Whyalla | Developments & News

[claybro]

The Steel Wikipedia article starts "Steel is an alloy of iron and carbon ..."

Coal contains carbon. Hydrogen does not. To continue to make steel from iron ore (or scrap iron), a source of metallurgical carbon will be required. Is this a destination for all that stockpiled soft plastic? Will that have a high enough carbon content and consistent enough chemical content to use as a substitute for coal as an ingredient?

Isn't the article referring to fuelling the FURNACE, and not the components of steel production itself?

[mattblack]

The Steel Wikipedia article starts "Steel is an alloy of iron and carbon ..."

Coal contains carbon. Hydrogen does not. To continue to make steel from iron ore (or scrap iron), a source of metallurgical carbon will be required. Is this a destination for all that stockpiled soft plastic? Will that have a high enough carbon content and consistent enough chemical content to use as a substitute for coal as an ingredient?

Please do some research before posting blatant crap.

From AFR. Should clear up your desktop thought bubble.

Sanjeev Gupta in $500m push to make Whyalla steelworks ‘greener’

British billionaire Sanjeev Gupta’s GFG Alliance will shift to an electric arc furnace at the Whyalla steelworks in SA, ditching coal-based steelmaking by late 2025.

It has put in an order with Italian giant Danieli for the electric arc furnace. GFG also wants to build a direct reduction iron plant to process magnetite from a nearby mine in the Middleback Ranges.

The capital cost of the electric arc furnace is estimated to be up to $500m. GFG will seek to use a $50m grant on offer from the SA Government since 2016 for any large upgrade to the steelworks.

British billionaire Sanjeev Gupta says steel customers are increasingly willing to pay a “green premium” for steel produced without coal-based steel making, and that shift will only gather momentum.

His global entity GFG Alliance will spend up to $500 million on a new electric arc furnace at the Whyalla steelworks in South Australia as it phases out coal-based steel making, which has been in use since the mid-1960s.

Mr Gupta said on Tuesday that Liberty Steel, GFG’s steel unit, had ordered an electric arc furnace from Italian manufacturer Danieli, and that it aims to have it running at Whyalla by late 2025, a big step forward in the company’s “green steel” ambitions.

The Whyalla steelworks was bought by Sanjeev Gupta’s GFG Alliance in 2017. BHP built the steel plant, which has used coal-based processes for steel making since 1965. Ben Searcy

The modernisation will cut direct carbon emissions from steel making at Whyalla by about 90 per cent.

Mr Gupta also revealed longer-range plans to establish a direct reduction iron plant to process magnetite ore from GFG’s nearby mine in the Middleback Ranges. The overall investment is likely to top $1 billion across both projects.

He said industries such as car manufacturing and renewable energy infrastructure, such as wind farm towers, were at the forefront of wanting steel made with lower carbon emissions and were willing to pay more for it. “It’s beginning to happen, and it will continue on,” he said.

Electric arc furnaces make steel from melted scrap metal instead of iron ore. The Whyalla steelworks has used coking coal ovens and a blast furnace since its inception in 1965, when it was owned by BHP.

Mr Gupta said the 160-tonne electric arc furnace would lift steel making capacity at the Whyalla plant from 1 million tonnes annually to about 1.5 million tonnes.

Liberty Steel is one of the 215 highest carbon emitters under the federal government’s safeguard mechanism scheme.

Mr Gupta said GFG was a pioneer in wanting to cut emissions, and in favour of the safeguard mechanism as a tool for helping companies to steadily do that.

But it was crucial the federal government also moved quickly on a carbon border adjustment mechanism so that local manufacturers had a “level playing field” and were not penalised by higher costs in meeting the safeguard requirements, when offshore players were not subject to the same rules.

An adjustment similar to the European Union’s measures was needed to prevent carbon leakage to other countries. “Even for steel it’s a problem,” he said.

The hefty Whyalla investment comes after a rocky time for Mr Gupta’s GFG entity, which has 30,000 employees and runs steel plants in Europe, the UK and the US.

Mr Gupta’s Liberty Steel in November said it had taken a big step forward in refinancing most of the $5 billion that the collapsed Greensill empire had previously lent to his wider group. An in-principle agreement was signed then for a restructuring for most of the Greensill debt, giving GFG extra breathing space.

He said on Tuesday the financial woes of Credit Suisse, which was forced into a merger with UBS last month, was not hindering the refinancing. “We’re busy executing it,” he said.

Longer-term horizon

Mr Gupta said the investment in the electric arc furnace and associated infrastructure would be funded by Liberty Steel, but it would also apply for a $50 million grant first put on the table by the South Australian government in 2016 when administrators KordaMentha were running the steelworks and trying to find a buyer after the collapse of its parent company, Arrium.

The electric arc furnace will replace the existing coke ovens and blast furnace at Whyalla.

Mr Gupta is also eyeing a second project with a longer-term horizon for the Whyalla precinct. He wants to build a 1.8 million tonne per annum direct reduction plant (DRP) that would process local magnetite ore to produce low carbon iron.

Under those plans, the plant would initially use a mix of natural gas and green hydrogen as the reducing agent, before transitioning to green hydrogen as it becomes available at scale.

Mr Gupta said that low carbon iron can be fed into the electric arc furnace with scrap, to produce steel for Australian infrastructure projects, and to service the growing global demand for low carbon iron.

He aims to use the low carbon iron as a feedstock for Liberty’s other electric arc furnace steel plants in Australia and offshore. “The potential for Whyalla has no bounds,” he said.

The 2017 acquisition of the former Arrium by GFG also included an iron ore mine in the Middleback Ranges near Whyalla. GFG aims to lift magnetite ore mining from 2.5 million tonnes a year to 15 million tonnes a year by 2026.

Federal Climate Change and Energy Minister Chris Bowen said the Whyalla plan was “exactly the kind of investment that industry will make” following the safeguard mechanism reforms.

South Australian Premier Peter Malinauskas said the Liberty Steel plans were a big plus for the region. His government is funding a $593 million green hydrogen plant in the Whyalla precinct, which has attracted 29 bidders for the construction phase.

Andrew Forrest’s Fortescue is understood to be one of the bidders to build the green hydrogen plant in Whyalla.

[SBD]

Thank you for a clear assessment of my question: where does the carbon come from to make new steel from old iron and low carbon hematite? AFR said it won’t be from coking coal.

[mattblack]

Thank you for a clear assessment of my question: where does the carbon come from to make new steel from old iron and low carbon hematite? AFR said it won’t be from coking coal.

See article here

https://www.google.com/amp/s/stockhead. ... een/%3famp

[PD2/20]

Thank you for a clear assessment of my question: where does the carbon come from to make new steel from old iron and low carbon hematite? AFR said it won’t be from coking coal.

The question you raise regarding the proposed developments at Whyalla is a valid one. The proposals for Whyalla are twofold: The installation of an electric arc furnace (EAF) and the longer term adoption of direct reduction smelting of iron ore.

The current coke based smelting of ore produces carbon rich pig iron which has to have its carbon content reduced by the basic oxygen process to < 2% to yield steel. However EAF's are suited to production of steel from recycled steel and iron.

The direct reduction smelting processes have more stringent ore quality requirements (as described in the Stockyard article cited by Matt). However direct reduction produces carbon deficient iron which requires the addition of carbon to yield steel. Your original question relates to the source of this additional carbon. A recent article addresses this issue:
https://reneweconomy.com.au/greener-ste ... car-tyres/.

It in turn references a 2021 paper with the technical background and discussion of various sources of carbon including plastics:
https://www.mdpi.com/2075-4701/11/2/222.

[SBD]

Thank you for a clear assessment of my question: where does the carbon come from to make new steel from old iron and low carbon hematite? AFR said it won’t be from coking coal.

The question you raise regarding the proposed developments at Whyalla is a valid one. The proposals for Whyalla are twofold: The installation of an electric arc furnace (EAF) and the longer term adoption of direct reduction smelting of iron ore.

The current coke based smelting of ore produces carbon rich pig iron which has to have its carbon content reduced by the basic oxygen process to < 2% to yield steel. However EAF's are suited to production of steel from recycled steel and iron.

The direct reduction smelting processes have more stringent ore quality requirements (as described in the Stockyard article cited by Matt). However direct reduction produces carbon deficient iron which requires the addition of carbon to yield steel. Your original question relates to the source of this additional carbon. A recent article addresses this issue:
https://reneweconomy.com.au/greener-ste ... car-tyres/.

It in turn references a 2021 paper with the technical background and discussion of various sources of carbon including plastics:
https://www.mdpi.com/2075-4701/11/2/222.

Thank you. They address the question I thought I asked.

I was wrong on the detail of soft plastic, but on the right track to be reusing high-carbon waste that otherwise becomes landfill.

[1NEEDS2POST]

How will the EAF be powered? Can it be shut down when renewable energy is not available or do these EAFs need to run 24/7?

[mattblack]

New address by Gupta on Green steel future

https://youtu.be/ifX_V1W2vJo

[PeFe]

How will the EAF be powered? Can it be shut down when renewable energy is not available or do these EAFs need to run 24/7?

I presume Gupta has energy supply deal from a "supplier" this may involve gas.

Gupta can always go down the BHP road to be supplied by 100% renewables. Their deal involves 2 wind farms, a solar farm and a battery who have a constant 70mw supply to BHP......if the wind drops off the battery makes up the shortfall.

[mattblack]

Renewed calls for federal funding to help save Whyalla Airport

ABC North and West SA / By Arj Ganesan

Roughly 1,500 people used to fly in and out of Whyalla weekly.(ABC Eyre Peninsula: Jodie Hamilton)

In short: Whyalla City Council is renewing calls for federal support to help improve the viability of its airport.
The airport is the council's largest source of debt and is running on a deficit of $800,000 a year.

What's next? Council is working on strategies to help increase profitability and is due to meet with representatives from Qantas.

It has been nearly a year since Rex Airlines cancelled its services in the South Australian city of Whyalla and the knock-on effects are being felt.

The latest Essential Services Commission of SA (ESCOSA) report has again labelled Whyalla City Council "unsustainable".

According to the report the airport, which is owned and operated by the council, is the biggest contributor to the council's debt.

"Airport operations show an accumulated operating deficit of $2.8 million over the last five years [from 2018-19 to 2022-23]," the report said.

"With airport operations excluded, the council registers a $1.3m surplus over this period.

"Between 2023-24 and 2032-33 the council is forecasting an accumulated loss of nearly $5m, primarily due to the Whyalla Airport."

Rex Airlines ceased flying routes to and from Whyalla in July last year after Whyalla City Council attempted to pass on a $35-$40 per head passenger security fee, which was a split of an $80 per head fee with Qantas.

Calls for national levy

The City of Whyalla introduced the levy after federal funding to help support the initial implementation of security screening ceased.

Mayor Phill Stone said council had strenuously lobbied the federal government to introduce a national levy so smaller airports were not disadvantaged.

"Our council put submissions left, right and centre that if the government charged every single passenger at every airport 75 cents that would cover the entire cost of screening nationally," he said.

"The response was, 'Oh that's a bit ambitious, that's a bit too big. We can't cope with that at the moment — you guys just go out and sort yourselves out.'"

Before he departed from parliament, former senator Rex Patrick held several inquiries in regional Australia.

He also advocated for a national levy for security screening to keep airfares down.

"That's the approach they adopt in the United States and that's the approach they ought to be adopting here in Australia," Mr Patrick said.

"No-one is going to question security advice that says 'You need to have security screening at airports.'

"[But] these are national security requirements and the government is saying it's for the local regions to cover these national security costs — that simply doesn't make sense.

"National security is a national problem."

A strikingly-coloured building with a sign that reads "Whyalla Airport".

Passenger numbers plummet

Now that Rex Airlines no longer services Whyalla the council has passed on the $80 per head security screening fee to Qantas.

Cr Stone said that had partially contributed to the rise in airfares to and from Whyalla.

Prior to the pandemic and before security screening was introduced about 1,500 passengers travelled through Whyalla Airport per week.

That number now has dropped to roughly 900 a week.

Cr Stone said the airport's operating costs had stayed more or less static but the drop in passengers had caused a severe loss in revenue.

"We're losing about $800,000 per year operating the airport," he said.

A small passenger aircraft on a runway at a country airport.

Member for Grey Rowan Ramsey said he was incensed that the council had been left in a "no-win situation".

"This is pretty much what I warned would happen," he said.

"Now, if they want Whyalla to be the jewel of the north, the hydrogen hub of South Australia, well, they're going to have to start digging into their own pockets."

Cr Stone said he could not comment on whether the airport could be sold off or closed.

"Unfortunately that's a hypothetical question I can't answer at the moment," he said.

Mr Stone said he was due to meet with representatives from Qantas to discuss airfare prices.

Infrastructure, Transport, Regional Development and Local Government Minister Catherine King was contacted for comment.

[1NEEDS2POST]

Adelaide to Whyalla is about the range the first generation of electric airliners will have. There's potentially opportunity to ask for subsidies to trial electric airliners when they become available.

[rev]

Whyalla Hospital‘s $15.4m redevelopment with expansion to emergency and high dependency departments
A major regional hospital in the state’s north is getting a $15.4m revamp. See the designs.

Leon Georgiou
Leon Georgiou
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@TiserLG
less than 2 min read
July 9, 2024 - 1:42PM


The Whyalla Hospital is set to undergo a $15.4 million dollar redevelopment including an expansion to the emergency department and high dependency unit. Picture: Supplied.

The Whyalla Hospital is set to undergo a $15.4 million dollar redevelopment with an expansion to its emergency department and upgrades to the high dependency unit.

The redevelopment will include 12 new ED treatment bays – increasing from its current capacity of seven – along with a new reception and waiting rooms.

Other upgrades include a new negative pressure isolation room, two behavioural assessment rooms for patients in distress and a new triage and assessment zone.


The state government has committed $4 million towards the project, with the remaining $11.4 million being committed by the federal government. Picture: Supplied.


The redevelopment will include 12 new ED treatment bays. Picture: Supplied.

The redevelopment is set to begin this year and due to be completed by 2025 with no disruptions to hospital services expected.

The new announcement comes a week after the hospital resumed birthing services in its newly upgraded Woonabie Birthing Unit.

The state government has committed $4 million towards the project, with the remaining $11.4 million being committed by the federal government.

SA’s Minister for Health Chris Picton said the recent redevelopments represented the biggest investment in the Whyalla Hospital in a decade.

“The new Birthing Unit is already providing a wonderful service to the community in a fresh and welcoming space, now the ED and HDU are getting a revamp too,” he said.

“The staff here provide a fantastic service, and these new upgrades will help them deliver the best of care to the whole community.”

While Flinders and Upper North Local Health Network Chief Executive Officer, Craig Packard said the “state-of the art facilities”, would help the hospital attract much needed staff to the area.

https://www.adelaidenow.com.au/messenge ... 9d30b094b5


And before anyone asks what the word Woonabie means, it means connection between the women, the placenta, and the afterbirth, and was chosen by the Barngarla people.

[mattblack]

Whyalla set to take flight with sustainable aviation fuel project

Energy company Zero Petroleum will explore the development of a low-carbon sustainable aviation fuel production facility in Whyalla, with the support of the State Government and industry.
Zero Petroleum, a leading producer of synthetic fuel, is exploring the opportunity for a commercial-scale production plant - Plant Zero.SA - to be located in South Australia’s Upper Spencer Gulf.

It is undertaking a feasibility study which includes collaboration with an aviation industry consortium led by Adelaide Airport and Qantas Airways.

The State Government today signed a Letter of Intent to provide support to the feasibility study in a facilitating role.

Whyalla is at the epicentre of the State Government’s State Prosperity Project, which will see the construction of a world-leading renewable hydrogen facility, positioning the Upper Spencer Gulf as a hub for emerging industries that will leverage hydrogen production at scale, helping to significantly reduce emissions.

Synthetic fuels, or e-fuels, are created by combining renewable hydrogen with carbon dioxide to produce a low carbon fuel compatible with existing aircraft, road vehicles and maritime applications. Sustainable fuels are the key means for airlines to reduce emissions and will be critical to achieving the industry’s goal of net zero by 2050.

The six-month feasibility project will evaluate the technical, economic and environmental viability of a facility capable of producing up to 10 million litres of synthetic aviation fuel, gasoline and diesel annually.

The project has the potential to create up to 150 full-time-equivalent jobs during the construction phase, spanning engineering, technical and trade roles, with 25 to 30 ongoing operational positions.

This initiative would support the aviation industry’s global commitment to achieving net-zero emissions by 2050 and reinforce South Australia’s efforts as a global leader in the low-carbon transition while driving innovation and economic growth in sustainable industries.

https://www.premier.sa.gov.au/media-rel ... el-project