Tata Steel UK, a subsidiary of the global Tata Steel Group, has partnered with the UK Government to transform its Port Talbot steelworks by contracting Tenova to design and install cutting-edge steel production technology. Representing the largest investment in the UK steel industry in decades, the project aims to replace existing blast furnaces, significantly lower carbon emissions, and ensure the continued production of high-quality flat steel. This initiative marks a major milestone in decarbonizing the country's steel industry, with an estimated 50 million tons of direct carbon emissions reduction over the next decade.

Paolo Stagnoli, Tenova's Commercial Director, explained the historical and strategic importance of the Port Talbot region. A hub of steel production since the 1920s, it grew to house, in the 1960s, the largest European steelworks employing more than 18000 workers. After nationalization in 1967 and becoming part of the Corus Group, it was acquired by TATA Steel in 2007.

"Worldwide oversupply and increased costs of raw materials, combined with tightening environmental regulations and the introduction of rules penalizing the emissions of greenhouse gases, weigh heavy on the financial sustainability of blast furnaces in our continent," Stagnoli remarked.

To address these challenges, Tata Steel and the UK Government partnered with Tenova to install a state-of-the-art electric arc furnace with Consteel® continuous charging and an electromagnetic stirring system (EMS). This advanced configuration enables a productivity rate of 450 tons/hour, a significant leap forward in efficiency and sustainability.

The project scope also includes two ladle furnaces of the same capacity, a fume treatment plant, a material handling system, and a complete engineering package provided by Tenova to support the construction and commissioning phases. The production phase is scheduled to begin in 2027. The new electric arc furnace is designed to integrate seamlessly with existing facilities, including the secondary metallurgy equipment and continuous casters, replacing the blast furnaces and formerly used BOF converters. This integration allows for dramatic reductions in conversion costs while guaranteeing adequate productivity and quality.

Stagnoli emphasized the collaboration with Tata Steel during the project's contracting and negotiation phase: "The process was transparent and efficient, with open communication throughout. Tata Steel placed immense confidence in our expertise, given the results we've achieved in similar EAF applications worldwide, such as the Arvedi experience. Initially, Tata Steel conceived a project based on two smaller furnaces. Still, we demonstrated that a single furnace could achieve the same casting capacity while preserving much of the existing infrastructure. Once we demonstrated it could be done, the decision was clear."

Tenova's Consteel® technology played a pivotal role in the project's rapid approval. This innovative system uses waste heat from the fusion process to preheat the scrap metal to about 300°C before it enters the furnace. An oscillating conveyor continuously feeds these materials into the EAF, eliminating the need for repeated batch loading through the furnace's roof. This approach boosts operational efficiency and enhances safety by automating tasks near the stove, allowing operators to manage processes remotely.

"This innovation is a game-changer," Stagnoli added. "By streamlining the loading process and optimizing energy use, we've significantly improved both productivity and safety." Cases like Port Talbot demonstrate the strength of Consteel® technology as a fundamental tool in the energy transition toward cleaner steel production.

With this project, Tata Steel UK is setting a benchmark for the global steel industry, aligning with the broader goal of reducing carbon emissions while maintaining high production standards.