The new Tenova Consteel® electric arc furnace (EAF) with a new ladle furnace and twin vacuum degasser will enhance production and quality
Hasçelik Sanayi ve Ticaret A.S., one of Türkiye’s leading manufacturers of special steel with a total of five manufacturing plants and other locations worldwide, has ordered Tenova to install and commission state-of-the-art equipment in a new plant in Osmaneli, (Bilecik, Türkiye).
The new line will comprise Consteel® Electric Arc Furnace (EAF) equipped with Consteerrer®, electro-magnetic liquid steel stirring system, a Ladle Furnace (LF) and a Twin Vacuum Degasser (VD). All units are linked and governed by an extensive, advanced automation system to optimize the whole process and guarantee high quality steel grades.
Hasçelik’s selected unit will mark the first continuously charged EAF in Türkiye and will enable the steelmaker to leverage the inherent flexibility of the Consteel® EAF in addressing the challenges posed by the declining availability and quality of scrap materials. The continuous charging feature enhances the process's resilience to variations in scrap density, quality, and content of volatile compounds. At the core of this system lies the innovative Consteel® Evolution, which is built upon a full- platform EAF with a single-point roof lifting system. This combination delivers advantages such as enhanced energy efficiency, reduced workforce, increased reliability, improved productivity, and a reduced environmental impact.
Tenova has continuously enhanced the Consteel® system to cater to the specific requirements of its clients since its first industrial deployment in the USA in 1989. Today, it stands as the most applied EAF solution for continuous scrap charge and the waste heat recovery. Within the Consteel® system, the fumes produced by the EAF serve to pre-heat raw materials within the pre-heating section, while scrap is delivered to the crucible in a steady, controlled flow. Thanks to the uninterrupted charging process, the organic compounds developing from the non-metallic portion of the scrap undergo thorough pyrolysis and combustion within the system. This ensures the minimal generation of harmful substances, such as dioxins and furans. Additionally, the system significantly reduces noise, creating a safer and healthier working environment while eliminating the need for personnel operating in hazardous areas.
The new Consteel® furnace will be equipped with Consteerrer®, a technology jointly developed from ABB and Tenova under an exclusive global partnership agreement. Consteerrer® is an application of ABB's distinctive ArcSave® non-contact electromagnetic stirring technology, explicitly tailored for continuous charging EAFs. This innovation brings about several advantages, including the reduction of thermal losses, an increase in melt rate, rapid homogenization of the liquid steel, and a decrease in the oxygen content within the bath. In addition, this technology can be customized to align with the specific requirements of various EAFs, even as a retrofit option for existing units.
Chairman of the board, Hasçelik
“Together with Tenova experts, we designed a tailor-made solution that allows us also for a future expansion of the current facility. In addition to this, the specific technologies of Consteel® and Consteerrer® perfectly fit with our needs.”
Tenova Area Manager Europe Electric Arc & Ladle Furnaces
“With this project, Hasçelik is investing to increase its competitiveness within the market of high steel grades. Scrap characteristics in terms of purity and density are, in fact, worsening and the Consteel® technology is fundamental to maintaining a high-quality production.”
Global Sales Manager Metallurgy Products, ABB
“In light of rising commodity and energy costs, as well as a greater focus on sustainability, process efficiency is more important than ever. Using the unique and proven ABB ArcSave®-based electromagnetic stirring technology found at the core of Consteerrer®, Hasçelik will be able to increase productivity and energy efficiency in their electric arc furnace process, and to contribute to both financial and sustainability goals.”
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