Zero@Steel - Sustainable Steel Production

Zero@Steel Demo Mode — Dashboard view only. Write, export, report and admin actions are restricted.

Annual Steel Production

2.4M tons

+8% vs 2024 (2.22M tons)

CO₂ Intensity

1.45 tCO₂/t

Industry avg: 1.85 tCO₂/t steel

Scrap Utilization Rate

42%

Target: 50% by 2027

Green Steel Capacity

18%

H2-DRI + EAF production

🏭 Select Plant

Plant A - İzmir Green Steel Hub

70% H2-DRI + 30% EAF | 0.62 tCO₂/t

Plant B - Karabük Legacy Steel

100% BF-BOF | 2.10 tCO₂/t

Plant C - İskenderun Scrap Hub

100% EAF | 0.48 tCO₂/t

Plant D - Ereğli Integrated

60% BF-BOF + 40% EAF | 1.29 tCO₂/t

Plant A — H₂ Share Trend

Plant B — EAF Share Trend

Plant C — EAF Share Trend

Plant D — EAF Share Trend

Financial Impact Today (Plant A - İzmir)

€28,400 — Net Savings

CBAM avantajları, enerji sapmaları ve verimlilik kazanımlarından oluşan toplam değer

Demo verisi — gerçek projede SAP FI/CO, enerji faturalama ve ETS hesap motoru bağlanır.

👷 Plant Manager Dashboard

Shift operations, OEE drill‑down, LOTO evidence and handover.

♻️ Green Steel Capacity by Plant

🏭 Steel Production Process Flow

⛏️

Iron Ore Mining

0.12 tCO₂/t

→

🔥

Blast Furnace

1.80 tCO₂/t

→

⚗️

Basic Oxygen

0.08 tCO₂/t

→

🔨

Continuous Cast

0.05 tCO₂/t

→

🏗️

Rolling Mill

0.15 tCO₂/t

🏭 Select Plant for Safety Review

Plant A - İzmir Green Steel Hub

LTIFR: 0.38 | Zero incidents (90 days)

Plant B - Karabük Legacy Steel

LTIFR: 0.52 | 2 near-miss this month

Plant C - İskenderun Scrap Hub

LTIFR: 0.35 | Best performer

Plant D - Ereğli Integrated

LTIFR: 0.44 | 1 lost-time incident

📊 Production Mix & Emissions Breakdown

Primary Steel (BF-BOF)

1,968,000 tons (82%)

BF-BOF CO₂ Emissions

3,640,800 tCO₂

Secondary Steel (EAF)

360,000 tons (15%)

EAF CO₂ Emissions

162,000 tCO₂

Green Steel (H2-DRI)

72,000 tons (3%)

H2-DRI CO₂ Emissions

10,800 tCO₂

Total Annual CO₂ Emissions

3,813,600 tCO₂

Average Intensity

1.59 tCO₂/t

Industry avg: 1.85 tCO₂/t

CBAM Impact (Today)

€47,320

BORDER-CARBON

saved

Energy Variance vs Budget

-€12,450

ENERGY RISK

Efficiency Gain vs Baseline

€89,200

EFFICIENCY

How CFO uses this view?

Plant bazında CBAM exposure'ı hızlı görmek
Enerji sapmasının anlık tespit etmek
Verimlilik projelerinin nakit etkisini doğrulamak

Prod versiyonda buraya SAP FI/CO, enerji faturalama ve ETS hesap motoru bağlanır.

🏭 4-Plant Financial Breakdown (Multi-Scenario Analysis)

Plant A - İzmir Green Steel Hub

Location: İzmir, Turkey | Capacity: 600,000 t/year

BEST PERFORMER

Production Route

70% H2-DRI + 30% EAF

CO₂ Intensity

0.62 tCO₂/t

CBAM Savings

+€28,400/day

Energy Efficiency

+€9,100/day

Strategy: Flagship green steel facility with 45 MW electrolyzer, 100% renewable energy (wind+solar), EU Innovation Fund recipient (€35M grant)

Plant B - Karabük Legacy Steel

Location: Karabük, Turkey | Capacity: 1,200,000 t/year

HIGH CARBON

Production Route

100% BF-BOF (Traditional)

CO₂ Intensity

2.10 tCO₂/t

CBAM Exposure

+€11,600/day saved

Energy Cost

-€7,800/day over budget

Challenge: Aging BF infrastructure (55 years old), requires €180M modernization or phase-out by 2032. Natural gas price volatility creating budget variance.

Plant C - İskenderun Scrap Hub

Location: İskenderun, Turkey | Capacity: 450,000 t/year

CIRCULAR ECONOMY

Production Route

100% EAF (Scrap-based)

CO₂ Intensity

0.48 tCO₂/t

CBAM Benefit

+€7,320/day

Energy Savings

+€2,250/day

Opportunity: 58% renewable energy mix, scrap sourcing from Mediterranean region, potential to scale to 600K t/year with €25M investment.

Plant D - Ereğli Integrated Complex

Location: Zonguldak-Ereğli, Turkey | Capacity: 800,000 t/year

HYBRID TRANSITION

Production Route

60% BF-BOF + 40% EAF

CO₂ Intensity

1.29 tCO₂/t

CBAM Position

Neutral (-€180/day)

Energy Mix

+€1,850/day efficiency

Roadmap: Transitioning from 80% BF-BOF (2023) to 40% EAF (2026) to 70% H2-DRI (2030). CCUS pilot capturing 85K tons CO₂/year operational.

Multi-Plant Strategy: Portfolio approach balancing green steel leadership (Plant A), circular economy (Plant C), managed transition (Plant D), and legacy infrastructure modernization (Plant B). Combined CBAM savings: €47,320/day (€17.3M/year).

📊 CEO/CFO Strategic Analysis

Annual CBAM Savings Potential

€17.3M

Based on current production mix

ROI on Green Steel Investment

3.8 years

H2-DRI expansion payback period

Green Premium Capture

€85/ton

Current market premium for green steel

🔧 Assumptions & Controls

Currency

Carbon Price (€/tCO₂)

CBAM Rate (€/t)

Energy Index (x)

💰 Monthly Cash Flow Impact Trend

🔍 Cost Breakdown by Production Route

📉 EBITDA Impact Waterfall

🏷️ Green Premium by Product Mix

Product	Monthly Volume	Premium/ton	Total Premium
Flat Steel (Auto)	42,000 t	€85	€3.57M
Long Steel (Construction)	95,000 t	€35	€3.33M
Specialty (Energy)	12,500 t	€110	€1.38M

🧪 Segment Price Elasticity

Automotive Premium

€85/ton

Construction Premium

€35/ton

Energy Premium

€110/ton

📊 Investment KPIs

WACC

7.8%

Blended capital cost

CAPEX Plan (3y)

€85M

H2-DRI expansion + EAF upgrades

NPV (10y)

€42M

Discounted cash flows

IRR

14.6%

Above WACC

💵 Contribution Margin by Product

Product	Price/ton	Cost/ton	Carbon/ton	Margin/ton	Total Margin

⚠️ Top Risks & ✅ Opportunities

Target KPI — Production

Target KPI — Green Share

🧭 CEO Executive Dashboard

Production YTD

2.18M tons

91% of annual target

EBITDA Margin

17.4%

+120 bps vs LY

Safety (LTIFR)

0.42

Target <0.5 | Industry 1.2

Renewable Energy Share

62%

PPAs + on-site generation

Order Backlog

€920M

6.2 months coverage

On-Time Delivery

96.2%

Best-in-class logistics

Green Steel Capacity

18%

Target 25% by 2028 · Roadmap to 70% H2-DRI by 2030

🛡️ Energy Hedge Coverage & Sensitivity

Hedge Coverage

62%

Rolling 12-month PPAs + swaps

Exposure

38%

Spot-indexed consumption

Move	P&L Impact (monthly)

📁 CFO Scenarios

Baseline Energy Price (€/kWh)

ETS Unit Factor (€/tCO₂)

CBAM Unit Factor (€/tCO₂)

Segment & Product Coefficients

Automotive ETS

Automotive CBAM

Construction ETS

Construction CBAM

Energy ETS

Energy CBAM

Product Name

Product SKU

ETS (€/tCO₂)

CBAM (€/tCO₂)

Profile

⚠️ Financial Risk & Opportunity Matrix

🔴 High Risk Items

BF-BOF CBAM exposure: €2.8M/year
Natural gas price volatility: ±€1.2M/quarter
Carbon price sensitivity: €5/ton = €400K impact

🟡 Medium Priority

Scrap steel price hedging needed
Renewable energy PPA optimization
Process efficiency improvements: €1.5M/year

🟢 Opportunities

Green steel premium capture: €6.1M/year
EU Innovation Fund grants: €45M available
Carbon credit generation: 120K tons/year

🎯 Recommended C-Suite Actions

1. Accelerate H2-DRI Expansion

HIGH PRIORITY

Target 25% green steel capacity by 2028 to capture €12M+ annual CBAM savings and €85/ton green premium

CFO Impact: 3.8 year payback, €85M CAPEX required, EU Innovation Fund eligible

2. Optimize Energy Procurement

MEDIUM

Implement dynamic energy hedging strategy to reduce ±€1.2M/quarter volatility exposure

CEO Impact: Stabilize EBITDA margins, reduce quarterly earnings volatility

3. Launch Carbon Credit Program

OPPORTUNITY

Monetize 120K tons/year of avoided emissions through verified carbon credit sales

Revenue Potential: €7.2M/year at €60/ton carbon credit price

OEE Breakdown

Shift Throughput

Crew Attendance

Active Alarms

OEE by Line

LOTO Checklist

Equipment	Lock	Tag	Verify	Evidence

Work Schedule Adherence

Line	Planned	Actual	Adherence	Status

Shift Checklist

Task	Owner	Status

Open Actions

Action	Owner	ETA

Shift Handover

Outgoing Notes

Incoming Confirmation

Approver Name

Supervisor Approval

Approved

Digital Signature

Alarm History & Root Cause

Time	Equipment	Severity	Root Cause	Action

User Action Log

Shift Production Target

850 tons

Current: 742 tons (87.3%) | On track

Crew Attendance

47/50

3 absences (2 sick, 1 planned leave)

Active Alarms

5

2 critical, 3 warnings

Equipment Availability

98.2%

1 minor downtime (12 min)

🏭 Real-time Production Board

Equipment	Current Heat	Grade	Status	Tons	ETA

📈 Shift Production Trend

AI-powered recommendations for process efficiency and emissions reduction across all production routes.

Active Recommendations

7

Potential savings: €245K/month

CO₂ Reduction Potential

8,500 t/year

From optimization alone

Implementation Status

4/7

Recommendations in progress

🎯 Top Recommendations

1. Optimize BF Blast Temperature

HIGH IMPACT

Increase hot blast temperature from 1,180°C to 1,220°C to reduce coke consumption by 3.2%

Annual Savings

€1.85M

CO₂ Reduction

3,200 t/year

Payback

8 months

2. EAF Power Factor Correction

MEDIUM

Install reactive power compensation to reduce electricity consumption by 2.8 kWh/ton

Annual Savings

€420K

CO₂ Reduction

1,100 t/year

Payback

14 months

3. Predictive Maintenance AI

IMPLEMENTING

ML model to predict equipment failures 72 hours in advance, reducing unplanned downtime by 40%

Annual Savings

€3.2M

Uptime Gain

+2.8%

Status

Phase 2/3

Total Inventory

24,500 t

3.2 weeks supply at current rate

Grade A (Prime Scrap)

18,200 t

74% of inventory | €380/ton

Grade B (Secondary)

6,300 t

26% of inventory | €220/ton

📊 Utilization Metrics

Current Scrap Utilization Rate 42%

Target: 50% by 2027 | Industry avg: 35%

Source	Monthly Volume	Price	Quality
Internal Returns	2,400 t/month	€0 (free)	Grade A
Local Suppliers	8,500 t/month	€360/ton	Grade A/B Mix
Import (EU)	3,200 t/month	€420/ton	Grade A
Automotive Sector	1,800 t/month	€395/ton	Grade A

💡 Optimization Opportunity

Increasing scrap utilization from 42% to 50% would reduce annual CO₂ emissions by 42,000 tons and save €8.2M/year in raw material costs.

November 2025 Summary

Total Production

198,500 t

+4.2% vs October 2025

CO₂ Emissions

326,200 t

1.64 tCO₂/t steel average

Energy Consumed

112,400 MWh

566 kWh/t steel

📈 Production by Route

Production Route	Volume (tons)	% of Total	Avg CO₂ Intensity
BF-BOF (Blast Furnace)	162,770	82%	1.85 tCO₂/t
EAF (Electric Arc)	29,775	15%	0.45 tCO₂/t
H2-DRI (Green Steel)	5,955	3%	0.15 tCO₂/t

📅 Year-to-Date Performance

YTD Production

2.18M tons

91% of annual target

YTD Emissions

3.58M tCO₂

-6% vs 2024 YTD

Revenue (Est.)

€1.74B

€800/ton avg price