US steel producer selects Primetals for EAF with innovative power solution

A steel producer in the United States has awarded a contract to Primetals Technologies for the supply, engineering, and startup of a 68-ton EAF Ultimate electric arc furnace (EAF), along with an integrated Active Power Feeder system. This new setup is designed to replace two outdated spout-tapping electric arc furnaces and is expected to begin operations by the end of 2026.

The project also includes the installation of a primary dedusting system, material handling infrastructure, auxiliary equipment, and advanced automation systems (Level 1 and Level 2). The new furnace aims to enhance production efficiency and environmental performance while supporting the steel producer’s specialization in medium carbon, high-alloy, and free-cutting steel grades.

Cutting-Edge Features of EAF Ultimate

The EAF Ultimate represents the latest in electric steelmaking technology, featuring fully automated operation and short tap-to-tap times. A key component is its eccentric bottom-tapping (EBT) system, which prevents slag from escaping during tapping, thereby ensuring higher-quality steel production.

The new furnace is expected to deliver an annual production capacity of 0.75 million tons, bolstering the producer’s ability to meet market demands while improving operational efficiency.

Industry-First Active Power Feeder Technology

The integration of Active Power Feeder technology marks a significant milestone for the steel industry. This system utilizes direct AC-AC conversion through Modular Multilevel Matrix converter (M3C) technology at medium voltage—a first for steel production globally. The innovation provides rapid dynamic current control, optimizing energy input while minimizing grid disturbances.

By pairing the Active Power Feeder with the Melt Expert system, the solution enhances the melting process, reducing energy consumption, electrode usage, and overall production costs. It also ensures process stability and compliance with utility regulations. Additionally, the power system’s symmetrical power draw eliminates the need for a separate compensation system for the ladle furnace.

Source and Photo: Primetals