NSW Government has granted planning approval for a refurbishment of BlueScope’s 60-year-old plate mill, aiming to boost production, invigorate the state’s economy, and create new local jobs.

This development marks a significant endorsement of NSW’s local steel operations, promising an estimated $650 million economic stimulus, the government said in a media release.

The upgrade will enhance production capability and capacity at the Port Kembla site, where steel slabs are processed at 1300 degrees Celsius, to meet increased demand in the construction, renewable energy, and defence sectors.

The multimillion-dollar project includes replacing two existing furnaces with newer, more energy-efficient alternatives, upgrading infrastructure, and modernising processing equipment.

This modernisation will also reduce environmental impacts, significantly cutting fuel consumption.

The project is set to boost production capacity from 430,000 to 600,000 tonnes annually, inject $650 million into the NSW economy, and create 95 full-time construction jobs at peak times along with 18 additional operational positions.

The State Significant Development approval will enable BlueScope to support the emerging renewable energy sector in the Illawarra by producing more high-quality steel plates, aiding the state in achieving its Net Zero by 2050 target.

In a broader show of support, the government has also announced the formation of a ‘whole of government’ Working Group, chaired by the Minister for Planning and Public Spaces and Member for Wollongong.

This group will coordinate decision-making for the largest industrial land reactivation proposal in the world, akin to transforming land use in Sydney CBD from Circular Quay to Central Station, potentially providing employment for up to 30,000 people.

Minister for Planning and Public Spaces and Member for Wollongong Paul Scully remarked, “Port Kembla Steelworks is an important part of Wollongong with a history of steelmaking of nearly 100 years. This major project represents the most comprehensive upgrade of the plate mill since it was built in 1963.”

He added, “Much of the original plant is still in use today including the original reheat furnaces, and 6 decades later, this upgrade is needed to modernize operations and increase efficiency.”

Scully also highlighted the broader impact, “Combined with the reline of the number 6 blast furnace and the approved jetty upgrades, these investments signal a strong future for steelmaking in the Illawarra.”

“I look forward to this upgrade getting underway and these new highly skilled job opportunities being offered to the local community,” he remarked.

Chief Executive of Australian Steel Products Tania Archibald emphasised the strategic importance, stating, “This project is a testament to BlueScope’s vision to be a vibrant, modern, and sustainable manufacturer in Australia.”

Works are set to commence in July 2024 and will take three years to complete.

For more information, visit the NSW Planning Portal.

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Australia’s top iron ore producers, Rio Tinto and BHP, have joined forces with the country’s largest steelmaker, BlueScope, to spearhead efforts in decarbonising steel production.

The trio has committed to jointly explore the development of Australia’s inaugural ironmaking Electric Smelting Furnace (ESF) pilot plant, marking a significant stride towards sustainable steel manufacturing.

Under a newly inked framework agreement, Rio Tinto, BHP, and BlueScope will consolidate their respective expertise and resources to propel the advancement of ESF technology, Rio Tinto said in a news release.

This initiative aims to demonstrate the viability of producing molten iron from Pilbara ores using renewable energy sources, coupled with Direct Reduced Iron (DRI) process technology.

If successful, this initiative could pave the way for steelmakers reliant on Australian iron ore to achieve near-zero greenhouse gas emissions.

The partnership underscores a commitment to collaborative innovation, leveraging BHP’s and Rio Tinto’s profound understanding of Pilbara iron ores alongside BlueScope’s operational proficiency in ESF technology.

By pooling their strengths, the companies seek to expedite the transition to low-carbon steel production methods.

Assessments for potential pilot plant locations across Australia are already underway, taking into account various factors such as infrastructure availability, workforce accessibility, and suitability for operational trials.

The pre-feasibility study is slated for completion by the end of the year, with plans for the pilot facility to be operational as early as 2027, pending approval.

Simon Trott, chief executive of Rio Tinto Iron Ore, emphasised the urgency of addressing the carbon intensity of steelmaking.

“We must find better ways to enable these materials to be made more sustainably through leveraging technology,” he noted.

Echoing Trott’s sentiments, Tim Day, incoming BHP Western Australia Iron Ore Asset President, expressed enthusiasm for the partnership’s potential to revolutionise steel production, calling collaborations like this “so important for the success of these technologies.”

Tania Archibald, chief executive Australia of BlueScope, outlined the company’s vision for sustainable manufacturing, emphasising the significance of leveraging Australia’s natural advantages in iron ore resources and renewable energy potential.

“We believe that this collaboration where we can contribute BlueScope’s unique experience in operating an ESF will be key to cracking the code for Pilbara ores in low emission-intensity ironmaking,” Archibald concluded.

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The Australian government has announced $200 million in grant funding that aims to help Australian steel manufacturers be globally competitive and secure the future of the local steelmaking industry. 

The grant marks the launch of the first round of Powering the Regions Fund (PRF), delivering support to BlueScope Steel Limited and Liberty Steel Australia. 

BlueScope received $136.8 million in funding to reline and upgrade its No. 6 Blast Furnace at the Port Kembla Steelworks. The project aims to maintain domestic production, reduce emissions, and support pathways to produce even lower-emissions steel in the future. 

Approximately 250 additional workers are expected to be hired during the upgrade and relining of the blast furnace.

The BlueScope project is also expected to help secure the local workforce over the long term, including the thousands of jobs at the Port Kembla Steelworks. 

Meanwhile, Liberty Steel Australia was awarded $63.2 million in funding, which it will use to replace its existing traditional blast furnace at the Whyalla Steelworks with a low-carbon electric arc furnace (EAF). 

The new EAF will support the manufacturing of green steel and help Liberty reach its carbon neutrality goals by 2030. 

Liberty’s transition to green iron and steel is expected to scale the company’s workforce by around 24 per cent over five years and help provide retaining and opportunities to learn new skills for a substantial number of existing employees.

“This $200 million investment in the steel sector is about securing the long-term future of the steel industry in Australia. As we undergo the transformation to Net Zero it is vital that we support our industries to adopt and manufacture cleaner technologies,” said Minister for Climate Change and Energy Chris Bowen. 

“Steel is essential for our energy transformation. Ninety per cent of the materials that go into making a wind turbine are steel and cement, and we’re going to need a lot more of it.”

 “Regions like the Illawarra and Whyalla have been industrial powerhouses for generations, making the steel used in building our houses, infrastructure and industry, while creating jobs, and we want to see this continue,” Bowen added. 

The grants mark the rollout of the PRF under the Critical Inputs to Clean Energy Industries program. 

The initiative aims to support hard-to-abate sectors like steel to allow Australia to keep making things that are vital to the energy transition, including electricity and rail infrastructures like wind towers, solar farms and energy transmission, and the construction of energy-efficient buildings. 

The Albanese government also recently announced $200 million in grant funding to support hard-to-abate cement and lime and alumina and aluminium sectors. 

Successful projects are slated to be announced in the coming months. 

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BlueScope is set to make modifications to its external reporting segments to consolidate and simplify the reporting of its North American operations, following its recent acquisitions in the United States.

The ASX-listed company said that its Coated Products North America business, which includes the Steelscape and ASC Profiles businesses from the joint venture with Nippon Steel, will be moved from the existing Building Products Asia and North America segment and combined with the Buildings and Coated Products North America segment.

The existing Building Products Asia and North America segments will be renamed Coated Products Asia, and will now include the ASEAN-based operations of the joint venture with Nippon Steel, the wholly-owned BlueScope China business, and the Tata BlueScope business.

According to the steel company, there are no further changes to BlueScope’s existing reporting segments, and this reporting change will take effect for the fiscal year ending 30 June 2023 and subsequent years.

The adjustments to BlueScope’s reporting segments have no effect on the combined group’s reported statutory or underlying results for the current or past periods.

Comparisons of sales revenue, reported EBITDA, reported EBIT, underlying EBITDA, and underlying EBIT for the previous three years under the new and former segments, together with restated despatch volumes can be found in the company’s ASX release. 

The updated reporting segment structure will be reflected in an update of BlueScope’s extended financial history, which will be made available on the company website on 4 August 2023.

BlueScope, originally a BHP business group, became an independent steel company on 15 July 2002 and was publicly traded on the Australian Stock Exchange (ASX).

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