The net zero emission target for steelmaking is pushing toward the adoption of breakthrough technology. The process route based on iron ore pellets direct reduction requires also a fine tuning of the subsequent melting step in EAF. This, in turn, will require the adoption of modified operating practices, tailored to the EAF input charge of materials.
The blending of DRI and scrap is a way to...
The steel industry is accelerating toward decarbonization, and electric arc furnace (EAF) technology stands at the forefront of this transformation. Primetals Technologies introduces a portfolio of advanced solutions that redefine efficiency, sustainability, and operational flexibility: EAF Ultimate, EAF Quantum, and the innovative Ultimate Move.
EAF Ultimate represents the pinnacle of...
The BioReSteel project, funded by the European Union’s Research Fund for Coal and Steel (EU RFCS), has successfully carried out a pilot-scale electric arc furnace (EAF) campaign at Swerim in December 2025, aiming to validate the use of biomass-derived carbon materials as partial substitutes for fossil carbon in electric steelmaking. The campaign evaluated a range of hydrochar-based materials,...
It has been known that approx. 7% emissions of CO2 arises from the steel industry sector. Hence, many steel companies are trying to develop the electric arc furnace (EAF) and/or electric smelting furnace (ESF) steelmaking processes instead of blast furnace (BF) and basic oxygen furnace (BOF) integrated routes by employing high amounts of hydrogen gas direct-reduced iron (H2-DRI) to mitigate...
Electric steelmaking is undergoing a significant technological transformation propelled by innovations in power electronics, automation, and digitalization. This paper presents a comprehensive evaluation of two generations of digital power supply technologies for AC electric arc furnaces (EAF), highlighting the successful implementation of advanced control systems that drive productivity,...
To comply with tomorrow’s more stringent committed environmental targets for steelmaking, the world witness one of the most fast-paced transitions in the history of steelmaking. DRI-based EAF route will play a crucial role in transforming green steel production thanks to its carbon footprint, which is significantly lower than a blast furnace, while still ensuring the highest product quality....
Background
The HåBiMet projects (HåBiMet is a Swedish abbreviation for Sustainable Biocarbon for Metallurgical use) originate from a fundamental question: Why is there still no large-scale market for metallurgical biocarbon? Despite its potential to enable fossil-free metal production and deliver significant climate benefits, biocarbon faces critical barriers to industrial adoption. Handling...
The Electric Smelting Furnace (ESF) process represents a promising route for sustainable ironmaking by enabling the production of hot metal and slag suitable for steel and cement industries. A critical requirement for steel plant integration is achieving hot metal with a minimum carbon content of 3.0–3.5 wt% and controlled silicon levels (~0.4 wt%), while simultaneously producing marketable...
Electric arc furnaces (EAFs) play a very important role in modern steel making by offering both an environmental and operational advantages over blast furnaces. An important gain by EAF utilization relies in lower carbon emission, potentially a zero-carbon footprint when relying on renewable energy sources. Moreover, EAF offers greater operational flexibility and higher energy efficiency...
The acid gangue components in agglomerates used in the Direct Reduction–Electric Arc Furnace (DR-EAF) steelmaking route, particularly SiO₂ and Al₂O₃, have a significant impact on EAF performance. These oxides influence slag characteristics such as volume, foaming capacity, and viscosity and affect key operational parameters: metallic yield, electric energy and oxygen consumption, refractory...
The expansion of EAF production, alongside with the large-scale deployment of renewable energy sources, has significant impact on network stability and local capacity. Steel producers will face growing pressure to minimize disruptions to the electrical grid and meet ever increasing utility requirements. To tackle these challenges a novel multilevel converter for the decoupling of EAF operation...
Industrial Symbiosis is not a new concept in the steel sector. However, to achieve new opportunities and new synergies, it is crucial to involve other sectors and public authorities, making them aware of Industrial Symbiosis activities already done by the steel industry and the possible barriers hindering synergies and cooperations.
In this context, the project entitled “Fostering Industrial...
Technological advances in steel production have greatly contributed to industrial growth, yet the steelmaking process still faces a critical challenge: the emission of large amounts of CO₂. Achieving carbon neutrality and transitioning toward a sustainable steel industry require a fundamental shift in production methods that can sustainably reduce CO₂ emissions. In this context, hydrogen-based...
Linde’s CoJet® gas-injection technology, introduced in 1996 and now installed in over 175 EAFs, has become the industry standard for chemical energy input. To further decarbonize EAF operations and improve process efficiency, Linde has developed three hydrogen-ready systems: the 3-in-1 Injector, the Fluidic Burner, and the OPTIVIEW® flue-gas monitoring system.
OPTIVIEW® provides continuous,...
In Sweden, the transition toward fossil-free metallurgy increasingly considers biocarbon produced from sustainable biomass as a substitute for fossil coal in high-temperature processes such as electric arc furnaces (EAF), tunnel kilns (TK), and submerged arc furnaces (SAF). This study, part of the HåBiMet – Policy Perspective project, examines how EU and Swedish policy frameworks shape the...
Green steel requires massive investments into new decarbonized production technology and green energy supply, yet renewables are cheapest to produce in remote locations far from established steel production sites. Is it thus more sensible to relocate the energy intensive iron production step near renewable energy, or should investments aim at bringing green energy efficiently to the existing...
In the course of industrial decarbonization, the substitution of gas burners in industrial furnace systems is becoming increasingly important. All-electric plasma torches offer a viable alternative for retrofitting existing systems. These can be implemented without requiring a complete system overhaul.
Both electrode and electrodeless plasma systems are used. Electrodeless systems operate...
Decarbonizing steelmaking is one of the greatest challenges of the steel industry. Electrifying steel production—particularly through the deployment of Electric Arc Furnaces (EAF)—is a pivotal step in reducing CO₂ emissions. In the coming years, the installed base of high-power EAF is expected to expand significantly, notably as replacements for traditional blast furnaces. This rapid growth...
The global shift toward decarbonised steel production with the increasing use of low-grade iron sources has driven interest in introducing electric smelting furnace (ESF) to process low-grade direct reduced iron (DRI) and generate ESF hot metal as a replacement of the blast furnace (BF). At the same time, the gradual scarcity of high-quality scrap has increased interest in using hydrogen based...
In order to improve the sustainability of scrap-based steelmaking and making this route less dependent on fossil carbon markets, the replacement of anthracite and fossil foaming carbon with alternative carbon bearing materials is a promising solution. Different materials can be considered for this purpose, such as biomass, biochar, plastics and tires. All these materials are generally...
Tata Steel Netherlands (TSN), aims to reduce the CO2 emission by 40% and enhance circularity by increasing the scrap usage to 30% by 2030. These targets will be achieved by replacement of one blast furnace with an Electric Arc Furnace (EAF) which utilise Direct reduced iron (DRI) and scrap as charge material.Increasing scrap usage in EAF steelmaking is essential for enhancing circularity and...
In the steel production process, the Scrap Preheating Technique, which heats scrap to approximately 700°C through Electric Arc Furnace melting, enables a significant reduction in electrical energy consumption and, consequently, an increase in furnace efficiency. ”Furnace Energy Saving & Continuous Charging (FESCON) System’’ developed by GEMKOM, is a patented technology that brings significant...
Steel industry is currently undergoing a significant transformation, driven by the need to reduce greenhouse gas emissions and move towards more sustainable production methods. Hydrogen-based direct reduction of iron (H-DRI) is a promising alternative to traditional carbon-based reduction methods. The integration of hydrogen-based reduction technologies with electric arc furnace (EAF)...
The green transition of Europe’s energy-intensive industries and especially the steel industry through hydrogen and renewable energy sources as well as through industrial circularity and symbiosis demands technological readiness and systemic upskilling and reskilling. This contribution explores workforce transformation for Europe's energy-intensive industries, focusing on pro-active skills...
Steel scrap recognition plays a crucial role in energy consumption optimization in the electric arc furnace (EAF) steel production process. Scrap picking for basket loading is traditionally in charge of the operator, who operates based on the expected charge mix. This process is prone to human operator errors. Scrap loads typically consist of heterogeneous mixtures of metal waste with diverse...
The paper presents the new EAF digital furnace implemented at Hybar’s new 630,000 tpy rebar micromill in Osceola, Arkansas. The X-Pact® AURA was pre tuned before delivery using advanced development and testing methods with RTDS simulations (Real Time Digital Simulator), which allowed it to be commissioned in two days only and the EAF to be rumped up in only four heats. The X-Pact AURA family...
In recent years, the steel industry has increasingly adopted electric arc furnaces (EAFs). Currently, more than 70% of steel production in the United States is achieved through EAFs. In addition to their energy efficiency and operational flexibility, EAFs can reduce carbon emissions by up to 55% compared with the blast furnace–basic oxygen furnace route, making them a key technology for...
Badische Stahl-Engineering GmbH (BSE) is one of the world leading engineering & consulting companies belonging to the RSE-Group (Reinforcing Steel Europe B.V.) with its own steel plant Badische Stahlwerke GmbH (BSW) both located in Kehl/Germany
Based on over 40 years of engineering, and even longer operational, experience & competence in the field of EAF-technology, BSE developed and provides...
Electric arc furnace (EAF) steel making is increasingly impacted and challenged by volatile scrap markets, scrap quality, energy prices and supply chains. This makes it extremely hard to optimize the operational costs, because of constant daily changes in framework conditions. These dynamics limit the effectiveness of traditional heat-by-heat optimization, particularly when real production...
In the electric steelmaking industry, short-term production planning often remains siloed, with process areas like the Electric Arc Furnace (EAF) melt shop, secondary metallurgy, and casting machine scheduled in isolation. This operational separation creates significant internal friction, manifesting as waiting times, inconsistent thermal profiles, and excessive energy consumption whenever...
The ongoing digital revolution across industrial sectors has positioned Deep Learning and Computer Vision as pivotal technologies for transforming conventional operations, particularly in waste management and material recycling. This transformation holds significant implications for Electric Arc Furnace steel production, where scrap metal serves as the principal feedstock. The efficiency and...
Scrap plays a crucial role in steelmaking in order to enhance processes sustainability, as it reduces the reliance on virgin raw materials and supports the circular economy, while lowering CO₂ emissions and energy demand. However, current trends in the EU scrap market show a slight decline in pre-consumer scrap streams (E2, E6, E8, turnings, etc.) and a short- and long-term increase in...
Improving the quality of steel has been a matter of routine for metallurgical engineers and steelmaking companies in a demanding market for quality products. The traditional Electric Arc Furnace process has the lowest carbon emission compared to the integrated route, making it the best route for green steel production. In addition, the industry is focused on ensuring that high-quality steel...
At the ArcelorMittal Hamburg facility, steel production has long relied on electric arc furnaces (EAF), a process widely recognized for its resource efficiency and decarbonization potential. To further enhance operational performance, General Electric implemented a DirectFeed system, replacing the conventional static VAR compensator (SVC). This advanced high-voltage power conversion technology...
Steel decarbonisation is accelerating an infrastructural shift from Basic Oxygen Furnaces to scrap-based Electric Arc Furnace steelmaking. This shift places far greater reliance on post-consumer scrap streams, particularly end-of-life vehicles (ELVs), which supply 1.5-2 Mt of scrap annually in the UK and 8-9 Mt across Europe. Blending high-grade automotive steels with mixed co-materials can...
Reliable, precise, and maintenance-friendly weighing systems have always been essential for safe and efficient production in the harsh environment of steel melt shops. Today, modern technologies empower us to equip key production assets with weighing systems that are both robust and highly accurate. This enables steel producers to meet the growing demands for safety, process control and...
Electric arc furnaces (EAF) play a pivotal role in the steel industry’s transition toward renewable energy and reduced emissions. However, their grid-disturbing behavior makes it increasingly challenging to integrate new systems into weak grids.
To meet these demands, Primetals Technologies has developed the Active Power Feeder (APF) based on Modular Multilevel Converters (MMC) technology....
The present work will show a technique for assessing the amount of hot heel or liquid heel using robust hardware. Additionally: the same data stream used for assessing the Hot Heel, can be used for looking at the integrity of a part of the EAF itself.
Many people still operate by the principle: 1 sensor to track 1 problem or 1 property. This sometimes needs to be adhered to strictly, but...
Against the backdrop of the steel industry’s low-carbon transition, short-route production centered on the electric arc furnace (EAF) is attracting increasing attention because it can couple with renewable electricity and reduce CO₂ emissions substantially. However, current EAF operations face several challenges, when melting materials such as direct reduced iron (DRI), especially DRI from...
This paper presents the deployment and benefits of a comprehensive closed-loop process optimization system at Marcegaglia Sheffield, UK, covering Scrap Yard, Electric Arc Furnace (EAF), Argon Oxygen Decarburization (AOD), and Ladle Furnace (LF) operations.
The paper focusses on Scrap Yard and EAF as key stages, and discusses how advanced sensor systems in combination with closed loop control...
Ammonia (NH3) has emerged as a promising low-CO2 reductant for ironmaking, attracting growing interest in recent years. Unlike hydrogen, ammonia provides practical benefits for long-distance transport and storage, including a much lower liquefaction temperature and a higher volumetric hydrogen density that minimises losses during handling. Our previous thermodynamic evaluation demonstrated...
The transition to hydrogen-based reduction processes will alter slag compositions and volumes in ore-based steelmaking, with potential consequences for the established industrial symbiosis between steel and cement sectors. Presently, ground granulated blast furnace slag is widely utilized as a supplementary cementitious material (SCM), replacing clinker and thereby lowering the carbon...
Reliable real-time knowledge of bath oxygen and carbon is a long-standing challenge in DRI-based Electric Arc Furnace (EAF) operation, directly impacting energy efficiency, decarburization control, and endpoint stability. This paper presents a novel hybrid physics-guided machine learning framework for continuous bath oxygen and carbon prediction, explicitly coupling metallurgical first...
In Korea, approximately 20 million tons of slag are generated annually from ironmaking and steelmaking processes, underscoring the need for effective recycling strategies. Since CaO, a major component of slag, reacts with CO2 to form CaCO3, the utilization of slag as a CO2 sorbent has paid great attention.
Specifically, free-CaO (f-CaO) within the slag also participates in carbonation...
Several European steelmakers currently plan to transform integrated steel mills based on the BF-BOF route towards the DRI/HBI-EAF/ESF routes of steelmaking. This planned transformation goes hand in hand with the need to optimise the new process routes in order to produce the same high-quality products on these different and, for the steelworks concerned, new process routes.
The optimization...
The decarbonization of the steel industry is accelerating the transition toward production routes such as direct reduced iron (DRI), hot briquetted iron (HBI), hydrogen plasma smelting reduction (HPSR), and electric smelting technologies. As a consequence, the volume and typology of electric arc furnace (EAF) slags generated across the steelmaking chain are expected to increase significantly....
Electric arc furnace (EAF) steelmaking represents a critical pathway toward achieving carbon neutrality in the steel industry by 2050, as it significantly reduces CO₂ emissions compared to blast furnace and basic oxygen furnace processes. However, the localized heating from the electric arc limits the stirring efficiency of molten steel, necessitating enhanced mixing strategies. Bottom blowing...
EAF operations face critical variability challenges in scrap mix composition and quality that directly impact slag basicity control and alloy chemistry prediction. Traditional multivariate statistical approaches rely on reactive empirical adjustments where conventional analytical tools reach computational limits for real-time process optimization.
This study presents operational validation of...
Tata Steel Netherlands (TSN) produces approximately 7 million tonnes of steel annually, which is equivalent to the national consumption, resulting in about 12 million tonnes of CO₂ emissions per year, which accounts for around 7% of the Dutch total. Nearly 90% of these emissions originate from producing hot metal in blast furnaces.
To reduce emissions by 70% by 2035, TSN, under the Groeien...
Electric Arc Furnace (EAF) steelmaking, because of its flexibility, high energy efficiency and low emissions, plays a critical role in decarbonising the steel industry. EAF slag is a CaO-SiO2-FeO-MgO-Al2O3 system, comprising 30~60% CaO, 15~25% SiO2, 2~10% Al2O3, 2~15% MgO, and 10~30% FeO, depending on different raw materials used and varying EAF operating conditions. Majority of EAF slag is...
This paper presents the design and implementation of a fuzzy logic controller for regulating inter-stand tension in a tandem mill. The developed fuzzy controller utilizes input variables such as tension error, rolling force, exit speed, and speed correction, and applies a rule base derived from operator experience to adjust the gap position and speed references. The controller operates in...
As industries transition towards more sustainable supply chain principles, leveraging reliable LCA databases becomes crucial. Among others, the metals industry also faces increasing demand for transparent environmental data to support sustainability decisions and climate targets. However, the metals industry presents unique challenges to datasets’ creation (e.g., diverse extraction methods,...
A novel water heating system for steel sheet cleaning was developed, which recovers heat from high-temperature wastewater and utilizes a heat pump to heat the supply water. By integrating heat exchangers and heat pump heating, the system significantly reduces energy consumption and CO₂ emissions compared to conventional steam heating. The adoption of indirect heat exchange and multi-pass flow...
Increasing steel weight per heat is a recurrent theme at many steelmakers to increase the productivity of the plant. This is generally limited by the volume of the various aggregates, EAF, Transfer ladle, AOD and casting ladle. The steel shells are fixed and cannot be modified easily. There is only the potential to reduce the size and shapes of the used refractory material. To avoid a negative...
The environment surrounding the iron and steel industry has greatly changed. The Paris Agreement, a new climate change regime, has been in effect since ‘21, and the Parties announced the National Determined Contribution (NDC) in accordance with the Paris Agreement. After the establishment of the NDC in 2015, Korea revised its target to “reduce the greenhouse gas emissions by 40% compared to...
Steel production accounts for approximately 7–9% of global CO₂ emissions, making it one of the most critical industrial sectors in the transition toward climate neutrality, a strategic objective of the European Union by 2050. To reduce environmental impact, many steelmakers are converting traditional Blast Furnace–Basic Oxygen Furnace (BF–BOF) routes to more sustainable technologies such as...
In flat steel production, hot-rolled steel surfaces are subjected to acid pickling to remove surface oxide layers. During pickling, the iron concentration in the acid increases over time, and the spent acid is treated and recycled through an acid regeneration process. As a by-product of this process, iron oxide particles composed primarily of hematite and magnetite with an average particle...
Describing scrap dissolution has become a topic of renewed interest due to the increasing significance of the electric arc furnace in global raw steel production, as well as the growing complexity introduced by charging mixtures of scrap, DRI, HBI, and hot metal. We present a physically based, computationally efficient dissolution model built on a front-fixing moving-boundary formulation. The...
Based on the Ion–Molecule Coexistence Theory (IMCT) and the steel–slag equilibrium theory, this study establishes a thermodynamic equilibrium calculation model for the high-cleanliness production of crankshaft steel. Systematic calculations were performed to determine the rational distribution range of SiO2 in the slag, as well as the recommended CaO/Al2O3 ratio. The variations in inclusion...
One of the major challenges in scrap-based steel production is the retention of residual elements within the steel matrix, among which copper (Cu) is particularly critical. The inability to remove copper during steelmaking not only degrades mechanical and surface properties, but also causes significant operational problems in downstream processing stages.
Following hot rolling, oxide scale...
High-performance forged components (e.g., steam-turbine shafts) demand tight control of microstructure and creep behaviour. In industrial development, however, parameter selection and qualification frequently involve iterative loops (trial batches, rework and occasional scrap), which translate into avoidable material and energy losses. AID4GREENEST project tackles this challenge by combining...
In order to improve the distribution of large-sized NbC aggregation in S30432 austenitic heat-resistant steel, this study systematically investigates the mechanism of modified inclusions with different Ce contents. First, the morphology, size, and distribution characteristics of NbC formed under solidification segregation were observed using SEM; further, the three-dimensional morphology of...
Nitrogen is one of the most influential interstitial elements in steel, as it substantially alters mechanical properties through solid-solution strengthening. While elevated nitrogen levels enhance tensile and yield strengths, it simultaneously reduces elongation and promotes strain aging, thereby degrading formability. However, in the Electric Arc Furnace (EAF) process, nitrogen from the...
The HIsarna ironmaking process is a smelting reduction process under development at pilot scale at Tata Steel in IJmuiden, the Netherlands. The pilot trials have reached a stage where upscaling to an industrial scale can take place.
Over the past few years several significant upgrades were made to the pilot facility to improve operational stability and plant reliability to further explore the...
The iSteel-Expert project pioneers an advanced computer vision and machine learning framework for monitoring and analysis of Electric Arc Furnace (EAF) operations within steel plants. Co funded with the European Research Fund for Coal and Steel (RFCS) G.A. 101112102, the project's core mission is to develop a remote expert virtual system that enhances operator situational awareness, preserves...
The steel industry's transition toward intelligent manufacturing requires sophisticated monitoring systems capable of detecting operational anomalies in real-time. This study presents the development and implementation of Artificial Intelligence-based predictive models for automated anomaly detection in Electric Arc Furnace operations, conducted within the project entitled “Remote expert...
The European steel industry is urged to achieve CO₂‑free production by 2050, as the iron and steel industry is a major contributor to global anthropogenic CO2 emissions and thus to global warming. The transformation of steelmaking will require established processes, such as the Electric Arc Furnace (EAF), and novel technologies, including Hydrogen Plasma Smelting Reduction (HPSR) and the...
Mitigation of CO$_2$ emissions is an urgent challenge for the steel industry, which is one of the most CO$_2$-intensive sectors. As a promising approach to significantly reduce CO$_2$ emissions from blast furnace operations, the carbon recycling blast furnace process has been proposed. In this process, carbon recycled reducing agents are synthesized from CO$_2$ contained in blast furnace gas...
In the ironmaking process, more than 80% of the steel industry’s CO2 emissions are produces, and low-carbon blast furnace (BF) operations are needed to achieve carbon neutrality.
Sinter is a major raw material for the BF, and CO2 generation is inevitable because carbon materials (CM), such as coke and anthracite, are used during sintering process. It is necessary to reduce the use of CM to...
Electric Arc Furnace (EAF) steelmaking is increasingly central to modern steel production due to its ability to operate with low-carbon feedstocks and flexible charging strategies, yet its behaviour is far from steady-state. Energy input, oxygen lancing, carbon for slag foaming, flux additions, continuous slag removal and semi-continuous charging interact throughout the heat, making the...
Training Electric Arc Furnace operators requires time, controlled conditions, and supervised exposure to plant operations. Many critical events cannot or should not be observed during live training because they carry safety risks or depend on rare process conditions. Simulation based training addresses this gap by reproducing the operational environment without exposing personnel or equipment...
The steel industry accounts for roughly 7–9% of global CO₂ emissions, largely because traditional production relies on carbon-based reduction methods. Reaching climate neutrality demands alternative process routes that eliminate direct CO₂ emissions. The Hydrogen Plasma Smelting Reduction (HPSR) process is a promising carbon-free approach that uses hydrogen plasma simultaneously as a heat...
Abstract:
The growing digitalization of Electric Arc Furnace (EAF) steelmaking demands a workforce capable of operating increasingly complex and highly automated plants. Traditional training methods—shadowing, manuals, and classroom-based onboarding—are no longer sufficient to ensure consistent operational performance, safety, and rapid adaptation to new technologies. Within the EU...
The global steel industry`s transition toward low-carbon ironmaking is driving the expanded utilization of direct reduced iron (DRI) and hot briquetted iron (HBI). During the DRI process, carburization occurs concurrently with iron ore reduction in gas mixtures containing CO-H2-CH4, and it is critical for reducing the melting point of the product, thereby enhancing the energy efficiency and...
The collaboration between Tenova and Polytec at ORI Martin’s Electric Arc Furnace (EAF) facility represents a major advancement in the use of robotics and intelligent monitoring in steelmaking. At the core of the project is the PolySAMPLE robotic solution — a 6-axis industrial robot with heavy-duty protection and tool-changing capability — designed to automate critical EAF operations such as...
Natural chromite ores can be classified into high-grade, sub-grade and low-grade chromium ore regarding the concentration of Cr2O3. All categories of chromium ores are available for ferroalloy production. Around 80%-90% of ferrochrome (FeCr) which yields from the energy intensive carbothermic smelting of chromium ore is consumed by the production of stainless steel. Stainless steel is widely...
Flash reduction ironmaking is being developed as an alternative pathway for producing DRI from iron ore fines. Producing DRI directly from fines eliminates pelletising step. Flash reduction in ironmaking was pioneered by Sohn et al. where they used co-current flow of hydrogen at a temperature between 1200 to 1600°C with iron ore particle size between 20 to 53 µm. Calix is developing Zero...
This study experimentally analyzed the combustion characteristics of Biocarbon and Carbon Black as potential substitutes for PCI coal in the blast furnace process. Thermogravimetric analysis was employed to determine the basic combustion properties of each sample, while drop tube furnace and laminar flow reactor were used to evaluate combustion performance and visualize single-particle...
The European Green Deal and its consequences represent a disruptive change in steelmaking as the iron and steel industry contributes up to 7 % of total European greenhouse gas emissions. The goal to reach CO2-neutrality until 2050 requires a variety of new technologies such as direct reduction using hydrogen. Since the availability of both facilities as well as green hydrogen will not be...
During EAF steel making, an electrode joint break is a highly disruptive event with significant implications to productivity and safety. It is well known, the quality of the electrode build practice is paramount to the integrity of the joint and will greatly reduce the probability of a pin break.
A poorly assembled joint has a very high risk of triggering a pin break, because it places...
The formation of freeze lining (FL) – a solidified slag layer that protects the furnace inner walls and refractory linings from chemical corrosion and physical degradation – is essential for the safe, energy-efficient, and long-term operation of high-temperature metallurgical reactors. Building upon a successful prior research program, a new consortium has been established, bringing together...
With growing regulatory pressure and the need to achieve net-zero targets, new technologies for ‘low carbon’ steelmaking are being urgently explored. Volteron™, developed by the John Cockerill Group and ArcelorMittal Group, introduces a novel electrochemical ironmaking route based on low-temperature electrowinning of iron oxide. The technology eliminates direct CO₂ emissions and leverages...
Achieving net zero ironmaking demands a fundamental shift away from conventional blast furnace routes, which remain among the largest industrial sources of CO₂ emissions due to their dependence on fossil fuels and limited integration of hydrogen. The Hy4Smelt industrial demonstration project addresses this challenge by combining hydrogen based fine ore reduction using the HYFOR® process with...
The European Steel Technology Platform (ESTEP) continues its mission to drive innovation in sustainable steel production, with ongoing initiatives and collaborations shaping the industry's journey toward climate neutrality. The Clean Steel Partnership (CSP) has further expanded the collaborative research framework established by the Research Fund for Coal and Steel. CSP enables the development...
The hydrogen reduction iron- and steelmaking route is attracting global attention as an eco-friendly process for reducing carbon dioxide (CO2) emissions. It produces hot metal by melting hydrogen-based direct-reduced iron (H2-DRI) in an electric smelting furnace (ESF). In conventional blast furnace (BF) processes, the Si content of the hot metal is used as an indicator of hot metal quality and...
Steel hot rolling is a critical downstream process in steel production and remains highly energy-intensive due to reheating furnace losses, unplanned mill delays, and insufficient coordination between furnace operation and rolling schedules. While significant progress has been achieved in improving energy efficiency and decarbonization in primary steelmaking, downstream processes such as...
Contemporary stainless steelmaking is based predominantly on the duplex route, consisting of an electric arc furnace (EAF) followed by argon–oxygen decarburisation (AOD), or on the triplex route, in which EAF and AOD processing is followed by vacuum–oxygen decarburisation (VOD). Raw materials strongly influence slag chemistry in the EAF, and therefore understanding the properties and evolution...
Hydrogen ironmaking is considered a promising technology for achieving carbon neutrality in the steelmaking industry. Hydrogen reduction is an endothermic reaction, whereas the conventional CO reduction is exothermic. Therefore, the heat supply to the reaction site is an important issue. Macroscopically, heat is transferred by the hot reducing gas flow, and thermal-fluid analysis is a useful...
In order to help reduce the emissions from the global steel industry, many operators are looking to adopt the Electric Smelting Furnace (ESF), and utilising biocarbon as a substitute for fossil carbon to produce pig iron. The ESF can be operated using renewable electricity, and has the capability to treat low grade iron ore, making the ESF favoured in areas where low grade iron ore is...
Currently, the European steel industry is undergoing a transformation, driven by two major forces. Firstly, to stay competitive in difficult market situations, new ways to improve processes, reduce losses and increase resource efficiency have to be developed. Secondly, economic and regulatory forces drive a transition of the steel industry towards production processes with lower carbon...
Dear Scientific committee,
As the global market leader in monitoring and measurement solutions for steelmaking processes, Heraeus Electro-Nite is dedicated to advancing the industry through innovation. Our commitment to research and development enables us to deliver disruptive technologies that enhance efficiency, quality, and sustainability in steel production.
In recent years, we have...
The decarbonization of the iron and steel industry, responsible for approximately 7% of global energy-related CO2 emissions, represents a critical challenge due to its high energy demand and the intrinsic characteristics of the processes, making it strongly dependent on fossil fuels. Hydrogen-based direct reduced iron (H2-DRI) has gained increasing attention and is currently considered one of...
ABSTRACT
Key words: Electric Smelter Furnace (ESF), Joule Heating, CFD, Radiation, Convection
Steel production involves the reduction, melting, and refining of iron ore. In this processing route, the Electric Smelter Furnace (ESF) is employed to melt the ore and produce molten iron for subsequent refining. Unlike traditional blast furnaces, which rely heavily on carbon-intensive coke,...
Make the slag, and the steel makes itself. This expression underlines a central idea in electric arc furnace (EAF) steelmaking: slag is a key part of the process, even if it is not part of the product. “Good” slag influences energy consumption, refining quality, and overall process stability. However, recent findings strengthen the impression that today’s slag analysis methods often do not...
Slag rheology is one of the important parameters in Electric Arc Furnace (EAF) steelmaking, as it significantly impacts process stability, energy efficiency, and the degradation of refractory materials, with its behavior strongly determined by the composition of the slag. The aim of this research is to understand the influence of Al₂O₃ on the structure and properties of EAF slag, thereby...
On the path toward low-carbon steelmaking and increased circularity, the Electric Arc Furnace (EAF) will be pivotal for European steelmakers. Within the EU-funded Horizon Europe project “Demonstration of Digital twins for a Green Steel value chain (DiGreeS)” an integrated digitalisation approach is being developed across the steel value chain to leverage process data and human experience for...
Steel industry is a major contributor to the global economy but generates significant amounts of residues. Most are valorised by internal recycling or external use. Significant amounts of carbon and iron units cannot be recycled because the zinc content in the dust and sludge is too high for steelmaking, yet too low and contaminated with impurities to be processed by zinc producers The...
The iron and steel industry is widely recognized as a hard-to-abate sector due to its high energy demand and reliance on high-temperature processes. While significant attention is often devoted to primary steelmaking routes, secondary systems such as coke ovens also play a crucial role in overall energy efficiency and environmental performance. In this context, the optimization of refractory...
Direct Reduced Iron (DRI) is increasingly utilised as an alternative metallic charge in electric arc furnace (EAF) steelmaking for flat product manufacturing, due to stringent quality standards required for these steel grades. It is also being adopted in long product production, where scrap availability is often a bottleneck.
DRI quality fluctuations require continuous adjustments to the...
Accurate prediction of thermodynamic behavior in metallurgical melting processes is essential for optimizing industrial operations and reducing experimental costs. This work introduces a computational tool that integrates the Process Metallurgy module of Thermo-Calc with MATLAB to enable automated, scalable evaluations of multiple process scenarios. Traditionally, performing sequential...
Transition towards fossil-free iron and steel production increases the role of electric arc furnaces (EAF), whereas the role of blast furnaces (BF) decreases. This has drawn an increasing attention towards the valorisation of EAF slags with the target in the high value applications such as supplementary cementitious materials (SCM). This is supported not only by the declining production of the...
Ironmaking and steelmaking decarbonization involves significant transformations in existing production processes, and electric-based melting units are acquiring even more importance. Both Electric Arc Furnace (EAF) and Electric Smelting Furnace (ESF) are indeed considered at the bases of future steel and hot metal production, respectively. EAF is a well-known technology deeply used in...
Abstract
This work introduces an innovative method for controlling the stability of direct current (DC) arcs in reducing argon-hydrogen atmospheres, a key enabler for hydrogen-plasma smelting reduction (HPSR) processes aimed at decarbonizing steelmaking. By dynamically adjusting current, the system maintains robust arc behaviour under challenging conditions, supporting both process...
Decarbonizing existing Blast Furnaces is a critical challenge for integrated steel plants aiming for climate neutrality. This paper introduces a technological pathway that uses thermal dry reforming of coke plant by-products and Paul Wurth Tempra for electric gas heating in a top gas recycling Blast Furnace scheme.
SMS group has developed the OXYTAR technology, which converts the...
This presentation introduces a scrap-aware adaptive electrode and process control concept for Electric Arc Furnaces (EAFs). The system performs an in-situ scrap classification based on process-integrated signals to identify scrap stratification, density distribution and expected melting behavior. These indicators drive an adaptive control layer that continuously adjusts transformer tap...
Ladle Furnace Slag (LFS) remains one of the least valorised metallurgical by-products in the European steel sector due to its unfavorable mineralogical structure generated by slow air cooling. This conventional Best Available Technique (BAT) produces γ-dicalcium silicate, leading to high dusting rates, significant water consumption, and limited external reuse. To address this bottleneck,...
Steel industry is in transition concerning heating methods due to requirement to reduce CO2 emissions. Use of hydrogen as a fuel in combustion for heating makes the reheating furnace a possible method to reduce use of fossil fuels. Furthermore, oxyfuel combustion increases efficiency of the heating process compared to air-fuel method. The complete combustion of the fuel is ensured by excess...
Refractory recycling has emerged as a key strategy in reducing the environmental impact of the steel and cement industries, where spent refractories often pose significant disposal challenges due to the presence of hazardous components such as bauxite, copper, magnesite, and chrome-bearing materials1,2. In line with its sustainability roadmap, RHI Magnesita is actively pursuing circular...
The steel manufacturing industry faces increasingly demanding technological challenges, particularly regarding the safety, efficiency, and reliability of maintenance processes. One of the most critical issues is monitoring the condition of refractory linings in furnaces, ladles, and converters without exposing operators to risk or interrupting production. In response to this need,...
HIsarna ironmaking is a breakthrough smelting-reduction technology with the potential to reduce CO₂ emissions by about 50% when operated with coal. However, further decarbonisation of the process requires replacing fossil carbon with sustainable alternatives. In this context, biochar derived from woody biomass emerges as a promising renewable carbon carrier, provided it can be produced...
Slag is a critical factor in all major steelmaking routes, including EAF, BOF, LF, and VD processes. It affects refining efficiency, energy consumption, refractory life, and overall process stability. Traditionally, slag chemistry is measured using pressed pellets and X-ray fluorescence (XRF). While widely used, this method has some limitations: sample preparation takes time, heterogeneous or...
It’s not a question anymore, it’s already a fact that the transition towards CO2 reduced steelmaking will come along with a great number of changes in numerous areas of the production chain. Focusing on the melt section, one of the biggest challenges is the entry of new/different equipment to process from scrap to casting. To cope with these, it is mandatory to use state-of-the-art technology...
Carbon reduction has recently emerged as a critical global issue, prompting many companies to implement measures to lower their emissions. In Korea, the steel industry accounts for approximately 39% of industrial carbon emissions, with blast furnace operations responsible for about 82% of that share. Consequently, effective carbon mitigation in the steel industry requires the development and...
Stahlwerk Thüringen (SWT) represents one of the most advanced real-world implementations of RHI Magnesita’s 4PRO business model, demonstrating how the pillars Performance, Partnership, People, and Planet converge to drive continuous improvement and deliver measurable metallurgical, environmental, and economic value.
This success is rooted in a 30-year partnership, during...
Electric Arc Furnace (EAF) steelmaking is an energy-intensive and highly dynamic process in which accurate bath temperature prediction is essential for stable refining, energy optimization, and minimizing tap-to-tap variability. This study develops a hybrid temperature prediction framework by integrating first-principles metallurgical modeling with machine-learning validation using historical...
Steelmaking facilities are significant sources of environmental noise pollution, with complex acoustic emissions arising from diverse operations including Electric Arc Furnace (EAF) melting, hot rolling, scrap handling, and material transport. Effectively managing and reducing industrial noise emissions requires identifying which specific processes and equipment mostly contribute to elevated...
The decarbonisation of Electric Arc Furnace (EAF) steelmaking requires the progressive substitution of fossil-based carbon with renewable, biogenic alternatives able to guarantee adequate melting performance, slag foaming behaviour, and process stability. The RFCS project BioReSteel addresses this challenge by developing and validating new biogenic Secondary Carbon Carriers (SCCs), with a...
A blast furnace (BF) is still the dominant process for making iron in the world. The blast furnace is charged with coke and iron burden materials including iron ore pellets, sinter and lump ore. While descending in the blast furnace the iron burden reduces. In order to simulate this, two different types of gas-temperature programs have been used. Program (1) has step-wise changes with gas...
Efficient management of the scrapyard is essential to improve steelmaking productivity, yet visual mapping and material classification often remain manual and error-prone. This paper presents new solutions developed by Polytec that combine advanced vision systems, AI-driven analytics, and robotic automation to map, classify, and sort scrap materials in real time. The systems integrate...
Scrap characteristics significantly influence the performance of the melting process in the Electric Arc Furnace (EAF). Along with other charged materials, scrap accounts for significant production costs. Hence, marginal process improvements can yield significant economic gains. However, the inherent heterogeneity of charged materials and the lack of elemental composition data on scrap...
Global crude steel production has shown a steady increase in recent years, with approximately 70% produced via the blast furnace–basic oxygen furnace (BF–BOF) route and the remaining 30% by the electric arc furnace (EAF) process. The BF–BOF route consumes a large amount of fossil-based carbon materials, resulting in significant CO₂ emissions. Therefore, the transition from the BF–BOF process...
The defossilisation of hard-to-abate industries such as steel and cement is a major challenge for achieving climate-neutrality in 2050. In these sectors, some CO2 emissions are unavoidable due to chemical reactions during raw material processing (e.g., limestone calcination) and the use of carbon in steel production. Therefore, efficient and scalable carbon capture technologies are essential...
Industrial steel reheating furnaces operate at temperatures between 800°C and 1300°C and consume a significant fraction of energy for the heating process. These units are significantly energy-intensive, and accurate prediction of furnace gas and slab temperature distributions is essential. This can help to maintain slab quality, support operational decision-making, improve thermal efficiency...
Electric Arc Furnace (EAF) steelmaking generates CO₂ emissions from both direct process-related sources and indirect electricity consumption. While indirect emissions associated with grid electricity dominate overall emissions, direct process emissions—primarily from carbon additions used for slag foaming and refining—remain a significant and addressable source.
This paper will quantify...
John Cockerill is developing AI-assisted enhancements to its physics-based furnace control models to improve process efficiency and stability in steelmaking. Building on the Line Thermal Optimization Process (LTOP) experience, this work explores how artificial intelligence can refine transient anticipation, heat transfer estimation, and adaptive response under changing operating conditions....
The steel industry, which accounts for 7% of global anthropogenic CO2 emissions, is undergoing a major transition to reduce its carbon footprint, with several technologies being developed, trialled and commercialised at different scales, including scrap-based electric arc furnace (EAF), hydrogen direct reduced iron (HDRI)-EAF, hydrogen direct reduced iron (HDRI)-electric smelting furnace...
Abstract
In this study, various methods and stages of direct air capture (DAC) of CO₂ are first reviewed. Subsequently, major DAC companies and projects worldwide are examined, with a particular focus on the technologies developed by the Swiss company Climeworks in the field of DAC—especially its latest innovation, the structured amine-based sorbents. The study then compares different DAC...
The global steel industry is under pressure to reduce carbon emissions. Electric Arc Furnaces (EAF) plays a major role in current steel production with low carbon footprints. Currently, around 30% of global steel production is carried out using EAF. With the growing demand of lower carbon footprint Direct Reduced Iron (DRI) process and increased amount of scrap, demand for EAF steel making is...
Accurate prediction of molten steel temperature in electric arc furnaces plays a crucial role in optimizing steelmaking processes. However, the EAF smelting process is characterized by strong nonlinearity, complex multivariable coupling, and significant uncertainty, which pose substantial challenges to conventional mechanism-based temperature models.
To address these challenges, a data-driven...
It is known that the steel industry is evolving towards production methods aiming at efficiency improvement and reduction of the environmental impact. It follows that a transition from blast furnace production towards the electric furnace route has been underway for some time now, and it is therefore possible that users of this kind of steel will have to rely on new suppliers with EAF...
Electric arc furnaces (EAFs) rely on carbonaceous materials (e.g., anthracite, coke breeze, or synthetic graphite) for slag foaming, oxygen refining, and energy efficiency. Replacing fossil-derived carbon with hydrochar, produced via hydrothermal carbonization (HTC) of biogenic residues, could lower the environmental footprint of steelmaking. Yet the net benefit depends strongly on feedstock...
Slag foaming is a very important phenomena in the operation of the Electric Arc Furnace due to multiple benefits. It has been extensively investigated from an academic view point, however there are still many unresolved issues dealing with the real conditions that promote these phenomena. I many of the previous investigations the gas is artificially injected, rather than created at the...
Transitioning from traditional integrated steelmaking using blast furnaces to direct reduction combined with electric arc furnaces is among the most promising strategies to reduce CO₂ emissions in iron and steel production. However, the availability of raw materials required for this route, such as high-grade iron ores, is limited. To overcome this constraint, alternative green production...
The technologies related to EAF steelmaking have continuous developments aiming the improvement of the process performances and of the environmental impact mainly through the reduction of energy consumption, the increase of productivity, the increase of metallic yield and promoting the reduction of CO2 emissions.
These improvements pass strongly by improved capability to monitor and control...
The steel industry’s transition towards lower CO2 emission is accelerating the shift from BF/BOF routes to direct reduction and electric arc furnace (EAF) operations. This green steel transformation will significantly increase EAF-related byproducts such as slags and dusts. Unlike BF slag, widely used as a secondary cementitious material (SCM), EAF slag faces limited utilization due to...
Electric arc furnaces (EAFs) have become a key steelmaking technology in recent years. Today, more than 70% of steel produced in the United States comes from EAFs, which can reduce carbon emissions by up to 55–60% compared with the traditional blast furnace–basic oxygen furnace route. This makes EAFs a critical pathway for decarbonizing the steel industry. Despite these advantages, further...
This study presents an innovative system developed within the AdriatiCO2 Project for the direct reduction of iron ore via a smelting process. The system substitutes conventional coking coal with sustainable carbon sources and/or biochar—a renewable reducing agent produced from biomass pyrolysis—and integrates efficient CO₂ capture to minimize the carbon footprint of steelmaking.
In the...
Calcium (Ca) treatment is widely used in ladle metallurgy to modify alumina-based inclusions and improve steel cleanliness. The effectiveness of this process largely depends on the type of Ca-cored wires employed and the refining conditions, which influences dissolution behavior, calcium recovery and ultimately inclusion modification. This study examines two commonly used wire types-pure Ca...
The global transition toward green steelmaking has accelerated the adoption of Electric Arc Furnaces (EAF) in both standalone and integrated steel plants. While EAF technology offers flexibility in raw material use and supports decarbonization goals, its implementation introduces significant environmental and operational challenges. Compliance with increasingly stringent regulations on...
We present a design and the results of several trials of a Radar level probe. This probe measures the slag level during the EAF operation. The measured level can be compared to the model result of the slag foaming indication. The trend of the slag level indicates the end-of-batch by exactly identifying the rapid increase of the slag level. By accurately measuring the foaming level, batch to...
The aim of this self-setting monolithic refractory mass was to be the example of the easy and clean tundish work lining performance for a steel plant. This contribution will present the history and the evolution of this tundish working refractory product in the Steelmaking world during this recent years. The development of Coldmag in Europe and America had its origin in 2007 and 2010...
Optimizing the removal of impurities like phosphorus and sulphur is crucial for producing high-quality steel and enhancing process efficiency. This study systematically assesses how the firing conditions of lime —a primary slag-forming agent—directly influence the dephosphorization and desulphurization capacity of metallurgical slags. A series of controlled laboratory-scale equilibrium...
The Ladle Furnace (LF) serves as a secondary metallurgical process unit for adjusting the composition and temperature of molten steel for casting. Changes and transformations in the steel industry—such as green steel and digitalization—emphasize the need for real-time process control and enabling measurement solutions. This work aimed to study how optical emission spectroscopy (OES) data can...
In steelmaking, burners are essential for delivering heat, particularly in Electric Arc Furnaces (EAFs) and Reheat Furnaces (RFs). Within EAFs, despite the majority of heat being supplied through electric arcs, burners provide heat to cold spots to homogenise heat distribution, enhancing overall thermal efficiency and increasing output. Traditionally, these burners rely on carbon-intensive...
For over 90 years, Huisman has been active in heavy offshore lifting, engineering cranes with capacities up to 10,000 tons.
Today, we are adding a new chapter—one that aligns with the steel industry’s bold transformation toward low-emission steel production. As electric arc furnaces and hydrogen-based DRI technologies reshape steelmaking, we asked ourselves: how can lifting technology...
Hydrogen-based direct reduction is emerging as a promising strategy for steel production due to its low CO2 emissions. In this process, the melting of direct reduced iron (DRI) and the separation of steel and slag occur in the electric arc furnace (EAF). However, this process is affected by the thermophysical properties of slag, which are critical and ultimately affect both the yield and the...
In electric arc furnaces typically fossil coal in form of petrol coke or similar is used to create slag foaming in the refining phase. This is responsible for roughly 5-10 % of total CO2-emissions in electric steel production, which means potential savings of 30–60 kg CO2/t steel if carbon neutral sources are applied.
Therefore, a fundamental investigation of the reaction behaviour of...
The steel industry is under continued pressure to enhance efficiency to satisfy financial and sustainability goals. In stainless steel production, higher alloying costs and more complex process control requirements create additional challenges. At Walsin Lihwa’s Yenshui plant, two persistent issues - non-uniform bath temperature distribution and bottom skull formation - were limiting melting...
In the blooming market of mini mill plants, our latest plant at Hybar, Osceola, Arkansas, has been starting up a 630,000 tpy rebar production since September 2025, setting new benchmarks for productivity, performance, safety and environmental emissions, while fully meeting the requirements of a CMT mini mill. The paper presents latest EAF technologies including the X-Pact® AURA DC power...
Piero Frittella, Lorenzo Angelini, Massimiliano Bersani, Christian Senes, Cosmo di Cecca, Vincenzo Duro, Gioele Badina, Gabriele Mazzi, Giuseppe Miglietta, Salvatore Conte .
The necessity to improve the EAF process performances and its sustainability are becoming more and more relevant id last years for several reasons.
In fact the increase of steel production rates through EAF instead of...
The steel industry faces increasing pressure to decarbonize while maintaining reliability, cost competitiveness, and product quality. While electrification and hydrogen play important long-term roles, many steel plants still depend on high-temperature thermal processes where fossil natural gas remains dominant. This creates an urgent need for scalable, renewable alternatives that can be...
Over the past years Linde has been supporting decarbonization at its steel industry customers by developing and implementing new technologies focused on energy-efficiency and use of hydrogen. The paper discusses these successful activities, taken place in close and direct cooperation with steelmaking companies, and show examples of the excellent results obtained.
Energy-efficient use of...
This study aims to evaluate the natural CO2 absorption potential of steelmaking slag, focusing on both black (EAF) and white (LF) slag generated during steel production. Such slags contain significant amounts of calcium and magnesium compounds capable of reacting with atmospheric CO2 through carbonation, forming stable carbonates and thereby enabling permanent carbon sequestration....
Electrical steelmaking is at the forefront of sustainable innovation, delivering major gains in energy and resource efficiency. Yet, even today, up to 30% of the energy input in EAF steel production escapes through off-gas emissions—representing lost value and increased environmental impact. Tenova’s iRecovery® system transforms this challenge into an opportunity. By capturing the thermal...
In 2016, SDI's Structural and Rail Division (SRD) in Columbia City, Indiana initiated a strategic upgrade to its electric arc furnace (EAF) operation. The facility transitioned from pressurized tubular water-cooled panels to a modern spray-cooled upper shell system. This enhancement aimed to address safety concerns, improve thermal performance, and lower maintenance demands. Over time,...
Foamed slag technology is the core process of ultra-high-power electric furnace steelmaking, which is crucial for enhancing thermal efficiency, protecting furnace lining and optimizing molten steel quality. This paper takes biomass charcoal as the research object, systematically analyzes its performance and influencing factors as a blowing agent, and compares it with traditional fossil-based...
Monitoring off gas of an EAF allows to predict the decarburization process and hence the melt performance of the tap during the melting process. Using the off-gas data events such as scrap cave-ins, overdrafting and varying scrap moisture can be visualized in real time and hence predictions can be made about necessary changes in O2 lancing, electrode power as well as carbon injection. The...
Electric Arc Furnace (EAF) steelmaking plays a central role in the transition toward low-carbon and resource-efficient steel production. Increasing energy costs, environmental regulations and needed raw material flexibility demand continuous improvements in energy efficiency and process performance. The operating personnel in steelmaking plants getting younger, more than 10 years in the same...
Utilizing biochar in electric arc furnace (EAF) steelmaking has become a crucial step towards reducing fossil CO2 emissions. The present research examines the interaction between V2O5 and TiO2-containing EAF slag and pinebark-derived biochars, which were pyrolyzed at two different temperatures (600 °C and 800 °C). Optical dilatometry (OD) and thermogravimetry (TG) studies, supported by X-ray...
Minimum conversion cost of alloyed steel production in the electric arc furnace require optimum mixing of the molten metal during melting and refining. Improved heat transfer accelerates the melting of larger scrap pieces for time and energy savings. Homogeneous distribution of alloy elements and carbon in the melt decreases the unwanted oxidation of alloys, e.g. Chromium for better metal...
In order to comply with the stricter environmental regulations, efficient cleaning of the process and waste gases is crucial. In this context, even small, cost-negligible components such as nozzles and separators play an important role, as they have a significant influence on trouble-free, low-maintenance production and environmental regulations.
Lechler is a well-known manufacturer of...
Enhancing thermal efficiency and reducing operating costs are critical objectives in seamless pipe production, particularly in processes where billet preheating constitutes a major portion of total energy demand. In rotary hearth furnaces operating at billet temperatures near 1280 °C, a significant fraction of the fuel input is released as high-enthalpy flue gases, representing a valuable but...
In the steelmaking industry, safety and precision during refractory maintenance are critical. MAGNA, with extensive experience in robotic gunning for Electric Arc Furnaces (EAF), has identified a key operational challenge: gunning is typically performed manually by an operator using a remote control, positioned near the furnace with direct visual contact. This exposes personnel to intense...
Power-off time (POFF) is a key driver in electric arc furnace (EAF) steelmaking for productivity, energy efficiency, operation costs, and CO₂ performance.
Consequently, Badische focuses on the human and organizational dimension of POFF reduction. Top equipment can only bring financial benefits when it is operated and maintained well in the long run. Improving maintenance strategies,...