ABB has partnered with Tenova, a developer and provider of sustainable solutions for the green transition of the metals industry, to install and commission equipment in a new Hasçelik steel plant in Osmaneli, Turkey, about 200 km south-east of Istanbul.
Hasçelik is one of Turkey’s leading manufacturers of “special steel” with a total of five manufacturing plants and other locations worldwide.
The new line will comprise Consteel Electric Arc Furnace (EAF) equipped with Consteerrer electromagnetic liquid steel stirring system, a ladle furnace and a twin vacuum degasser.
All units are linked and governed by an extensive, state-of-the-art automation system to optimize the whole process and guarantee high quality steel grades.
The unit selected by Hasçelik will be the first continuously charged EAF in Turkey and will allow the steelmaker to leverage the inherent flexibility of the Consteel EAF to tackle declining scrap availability and quality.
The continuous charge makes the process robust to the variation of the scrap density, quality and content of volatile compounds.
At the heart of the system is the new Consteel Evolution based on a full-platform EAF with single-point roof lifting system, a combination that brings the benefits of energy efficiency, reduced workforce, increased reliability, improved productivity and reduced environmental impact.
The new Consteel furnace will be equipped with Consteerrer, a technology jointly developed by ABB and Tenova as part of an exclusive global partnership agreement.
Consteerrer is an application of ABB’s unique ArcSave non-contact electromagnetic stirring technology designed specifically for continuous charging EAFs.
ABB says it reduces thermal losses, increases melt rate, rapidly homogenizes the liquid steel and reduces oxygen content in the bath.
The technology can be customized to match the needs of different EAFs and retrofitted on existing units.
Zaeim Mehraban, global sales manager, metallurgy products at ABB, says: “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 increase productivity and energy efficiency in their electric arc furnace process and accelerate financial gains as well as progress to sustainability goals.”
Davide Masoero, Tenova area manager Europe electric arc and ladle furnace, says: “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 high quality production.”
Naci Faydasiçok, Hasçelik chairman, says: “Together with Tenova experts and drawing on ABB technology, we have designed a tailormade solution that also makes provision for future expansion of the current facility. The specific technologies of Consteel and Consteerrer perfectly fit with our needs.”
With production facilities in İstanbul and Konya and a total of nine warehouses in seven provinces, Hasçelik Sanayi ve Ticaret produces and supplies “hot-rolled special steel and cold-worked special bright steel and sells and distributes seamless pipes”.
It is the flagship in the Faydasiçok Holding group of companies and comprises bright steel production facility Hasçelik Cold Processing Center with an annual production capacity of 170,000 tons and Hasçelik Special Steel Rolling Mill with a production capacity of 300,000 tons per year.
