glenbrook steel mill tours

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Exploring the Heart of Steel Manufacturing

29 Jun 2023

Industrial Tube Manufacturing, a long-standing customer of NZ Steel, recently visited the heart of New Zealand steel production. In an effort to deepen their understanding of the manufacturing process of steel manufacturing, Industrial Tube arranged for their staff to visit the iconic Glenbrook Steel Mill.

Accompanied by a team of knowledgeable guides, Industrial Tube’s staff received a comprehensive tour of the Glenbrook Steel Mill. The visit included an introduction to the mill’s rich history, tracing its roots back to its establishment in 1968. From there, the Industrial Tube team witnessed the remarkable transformation of raw materials into the building blocks of modern infrastructure.

The tour highlighted various stages of the manufacturing process, showcasing the advanced technologies and meticulous quality control measures that NZ Steel employs. The Industrial Tube team saw footage of the massive furnaces, making molten steel. They witnessed the process of red-hot slabs being transformed into coils, plates, and sheets, ready to be shaped and used in countless applications.

Throughout the visit, Industrial Tube staff gained insights into the complexities of steel production. They learned about the careful alloying process that imparts specific properties to the steel, ensuring it meets the diverse requirements of various industries. Additionally, they discovered the significant emphasis placed on sustainability, as NZ Steel showcased its commitment to reducing environmental impact through energy efficiency and recycling initiatives.

The firsthand experience of the Glenbrook Steel Mill was greatly appreciated by Industrial Tube’s staff, opening their eyes to the immense effort and ingenuity behind the steel manufacturing process. This visit has strengthened the bond between Industrial Tube and NZ Steel, a strong long-standing partnership.

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New Zealand Steel Glenbrook Plant

The production of steel from titanomagnetite sand had never been achieved before, and this plant at glenbrook, south auckland, is the only one of its kind. it was designed to use a process largely developed by new zealand engineers to produce steel from indigenous ironsand and sub-bituminous coal and is the biggest single-site development in new zealand..

The original plant, designed to produce 150,000 tonnes per year of steel billets, was built between 1967 and 1969 and commissioned in 1970. It was then subject to extensive modifications with additional plant and other improvements completed in 1978.

The Stage One expansion from 150,000 tonnes per year to 750,000 tonnes per year commenced in late 1985.

The following features were all optimised in the original 150,000 tonne per year plant:

• The utilisation of the multiple hearth furnaces to pre-heat the ironsand concentrate and de-volatilise the coal
• The hot pan conveyors that transport this material to the kiln
• The reduction kiln process.

Although the major plant items have been used elsewhere in the world (for different purposes) the configuration of the plant and the method of operation are unique.

The plant design also includes significant innovations to improve productivity and reduce operating costs including a 34-megawatt-capacity co-generation plant.

New Zealand Steel Glenbrook Plant, circa 1990. Engineering New Zealand.

Construction professionals

• Owner: New Zealand Steel Limited
• Designers: W S Atkins & Partners
• Contractors: Dillingham – Stevenson.
• Stage 1 Expansion (iron and steel making only)
• Project managers/engineers: Davey McKee (Stockton) Limited
• Major plant contractors: G E C Materials Handling Ltd, Lurgi GmbH (kiln) Elkem A/S (melters), Flakt – Aust. (waste gas treatment), Davey McKee (KOBM).

Heritage recognition

Ipenz “engineering to 1990” project.

This item of New Zealand’s engineering heritage was recognised as part of the IPENZ “ Engineering to 1990 ” project which the Institution organised to help celebrate the country’s sesquicentenary in 1990. A plaque was unveiled to mark the significance of this place as part of the development of the nation.

More information

Further reading.

John Ingram, " Steel from Ironsand ," in Evolving Auckland , ed. John La Roche (Christchurch: Wily Publications, 2011), 245-261.

Public tours by arrangement with the company.

131 Mission Bush Road, Glenbrook, South Auckland.

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Quality worth making room for

Govt offers NZ Steel $30m more in bonuses for bigger, faster emissions cuts

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Sustainable Future in association with

NZ Steel and the government have agreed to invest $300 million in a major upgrade of the Glenbrook steel mill south of Auckland that will cut the plant’s greenhouse gas emissions by about 45 percent.

The Government will contribute $140m to the project through its flagship fund to help industries decarbonise.

The 800,000 tonnes of emissions removed will represent 45 percent of NZ Steel’s current emissions, 1 percent of NZ’s annual emissions and 5.3 percent of the emissions cuts New Zealand needs to achieve under its 2026-2030 carbon budget.

READ MORE: *  Steel mill expects 20-plus year consent, thanks to loophole in climate law *  Bluescope Steel offers hope of continued production at the Glenbrook mill 

The investment in the new electric arc furnace will allow NZ Steel to decommission two of its existing but elderly blast furnaces fuelled by coal.

“This is a necessary step to secure steelmaking in NZ for many years to come,” said Robin Davies, the company’s chief executive.

“This model will make NZ as close to self-sufficient as possible using renewable energy to recycle domestic scrap steel rather than shipping it offshore.”

Currently New Zealand generates some 500,000 tonnes a year of scrap metal, most of which is exported to steel repressors abroad. The new furnace will require some 300,000 tonnes of scrap a year, which the company is confident it can source economically, he added. It will also use some iron from NZ Steel’s existing production.

NZ Steel has agreed in principle to a 30MW, 10-year electricity supply agreement with Contact Energy.

This will help underpin Contact’s current plans to invest $1.1 billion in new renewable generation, which is equal to some 5 percent of the country’s current electricity supply, said Mike Fuge, Contact’s chief executive.

Moreover, NZ Steel will be able to reduce the furnace’s output at times of peak electricity demand, thereby taking the pressure off generators and Transpower, the operator of the grid.

BlueScope, NZ Steel’s Australian parent, runs two large electric furnaces in the US making some 3 million tonnes of steel a year, and one in Australia.

The NZ Steel deal showed the power of well-constructed public/private partnerships, said Mark Vassella, BlueScope’s chief executive, who attended the Glenbrook announcement made yesterday by the Prime Minister. Energy Minister Megan Woods and Climate Minister James Shaw accompanied Chris Hipkins.

“This is the biggest example we have in New Zealand of the move towards electrification and is tangible evidence of the demand for renewable energy.” – Mike Fuge, Contact Energy

BlueScope has warned in recent years that it was considering closing the plant. Glenbrook and Pacific operations account for some 8 percent of BlueScope’s operating earnings.

In 2016, BlueScope wrote down the value of NZ Steel by half and put up for sale the rights to the Taharoa ironsands that are the feedstock for the steel mill.

This February, NZ Steel said it was considering investing in an electric furnace for Glenbrook. While it had first floated the idea with the government about a year ago, detailed studies and negotiations between the two parties have take place over the past six months or so.

The Glenbrook investment is the largest investment commitment to date by the Government Investment in Decarbonising Industry (GIDI) fund, run by the Energy Efficiency and Conservation Authority. The emissions saved will be larger than those from some 65 prior GIDI investments over recent years.

“An electric arc furnace makes sense when there’s enough affordable renewable energy and scrap steel available, a way to get that scrap steel to site, and the right policy settings.” – Robin Davies, NZ Steel

Some of the government’s investment is performance-based: NZ Steel will earn a $10m incentive payment if it gets the new furnace operational by January 2027 and another $20m if it can double by 2030 the 800,000 tonnes of emissions savings it is initially targeting.

“An electric arc furnace makes sense when there’s enough affordable renewable energy and scrap steel available, a way to get that scrap steel to site, and the right policy settings,” Robin Davies said.

“We’ll firm up the details of the different aspects of the project over the coming months but crucially, New Zealand has all these essential enablers in place.”

And BlueScope and NZ Steel will continue to investigate the use of hydrogen and natural gas to eliminate carbon emissions when processing ironsands into iron before it is then turned into steel in the electric arc furnace.

This is the main decarbonisation pathway the steel industry is pursuing worldwide to turn iron ore into steel. If it turns out to be feasible, commercial deployment is at least decade away, he added

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NZ’s biggest ever emissions reduction project unveiled

The Government is partnering with New Zealand Steel to deliver New Zealand’s largest emissions reduction project to date, with half of the coal being used at Glenbrook steel to be replaced with electricity to recycle scrap steel.

Prime Minister Chris Hipkins made the announcement alongside Energy and Resources Minister Megan Woods and Climate Change Minister James Shaw at the Glenbrook steel factory in South Auckland today.

“This size of this project demonstrates how serious the Government is about reducing New Zealand’s emissions as fast as possible,” Chris Hipkins said.

“This project dwarfs anything we have done to date. Alone, it will eliminate one per cent of the country’s total annual emissions. 

“The plan means New Zealand businesses will have access to locally produced, cleaner steel, and high value jobs are protected that otherwise might have gone offshore. 

“Partnering on this project with New Zealand Steel makes sense because it delivers such huge benefits for our environment. Without Government investment this wouldn’t have happened, so it’s fantastic to see what working together can deliver,” Chris Hipkins said.

The conditional deal with NZ Steel will be part funded up to $140 million from the $650 million Government Investment in Decarbonising Industry (GIDI) Fund, which enables partnerships with industry to reduce their emissions. The rest will be funded directly by NZ Steel.

“The Government is partnering with NZ Steel to reduce 800,000 tonnes of climate pollution from its Glenbrook mill each year. That’s the equivalent of taking approximately 300,000 cars, or all the cars in Christchurch, off the road,” Megan Woods said.

“The Government will help co-fund an electric arc furnace to replace the existing steelmaking furnace and two of the four coal-fueled kilns.

“The installation of an electric arc furnace at Glenbrook means NZ Steel will cut its emissions by more than 45 per cent and will produce 100 per cent of its annual steel production as lower carbon steel.

“To understand the scale of this project, it reduces more emissions on its own than all the other 66 GIDI projects we have approved to date. 

“Our partnership with NZ Steel shows we can tackle the challenge of decarbonising even our hardest to abate and largest emitting industries. This investment would not happen without government support. 

“Steel is critical to our economy for manufacturing and construction. Lower carbon steel production at Glenbrook has massive wins for our materials supply chain. It also helps retain a significant local source of employment.

“We are proving once again that decarbonisation does not mean de-industrialisation. It demonstrates how the transition to a low emissions economy can not only be good for the climate, but also a win for minimising waste, retaining jobs, and improving New Zealand’s economic resilience,” Megan Woods said.

“Melting scrap steel using electricity, instead of converting ironsands into steel using coal, will substantially reduce the emissions generated from NZ Steel’s current activities. It will also build a more circular, resilient economy. This will put New Zealand in a much better position to meet its climate target of net zero carbon by 2050,” James Shaw said.

“This deal is estimated to contribute 5.3 percent of the emissions reductions needed under New Zealand’s second emissions budget (2026-2030), and 3.4 percent within the third emissions budget (2031-2035).

“The economics of this really stack up, especially compared to current carbon prices. The lifetime abatement cost is forecast at $16.20 per tonne. Current carbon prices are around $55 per tonne. In the long term this saves the Government and the country money.

“We must reduce our reliance on fossil fuels to help avoid the worst of climate change. Switching to cleaner ways of generating process heat is one of the biggest opportunities we have to reduce our domestic emissions and meet our international climate commitments.

“Adaptation to protect our communities against our changing climate is important. But we cannot underestimate the need to cut the pollution that causes climate change in the first place. We cannot underestimate the benefits a low emissions economy will bring for New Zealanders,” James Shaw said.

Notes for editors:

The supply of electricity required for the new furnace will also include a demand response arrangement in partnership with Contact Energy – where NZ Steel can scale down power supply from the electricity grid when needed to secure electricity supply in the region at peak times.

Details will be completed over the coming months, including various assurances on critical parts of the new operation, to make sure the proposal can be given the full green light and the agreement can become unconditional.

This deal is the first in a number of bespoke opportunities that the Government is exploring, through the expanded GIDI Fund, to deliberately target appropriate support for New Zealand’s largest emitters.

  Background on GIDI:  

• GIDI (Government Investment in Decarbonising Industry) was first introduced in 2020 – to ramp up decarbonisation of our industrial process heat while stimulating our economic recovery post the pandemic, to create and protect jobs.
• The $650m expansion of GIDI in Budget 2022, funded from the Climate Emergency Response Fund is a key initiative to help deliver on the Government’s Emissions Reduction Plan (ERP).  
• The Fund enables partnerships between Government and businesses to accelerate emission reductions by supporting energy efficiency and fuel switching projects.
• GIDI helps get decarbonisation projects across the line and happening faster than they otherwise would, delivering larger and earlier emissions reductions for New Zealand.
• It helps ensure that decarbonisation happens in New Zealand by investing in New Zealand businesses instead of buying offsets overseas – and that we support our businesses with a just transition. 
• The project is forecast to have an abatement cost of $16.20 per tonne. The abatement cost per tonne is the cost of removing one tonne of carbon dioxide equivalent pollution.
• This partnership agreement is with EECA ( Energy Efficiency & Conservation Authority), with support from the Ministry for the Environment, and the Ministry of Business, Innovation and Employment.
• EECA – which delivers projects under GIDI – has a programme dedicated to ‘Partnerships with Very Large Emitters’ as part of the funding allocated.
• The conditional agreement will be co-funded by the GIDI Fund, with the rest funded directly by NZ Steel. The agreement has three components:
• base build funding support up to $110m
• an additional $10m commissioning funding incentive paid if NZ Steel can get the furnace up and running by January 2027
• a further $20m of performance funding paid upfront if NZ Steel can achieve a further 800,000 tonnes of emissions reductions by 31 December 2030 over and above the base amount committed to in the agreement.
• NZ Steel is New Zealand’s sole producer of flat rolled steel products for building, construction, manufacturing and agricultural industries.
• It operates a fully integrated steel mill at Glenbrook, about 60 kilometres south of Auckland, as well as Pacific Steel, a manufacturing facility in Ōtāhuhu and Steltech, a manufacturer of custom welded columns and beams in Takanini.
• It produces around 670,000 tonnes of steel each year for mainly domestic consumption. Key products include roofing, structural beams, steel framing and reinforcing steel.
• NZ Steel contributes over $900M to the economy per annum and adds $398 million in value to the Auckland region. It supports the employment of 4,000 people across its New Zealand and Pacific Island operations, employing 1,400 directly and the remainder indirectly. It trains more than 40 apprentices and graduates annually.
• NZ Steel receives industrial allocation under the Emissions Trading Scheme, as an 'emissions intensive, trade exposed’ business – recognising that ETS costs might impact the international competitiveness of these businesses.
• Emissions budgets set the amount of emissions New Zealand can produce in order to meet its climate change goals. These are described in New Zealand’s first emissions reduction plan, published in May 2022.

Moscow Free Tour

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Description

Highlights:.

• Hit the Red Square;
• Explore the nooks and crannies of Alexander Garden;
• Get a taste of the ancient Kitay Gorod;
• Learn about the tragic destiny of the Christ the Savior Cathedral;
• Roam through the heart of Moscow.

Walking Tour Itinerary:

Here are our TOP 7 things to help you start your Russian adventure or tick off before you say goodbye to Moscow.

Wander around the vast cobblestone square with rich past, gorgeous architecture, incredible GUM , bright colors of the Kremlin and swirling Saint Basil’s Cathedral .

Kitay Gorod

Walk across the Red Square to see the embankment of old Moscow river and plunge into the atmosphere of ancient Russian village where nobles preferred to settle in XV century.

Varvarka street

Walk up Varvarka street to find the landmark of Kitay Gorod - Palace of the Romanov Boyars, which was built in the XVI century and where lived the first Tsar from the Romanov dynasty.

Old English Court

Look at the Old English Court , which used to be the English Embassy in Moscow and where Ivan the Terrible confined the envoy from England, because Queen Elizabeth I refused to marry him.

Alexander Garden

Watch the solemn ceremony of the Changing of the guards , pay respect to the eternal flame at the Tomb of the Unknown Soldier , and the stone Grotto , The huge fountain in the centre adds a sophisticated feel to the almost 200 year old garden.

Christ the Savior Cathedral

Walk to the cathedral which is of a great cultural value to Russians. Its marvelous exterior, enormous golden domes, colossal bronze doors and pristine white walls will touch your feelings.

Patriarch’s Bridge

Pause on the bridge and marvel at the Kremlin, river cruises, monument after Peter the Great and Red October Chocolate Factory , which is now a nightlife hub for youngsters.

About Moscow:

We picked up a list of article that might be useful and helpful to you during your stay in Moscow. These are things to do in Moscow, tips about Moscow, best cafes in Moscow and simply fun facts about Moscow. Enjoy reading!

Before coming to Moscow:

• Our fun guides sharing their observations about their tours and best practices:
• https://friendlylocalguides.com/blog/moscow-private-guides-on-tours-in-moscow
• What you should know about Moscow:  
• https://friendlylocalguides.com/blog/5-things-to-know-before-you-go-to-moscow

Off the beaten path of Moscow:

• Kitay Gorod:
• https://friendlylocalguides.com/blog/moscow-must-see-fun-facts-about-kitay-gorod
• Zamoskvorechye:
• https://friendlylocalguides.com/blog/moscow-must-see-fun-facts-about-zamoskvorechye
• White City:
• https://friendlylocalguides.com/blog/moscow-off-the-beaten-path-white-city  

The best parks in Moscow:

• Muzeon Statues Park:
• https://friendlylocalguides.com/blog/moscow-off-the-beaten-path-muzeon-park
• Gorky Park: 
• https://friendlylocalguides.com/blog/moscow-gorky-park
• Tsaritsino Park: 
• https://friendlylocalguides.com/blog/moscow-must-see-37-reasons-to-visit-tsaritsyno
• Kolomenskoe Park:
•   https://friendlylocalguides.com/blog/things-to-do-in-moscow-kolomenskoe-museum-reserve

The most historical and beautiful streets of Moscow:

• Arbat  srreet: 
• https://friendlylocalguides.com/blog/things-to-do-in-moscow-arbat-street
• Tverskaya street: 
• https://friendlylocalguides.com/blog/moscow-things-to-do-tverskaya-street
• Downtown of Moscow: 
• https://friendlylocalguides.com/blog/things-to-do-moscow-streets

What to do in Moscow:

• How to have a Real Russian Experience:
• https://friendlylocalguides.com/blog/real-russian-experience
• Things to do in Moscow:
• https://friendlylocalguides.com/blog/21-things-to-do-in-moscow
• Architectural masterpieces, hidden gems of Moscow:
• https://friendlylocalguides.com/blog/things-to-do-in-moscow-off-the-beaten-path
• Top Moscow attractions:
• https://friendlylocalguides.com/blog/top-10-moscow-attractions

Budget travel:

• How to have fun in Moscow for less than $4:
• How to save money in Moscow:
• https://friendlylocalguides.com/blog/7-ways-to-save-money-while-travelling-to-moscow

Cafes & restaurants in Moscow:

• Moscow cafes with Russian breakfast:
• https://friendlylocalguides.com/blog/moscow-cafes-with-russian-breakfast
• Best Moscow restaurants:
• https://friendlylocalguides.com/blog/best-moscow-restaurants
• Best coffee shops in Moscow:
• https://friendlylocalguides.com/blog/moscow-best-coffee-shops

Moscow Metro:

• Facts about Moscow Metro:
• https://friendlylocalguides.com/blog/fun-facts-about-moscow-metro
• Myths about Moscow Metro:
• https://friendlylocalguides.com/blog/7-myths-about-moscow-metro
• Facts about Moscow:
• https://friendlylocalguides.com/blog/fun-facts-50-facts-about-moscow
• Fun Facts about Kremlin:
• https://friendlylocalguides.com/blog/33-fun-facts-from-our-kremlin-tours
• The best flea markets in Moscow:
• https://friendlylocalguides.com/blog/moscow-best-flea-markets
• Top 5 Russian souvenirs:
• https://friendlylocalguides.com/blog/top-5-russian-souvenirs

What you get:

• + A friend in Moscow.
• + Private & customized Moscow tour.
• + An exciting pastime, not just boring history lessons.
• + An authentic experience of local life.
• + Flexibility during the walking tour: changes can be made at any time to suit individual preferences.
• + Amazing deals for breakfast, lunch, and dinner in the very best cafes & restaurants. Discounts on weekdays (Mon-Fri).
• + A photo session amongst spectacular Moscow scenery that can be treasured for a lifetime.
• + Good value for souvenirs, taxis, and hotels.
• + Expert advice on what to do, where to go, and how to make the most of your time in Moscow.

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Steelmaking uses a lot of energy and managing this efficiently is an important part of New Zealand Steel's operation. New Zealand Steel is committed to commercially and environmentally responsible energy management and the promotion of energy efficiency in all of its operations. New Zealand Steel has taken steps to promote energy efficiency. It was a founding member of the national Energy Wise Companies Campaign and met targets specified in an early voluntary agreement with the NZ Government to reduce carbon dioxide emissions. Below are the energy resources New Zealand Steel uses.

The mill has a capacity to use 800,000 tonnes of coal a year. The coal is used as a source of carbon in the reduction process.

Electricity and Gas

At full capacity the Glenbrook operation consumes up to 1100 Gigawatt hours of electricity a year. This is approximately the amount that Wellington City (excluding Hutt Valley) uses each year. The bulk of this usage is by the plant's two iron melters which each consume up to 300 Gigawatt hours each year. Electricity accounts for 10 - 15% of the energy usage at the plant. The remaining energy needs are met with natural gas sourced from the Taranaki gas fields. The natural gas is used to preheat ladles for holding iron and steel and to reheat the steel slabs before they are rolled. A number of the downstream finishing processes also use gas fired furnaces for heating and drying.

Waste Energy Recovery

New Zealand Steel has developed a way of using one of the by-products of the ironmaking process, to provide an electrical energy source. This reduces its reliance on electricity purchased from the national grid. Hot waste gases are produced by the multi-hearth furnaces in the ironmaking process. New Zealand Steel has since the late 1970s taken advantage of this hot waste gas to produce energy for the production process, in what is called a Cogeneration plant. The Cogeneration process involves the multi hearth furnace waste gas being burnt in an afterburner to provide heat for the boilers. This superheated steam from the boilers drives two steam turbines to produce electricity. The Cogeneration plant provides approximately 20% of the site electricity requirements. In 1997 the company commissioned a second Cogeneration plant, taking waste hot gases from another part of the ironmaking process, the rotary kilns. This now means up to 60% of the steel mill's electricity is generated on site. The Cogeneration facility is an example of how New Zealand Steel makes better use of resources and by products. New Zealand as a whole benefits from Cogeneration at the steel mill as emissions from thermal power stations, such as Huntly and New Plymouth, are reduced and there are savings of coal and gas.

CO2 Emissions

Steelmaking generates greenhouse gas emissions, mainly carbon dioxide, both directly when making iron and steel, and indirectly through the use of electricity and gas. The majority of emissions (about 80%) come from the chemical process of making iron. New Zealand Steel has significantly reduced the intensity of its emission profile since the 1990s and is continuously looking at cost effective ways of reducing its energy usage and C02 emissions.

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