Using the case study below, answer the following questions with in-text citations and references:

1. Identify, at least, three (3) effective status reports used in project management.
2. Discuss challenges and pitfalls for each of the project status reports.
3. Explain the difference between the project status reports provided for teams, sponsors and steering committee, considering their unique needs.
4. Generate and justify a sample of a project status report that would be submitted to a chosen stakeholder of the project from the given Case Study.

Case Study

HISARNA - DEVELOPING A SUSTAINABLE STEEL PRODUCTION PROCESS INSTRUCTOR'S MANUAL This case is about HIsarna, a new steel production technology that was developed as an alternative for the existing steel production technologies, which were energy intensive processes and were high on CO2 emissions. The new process came about in the wake of Paris Agreement, which drove CO2 emissions globally. The European Union targeted to cut the emissions to 80- 90% of 1990 levels by 2050. The European Union was also looking at adopting circular economy, which would not only reduce pressure on the environment, but also enhance security of supply of raw materials and lead to economic growth. As far as the steel industry was concerned it was looking at increasing the efficiency of production, and redesign production processes to reduce CO2 emissions. In this direction, in 2004, the steel industry in Europe formed a consortium Ultra-Low Carbon Dioxide Steelmaking (ULCOS) to identify technologies to help reduce carbon emissions, ensure energy efficiency, and achieve flexibility in the selection of raw materials in the steel industry. The consortium was of the view that a completely new process needed to be developed as the limits of the existing production systems were already achieved. This led to a breakthrough technology - HIsarna, which removed a number of energy-intensive pre-processes, provided flexibility in terms of quality of raw materials, and use of fuels. In the process the CO2 emissions reduced by 20%, and by capturing the high quality CO2, the emissions could be reduced by 80%. The emissions of other fine particles could also be reduced. The technology was tested in pilot plant of Tata Steel Europe in the Netherlands and the 75 million project was funded by ULCOS, European Union and the Dutch Government. HIsarna was a combination of two different technologies, one from metal and mining company Rio Tinto and another from Tata Steel. After years of trial runs and experiments, Tata Steel was all set to take the new sustainable production process into an industrial scale. This called for more investments and it remained to be seen if the steel majors from across the world would show interest in adopting the new technology in a bid to reduce emissions, or continue with the traditional steel making processes.. INTENDED AUDIENCE/PLACEMENT/COURSE The case is intended for MBA students as part of the courses in Project Management, project execution Objectives To examine how steel industry could move toward a low-carbon future and reduce the negative impact of its production To examine an in-depth the circular economy and the role of steel To understand the industry's approach towards sustainable production To demonstrate the way in which manufacturing processes could be redesigned to increase production efficiency and achieve lower emissions 1) What is the role of new process like HIsarna in reducing the carbon emissions and making the production processes efficient? The industrial companies accounted for 1/4th of the global GDP and employment. Global steel production, which was approximately 1,600 million tons per annum in 2015, is projected to grow 30 percent to 2,100 million tons per annum by 2050. During this time the production of recycled steel was estimated to double and that of virgin steel would be constant. Production of steel emitted approximately 2.9 Gton CO2 in 2014, which is equivalent to about 7 percent of global emissions. Steel companies follow two main production processes for steel. The blast furnace-blast oxygen furnace (BF-BOF) process is used to make over 95 percent of the world's virgin steel. BF-BOF production is a coal-powered process by which iron ore is reduced and melted at temperatures around 1,200 C. The excess heat made during BF-BOF production allows steelmakers to use up to 20 to 30 percent scrap steel as a feedstock, which increases steel output without a corresponding increase in the use of coal. The second steelmaking process is employed to produce recycled steel and the remaining fraction of virgin steel. In this process, electric arc furnaces (EAF) are either fed with scrap steel to make recycled steel or fed with direct-reduced iron (DRI) to produce virgin steel. In an integrated steel plant, steel is processed further (e.g., rolling, coating) to make goods such as steel rolls that are used in manufacturing final products. The carbon used can be reduced by using charcoal instead of coal; biogas or hydrogen instead of natural gas, or through zero carbon electricity in EAF. To reach the reduction targets set by the Paris Agreement the industry needed to lower its emissions. Such reduction needed to happen in energy-intensive production processes like cement and steel companies. This can be done by using alternatives to hydrocarbon fuels, using electricity to produce heat, use biomass or hydrogen as feedstock or fuel and by capturing carbon. CO2 accounted for 90% of Greenhouse gases, and half of CO2 was emitted from four commodities - cement, steel, ethylene and ammonia. 45% of the emissions in these industries was from feedstocks, and changing fuels would not address this. 35% emissions were due to burning fossil fuels to generate heat. Going for alternative fuels calls for change in the furnaces. And any change in the furnace design and use, would call for change in several other processes down and upstream. Changing to new methods of production was also highly expensive. One of the main reasons for high carbon usage was use of coal as a major fuel (for melting iron) and feedstock (use of coke) in steel industry. Coal accounted for 26% of energy consumption in iron and steel industry. At the same time there were large regional differences. In china coal was the main fuel, while in the European Union and the USA other sources like electricity was prevalent. Complete reduction of CO2 emissions was not possible, as in steel industry feedstock also consisted of lot of carbon. And the high temperature required by these sectors could be given only by carbon based fuels. To replace these fuels with electricity or hydrogen needs change in the production processes. The steel production sites have a lifetime of more than fifty years. Any change in the production systems was capital intensive and was not economical for the companies. Using hydrogen or any other alternative fuel in steelmaking would require a nearly complete overhaul of the steel production process at existing facilities. Hence, hydrogen-based steel production processes will generally be more economical for regions where new facilities are being built. Steel was traded globally, and in case the companies adopt carbon neutral production systems, their cost would increase and they can no longer compete with companies from developing countries like China, which use highly carbon intensive systems, to achieve low prices. EU countries have introduced stringent environmental protection regulations and emission standards by increasing cost of carbon emission in various industries. Process efficiencies through HIsarna HIsarna was developed by Tata Steel in Ijmuiden, Netherlands. It was expected to allow production with atleast 20% lower CO2 emissions. The technology could significantly improve steel production sustainability. As a substitute to blast furnace process, HIsarna made the preprocessing of iron ore and metallurgical coal obsolete. In this process the materials were injected as powders and were converted into liquid iron. On further development to Industrial scale, HIsarna could reduce the carbon footprint by 20%. With the use of carbon capture and storage technologies the carbon footprint was expected to be 80% lower CCF and SRV is a win-win combination of technologies. The heat to reduce and melt the iron ore was produced through oxygen HIsarna technology eliminated the process of converting iron ore into sinter or pellet and converting coking coal into coke. HIsarna could use raw materials of low quality The carbon monoxide that was formed in SLV was used to create hot gases that were used to provide heat for the reaction occurring in CCF. It was 30% more energy efficient and 25% less CO2 intensive The CO2 produced was pure and it could be captured, stored and used. This could lead to further reduction in CO2 emissions, and 80% reduction in carbon footprint. It could significantly improve steel production sustainability performance. HIsarna is a revolutionary breakthrough technology. Its impact may be compared to the introduction of contiuous casting in the 20th Century, which has made the process steps of ingot casting and rolling redundant. It used nitrogen as carrier gas to dissolve carbon into hot metal. HIsarna did not require energy-intensive and heavily-polluting processers. Its carbon collection was highly efficient. It could use biomass or natural gas instead of coal and reduced CO2 emissions. The investments and operating costs were also lower due to wide range of feedstocks available Looking at economic aspects, HIsarna will require significantly lower capital investment costs and will produce semi-finished products with the same quality as current breakthrough technology at significantly lower operational costs 2) What is a Circular Economy? Examine how HIsarna helped Tata Steel deliver its ambition for low carbon and circular economy. Circular Economy According to European Union, " are valued highly, unlike in the traditional, linear economic model, based on a consume-throw away' pattern. In practice, a circular economy implies minimum as well as re-using, repairing, refurbishing and recycling existing materials and products. What used to be considered as Moving towards a more circular economy could deliver benefits, among which reduced pressures on the environment, enhanced security of supply of raw materials, increased competitiveness, innovation, and growth and jobs. However, it would also face challenges among which finance, key economic enablers, skills, consumer behaviour and business models, and multi-level governance." The circular economy refers to a move from linear business models, in which products are manufactured from raw materials, used and th products or parts are repaired, re- This concept is fundamental to the triple bottom line concept of sustainability, which focuses on the interplay between environmental, social and economic factors. ion In a circular economy, products and the materials they contain reducing waste to a 'waste' can be turned into a valuable resource. oving then discarded, to circular business models where -used, returned and recycled. (Refer to TN Figure I) TN Figure I play 'take-makereducing challenges, en The Circular Economy is based on waste prevention and re-use, repair and recycling of products and superior products design for long life. It implies that resources are brought back into the supply chain after the end life of the product. The characteristics of a circular economy are: The products and materials are used for as long as possible Waste and resource use are minimized Resources are kept within the cycle when a product has reached the end of its life, to be used over and over again When steel industry was taken into consideration, it had advantages in terms of - reduce, reuse, remanufacture and recycle. (Refer to TN Figure II for Steel in Circular Economy) TN Figure II Recycle: Steel can be recycled endlessly with no detrimental effect on its properties. The magnetic properties in steel allow it to be separated from waste streams. Steel has been recycled ever since it was first made. All available steel scrap is recycled, over and over again to create new steel products in a closed material loop. Recycled steel maintains the inherent properties of the original steel. These properties can be modified during the steelmaking process or through mechanical processes to create the many thousands of advanced and commodity steel grades available. The quality of the steel product can also be improved on recycling. The European Environment Agency (EAA) used steel as the example of resource efficiency in its 2015 report, "The European environment state and outlook 2015." It's easy to see why they would single out steel here, when you compare its recycling rate of 87% to those of aluminum (67%), concrete (20%) and timber (13%)." Reduce: Over the years the energy used for producing steel had reduced considerably. According to the Worldsteel Association, "the efficient use and recovery of energy has enabled steelmakers to reduce the energy required to produce a tonne of steel by 60% since 1960." Efficient processes use less raw material, and help in reducing CO2 emissions." Though the global steel production had increased fivefold since 1960, the energy consumption had reduced by 60% and the steel industry was looking at reducing it further. The consumption of steel in the world was more than the scrap it generated. The availability was expected to reduce significantly by 2050. This meant that the industry needed to rely on blast furnaces unless a breakthrough technology is invented. Reuse: Steel's durability enables many products to be reused at the end of their life. As well as extending the product's life cycle, reuse avoids the need to transport and re-melt the steel, and to create new products. This has significant advantages for the environment and maximises the use of resources. In a fully circular economy, the reuse of a manufactured product is considered in the earliest design phases of its creation. This allows both small- and large-scale products to be repurposed for another use quickly and efficiently once their initial use is fulfilled. Steel by-products are also put into use to create products so as to minimize the waste that was sent to landfills. Slag was used to make cement and fertilizers. Process gases were used to replace steam and electricity. Remanufacture : In a truly circular economy, products which stop working are restored to asnew condition in a process known as remanufacturing. Remanufacture involves the disassembly of a product, during which each component is thoroughly cleaned, examined for damage, and either reconditioned to original specifications or replaced with a new or upgraded part. The product is then reassembled and tested to ensure proper operation. The goal is to develop an application which can be offered with a guarantee that is equivalent or better than that of the original product. differs from repairing, which is a process limited to making the product operational as opposed to thoroughly restoring it. Many steel products such as construction and farm machinery, truck and car engines, electrical motors, domestic appliances, and wind turbines are already remanufactured. Remanufacturing takes advantage of the durability of steel components. Steel in a Circular economy Avoids 60% of the energy requirements Avoids 75% of the CO2 emissions Lower demand on raw materials Reduces the need for waste disposal Can make the same quality products Steel can be recycled over and over again Durable steel products can last for decades and centuries Recycling of steel is a well established practice More than 22 billion tons of steel scrap have been recycled (Refer to TN Exhibit III for Steelmaking by-products) TN Exhibit III The steel industry has been a pillar industry in the economic development and played a major role in industrial and economic development. The material was highly recyclable, and was the most recycled industrial product. The main drawback of this industry was its high requirement of capital, energy intensive production processes and high emissions. Though over the last few decades the emissions have been reduced, they still accounted for 6.7% of all the CO2 emissions in the world and consumed 6% of the energy produced globally. One ton of steel production consumed 3.54 GJ of energy and emitted 1.8 tons of CO2. In the changing scenario of environmental protection policies, steel industry came under heat for its energy consumption and emissions. With the release of the EU "Climate and Energy Policy Objectives of 2030", EU countries have introduced more stringent environmental protection regulations and emission standards. In this direction ULCOS was formed in 2004, to develop new new low-carbon steelmaking technology that can reduce CO2 emissions per ton of steel by 50% from its existing level. by the year 2050. The main members of the ULCOS program are from 15 European countries, involving steel, gas, equipment manufacturing, metallurgical engineering, research institutes and universities. The board is chaired by ArcelorMittal, and the members of the board of directors include Tata Steel. ThyssenKrupp Group, VAI, Swedish Steel and LKAB. The first phase (ULCOS I, 2004-2010) is the theoretical research and pilot-test phase, and the second phase (ULCOS II, 2010-2015) is the in-depth development phase for the preparation of industrialized application of the technical solution, New Smelting Reduction Process (HIsarna) HIsarna is a highly merging of Cyclone Converter Furnace (CCF) of Tata Steel and HIsmelt Smelt Reduction Vessel (SRV) from Rio Tinto. HIsarna, a new technology for producing steel consisted for a reactor, on top of which iron ore was injected. The ore is liquefied at high temperature cyclone and dripped to the bottom of the reactor. There coal was injected, and the powder coal reacted with the molten ore to produce liquid iron, that was the base material used to produce high-quality steel. Concentrated CO2 was emitted from the reactor. The technology helped in removing several pre-processing steps, and the quality of raw materials required was flexible, compared to traditional steel production systems. This resulted in several gains - reduction energy use; reduction of CO2 emissions by 20%, decrease in the emission of fine particles like sulfur dioxide, and nitrogen dioxide by 60-80% The CO2 that was emitted was highly concentrated, and was suited for carbon capture for either storage or use. It also removed the expensive gas separation stage. In case CO2 was captured, the emissions reduced by 80% . The HIsarna technology is expected to play an important role in meetingthe recycling ambitions of the circular economy. The primary steel making could be combined with recycling of upto 50% steel scrap, which was twice the existing theoretical maximum of Blast Furnace. HIsarna also allowed recovery of zinc from coated steel scrap Advantages of HIsarna The production process was more efficient than any of the existing high-energy consuming processes. The ores need not be pre-processed and the use of metallurgical coal could be done away with, thus phasing out an entire production stage of coking plants, sinter plants and pellet plants. The energy thus saved could be put to other use. HIsarna enabled the use of wide range of ore and coal qualities. Thus the steel companies will be able to produce high quality steel, irrespective of the quality of raw material. Biomass natural gas and/or hydrogen may be used as alternatives to coal which helped in energy efficient production systems. The most important benefit was in terms of the environment. The energy use was reduced and the emissions of CO2 reduced by 20%. HIsarna produced almost 100% pure CO2, which was ideally suited for capture and storage, eliminating the refining process Several steel production by-products could be reused from HIsarna could be reused, which helped in closing the loop of industrial manufacturing process. The emission of fine particles, sulfur dioxide and nitrogen oxide was also be reduced 3) Examine the sustainability challenges that the European steel industry faced? How did it find solution in HIsarna technology? List down the steps in the development of the new sustainable steelmaking process. The iron and steel industry is the largest source of CO2 emissions as the production process was energy intensive. It relied heavily on carbon-based fuels, leading to high emissions. As the steel consumption was all set to double by 2050, the EU commission was looking at reducing the emissions by half. The iron making in integrated steel plants accosted for 85% of CO2 emissions. Steel production required iron, scrap, and lime. Iron ore was smelted to produce impure metal or hot metal. Then coke and heat are used to remove oxygen from the metal ore. In this process CO and CO2 were produced. Reducing the CO2 emissions by 50% called for sweeping changes in operations of the iron making process. This could be done only through capturing CO2, but the process was highly expensive. At the same time the European Union was pressurizing the steel industry to cut emissions, ensure efficient use of energy and reduce the impact on the environment. This led to the formation of consortium ULCOS, with steel manufacturers, universities and research organizations. The consortium decided on HIsarna technology for sustainable production of steel. The project was executed by India-based Tata Steel's European subsidiary at its plant in the Netherlands. The technology was a combination of two existing technologies one from Tata Steel and the other from Rio Tinto. HIsarna process is a smelting reduction process for producing liquid iron directly from iron ore fines (IOF) and coal. It represents a new, potentially more efficient way of making iron. It eliminates prior processing of raw materials as needed by the blast furnace process. The process consists of pre-reduction of iron ore in cyclone converter furnace (CCF) of Tata Steel's Isarna technology and bath smelting of iron in smelting reduction vessel (SRV) of Rio Tinto's HIsmelt process. During the period 2005-2007, cyclone technology was selected as one of the four highpotential technologies. A theoretical answer was found to the earlier problems of the post cyclone part of the cyclone furnace and ULCOS brought into the project the HIsmelt technology by an agreement with Rio Tinto so as to have a win-win technology combination. This led to an ULCOS supported pilot plant project in Europe. This combination of two technologies resulted into HIsarna process. HIsarna process is carried out in a smelting vessel which is a combination of CCF and SRV. The process basically involves two stage counter current contact between IOF and the process gas. In both stages the operating temperature is above melting temperature. In stage 1, molten partly reduced ore is produced which runs downwards from the CCF into the SRV. The two stages are highly integrated in physical sense and both the process stages are carried out in a single smelting vessel. HIsarna process consists of a reactor in which IOF is injected at the top. The ore is liquefied in a high-temperature cyclone and drips to the bottom of the reactor where powder coal is injected. The powder coal reacts with the molten ore to produce liquid iron which is the base material to produce high quality steel. The gases that leave the HIsarna reactor are concentrated CO2. The development of this technology took several years and was done in several stages, called campaigns, by a teams from ULCOS, Tata Steel and the European Commission The Campaigns Pilot plant was started during April 2011 and was operated from 18 April to 11 June 2011 in its first campaign. There were four starts up. The first start up was not successful. The other three were successful. First successful tap of liquid iron was done on 20 May 2011. Available data from the operation has shown that the process operated as expected but more operating hours are needed to confirm this. Numbers of operating hours were below expectation. However, the objective of showing that theory works in practice, i.e. producing liquid iron without preprocessing of raw materials was achieved. Second campaign has run from 17 October to 4 December 2012. The objective of producing liquid iron for a longer, sustained period was achieved. Production at 80% of design capacity was achieved for periods of 8 to 12 hours. In the last run, full design capacity of 8 tph was reached. The third campaign has run from 28 May to 28 June 2013. The objective of producing liquid iron for sustained periods and running tests with various kinds of raw materials was achieved. For the first time, steel was made from HIsarna liquid iron. The fourth campaign has run from 13 May to 29 June 2014. The objective of sustained, stable production during several days on end and tests of various kinds of raw materials was achieved. The fifth campaign took place in 2017. In preparation for this campaign, the installation has seen a significant overhaul. A completely new off-gas duct has been installed. Next to the pilot plant, a complete coal grinding and a drying and screening facility for ore and lime have been constructed. Closed conveyor belts have been installed to transport the raw materials from the storage facility to the installation injection points. The raw materials storage capacity has been doubled and a gas analysis laboratory has been added. The electronic monitoring system has been completely reprogrammed. The sixth phase was the final phase, during which steel scrap and biomass were used and CO2 reduction of more than 50% was achieved