Future Days: The metals industry’s path to progress

They say that necessity is the mother of invention – and nowhere is this clearer than in today’s metals industry, as the sector finds itself under pressure from multiple directions. The innovation taking place in research labs and pilot plants worldwide offers the chance not only to overcome these current challenges, but also to imagine new possibilities – and expand horizons for the whole industry. After all, times of change tend also to be times of opportunity for those who know how to make the most of them.

Changes and challenges

With metal smelters claiming the dubious honor of being one of the most energy-intensive industrial processes in the world, the metals industry was seriously exposed to the 2022 energy price crunch. Although prices have since fallen, they remain significantly elevated from their 2020-21 levels, with energy costs a serious consideration for every producer. This has added a new dimension to the efforts that were already underway to reduce energy consumption for environmental reasons.

Around the world, legal regulations are tightening as climate targets on greenhouse gas (GHG) emissions become increasingly binding. The difference here is that, while often ambitious and challenging, regulatory changes operate on a schedule that is understood in advance. Cutting emissions certainly takes both investment and innovation, but the sudden arrival of vast energy bills delivered an especially sharp shock to global industry.

One extra confounding factor is the increasing diversity of raw material sources, as ore grades decline globally. With less consistent raw materials comes less consistent products – and the increased risk of waste. Re-melting off-spec material has never been so expensive.

However, it could be said that the metals sector was better prepared for all this disturbance in 2022 than it would have been in 2012. Innovations like automation, digitalization and on-line process monitoring may not have taken over the industry just yet, but they are gaining ground every day and will completely change the game once they fully arrive. The pilot plants are testing; the research is being done. There are plenty of reasons to be optimistic!

The path of progress

One great example is the potential impact of switching to direct-reduced iron (DRI) processes in steelmaking to enable the use of clean hydrogen power, rather than fossil fuels, reducing GHG emissions. This transition will drive the ‘green steel’ of the future – but, like any other new process (especially automated ones!), it will require careful monitoring to stay on track.

But before the pilots are complete and the steelmaking energy transition can forge ahead, steel and other metals producers are still struggling with high costs. What can we do in the meantime?

One important solution is to start implementing the process controls and on-line monitoring that will become necessary anyway as Industry 4.0 becomes a reality. By applying these controls to existing processes, it’s possible to maximize productivity and cut costs in a short time through a variety of interconnected benefits. More consistent raw materials mean less waste and inefficiency further downstream, and also results in consistently higher quality. It’s possible to optimize energy use, preventing further waste. Finally, any problems that occur during production can be addressed immediately when results are returned in real time – avoiding expensive downtime and off-spec product.

Join our upcoming Future Days event for the metals industry on October 4

At Malvern Panalytical, we work with partners in the steel industry around the world to support them with these exact solutions. We’re privileged to have a place at the table right from the beginning of this important transition – because our combined expertise in process monitoring and the metals industry is unmatched, and because optimizing the analytical chain has never been more important or impactful for metals producers.

This key supporting role gives us deep insight into how the industry is approaching this time of transition – and how to seize the opportunities it offers. That’s why the metals industry is the focus of our upcoming Future Days event on October 4, in which we hear from experts on some of the hottest topics shaping the industry today. With both in-depth presentations and lively roundtable discussion, it’s key to understanding where we’re at today – and where we’ll likely be tomorrow.

Register for Future Days Metals and see the full agenda here.

Explore our full range of solutions for the metals industry on our dedicated industry hub here.