STK0153 – The “Green Steel” Revolution – 10 years on

Description

Date: 16 September, 2025, 13.00 UTC.

Estimated Time: 1 hr

Language: English

Summary of the lecture

In 2015, the International Energy Agency predicted that achieving net zero by 2070 would depend on converting the high-emissions blast furnace/basic oxygen furnace (BF/BOF) route to green hydrogen-based direct reduced iron (DRI) melted in green-powered electric arc furnaces (EAFs). A decade later, how much progress has been made?

While technically feasible, the hydrogen DRI–EAF transition faces significant challenges. In this steelTalk, Dr Sara Hornby will examine the state of the Green Steel Revolution, the hurdles slowing down full-scale implementation, and the transitional solutions already in play. Emerging technologies at varying stages of readiness will also be explored, offering insight into both immediate and long-term pathways for climate-neutral steelmaking.

Speaker Introduction

Dr Sara Hornby, CEng, FIMMM
President,
Global Strategic Solutions, Inc.

Dr Hornby earned her BSc (Hons) and PhD in Industrial Metallurgy at Sheffield Hallam University, UK. She began her career in metallurgy with British Steel Corporation and later built over 17 years of experience in North America with Air Liquide, leading R&D and developing patented technologies for steelmaking. She has since held senior roles with Tenova Goodfellow Technologies, Midrex, Linde Gases, Inteco, and TMS International, focusing on EAF optimisation and green steel innovation.

As President of Global Strategic Solutions, Inc., Dr Hornby advises steelmakers worldwide on decarbonisation strategies. A Fellow of the Institute of Materials, Minerals and Mining, she has received multiple awards including the AIME/AIST Benjamin F. Fairless Award, the IoM3 Hadfield Medal, and the 2024 TMS/AIST Elliott Lectureship Award.