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How stainless steelmakers can reduce AUTHORS AKIO ITOSenior Partner Stainless steel producers are addressing Scope 1 & 2emissions, yet their product carbon footprints often exceedthose of conventional steel. The challenge lies upstream: MICHAEL POETZLPartner HANNAH ZUEHLKEPartner ROBERT BARONPrincipal Global stainless steel production has grown substantially over the past twodecades, reaching 62.6 million tons in 2024 – a 74% increase since 2010 and morethan twice the rate of overall crude steel production (Figures 1 and 2). This expansion Global stainless steel production has grown at more than twicethe rate of overall crude steel production As production of stainless steel scales, so does scrutiny of its carbon footprint.End-consumer awareness and tightening regulatory frameworks, such as the EU Ferroalloys carry high PCFs and embedded emissions Product carbon footprints of exemplary ferroalloys Moreover, while integrated (blast furnace–based) producers must primarilydecarbonize their production assets, secondary steelmakers face a differentchallenge: reducing the footprint of sourced input materials. Scope 3.1 emissions "With emissions factors up to82,000kgCO₂ per ton, upstreammaterials are the stainless steelindustry's largest carbon source, even AKIO ITOSenior Partner Stainless steelmakers are usually experienced scrap handlers, with many workingwith scrap traders or operating their own scrap facilities. Scrap carries no Through careful sorting – often distinguishing between more than a hundreddifferent types of scrap – producers can achieve scrap ratios of ~80-90% and higher •Lower melt shop productivity:Very high scrap ratios require lower meltingtemperatures to minimize losses, leading to longer tap-to-tap times and reduced •Higher costs:Additionally, more intensive sorting and handling increases •Higher process control requirements and reduced flexibility:Process controlbecomes more demanding with a higher scrap ratio. Quality deviations in liquid "To future prooftheir businessmodels, stainlesssteelmakers mustmaximize theirscrap sorting poten- •Scrap availability constraints:Availability of alloyed scrap is usually given foraustenitic and duplex grades with high nickel contents as these grades constitute Option 2: Securing low-carbon ferroalloys The need to decarbonize is beginning to shift supplier dynamics as well. Currently,green ferroalloy production is limited to specific alloys (e.g. ferrochrome, Broader availability will take years to develop and will likely command premiumpricing. Nonetheless, early market signals are emerging; some producers are Option 3: Developing secondary ferroalloy capacity ROBERT BARONPrincipal While steel recycling is well established, alloy recycling remains smaller-scale andtechnically complex. Hydrometallurgical processes can leach metals from waste Several facilities are in operation or planning stages. Investments in such facilities,whether by steelmakers or recyclers can increase the supply of secondary Green ferroalloys can significantly reduce CO2 burden, PCF of exemplary stainless steel grades1; grey vs hypothesized green options The optimal approach will vary based on grade, availability, prices, and individualproduction setup. To future proof their business models, stainless steelmakersshould investigate the potential of improved scrap sorting to maximize input and With the right approach, producers can transform Scope 3.1 emissions from a liability Roland Berger's Materials & Process Industries practice works withleading steel companies worldwide to design scrap and alloy strategies, AKIO ITO Senior Partner+49 89 9230 8583 MICHAEL POETZLPartner+49 89 9230 8430 HANNAH ZUEHLKEPartner+49 711 3275 7301 ROBERT BARON Principal+41 43 336 87 82 This publication has been prepared for general guidance only. The reader should not act according to anyinformation provided in this publication without receiving specific professional advice. Roland Berger GmbH © 2025 ROLAND BERGER GMBH. ALL RIGHTS RESERVED.