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Fero Prevents 450,000 Tons of CO2 Emissions

By: Elisabeth Rosen Elisabeth rosen
• November 2021

Steel production accounts for more than a fifth of greenhouse gas emissions from manufacturing, making it a prime target for emissions reduction. Fero software reduces the use of mined ingredients in steel production by up to 34%, an approach that can be scaled to eliminate millions of tons of CO2 emissions annually, according to a new report by the Global Partnership on Artificial Intelligence.

In the report, which lays out a comprehensive strategy for using AI to lessen the impact of climate change, Fero is featured as a case study of how manufacturing companies can use technology to improve their sustainability.

When employed by steel plants, Fero’s AI-driven optimization software reduces alloy usage by up to a third. Avoiding mining, smelting, and transporting these alloys has so far prevented an estimated 450,000 tons of CO2 emissions per year. If scaled to the rest of steel production in the US, this approach could prevent 11.9 million tons of emissions per year — equivalent to a quarter of New York City’s yearly CO2 emissions.

At the same time, this saves manufacturers money. The report details how Fero helps manufacturers reduce the amount of costly new alloys they add during the production process. Using an explainable AI approach called Bayesian machine learning, Fero’s software learns from historical data to recommend the minimum amount of additional new material (if any) that needs to be added to a particular batch of molten recycled steel, thereby reducing the amount of freshly mined materials used. As recommendations are provided in real time, this approach also decreases the amount of time that the steel must be maintained in a molten state, reducing overall energy usage during production.

Amid increasingly dire climate threats, including the latest IPCC warning of a "code red for humanity," tackling climate change is more crucial than ever. For manufacturers reluctant to jeopardize production speed or quality to comply with environmental regulations, Fero provides an easy solution to both lower costs and hit sustainability goals.