Green steel transformation at ArcelorMittal Eisenhüttenstadt

The challenge

ArcelorMittal Eisenhüttenstadt was developing their green steel transition concept — replacing BOF steelmaking with EAF-based production. The concern: the new EAF’s lower throughput and the effects of higher sulphur and nitrogen levels on secondary metallurgy. AMEH needed quantified data to navigate these variables and decide on the best path forward.

What FESIOS did

FESIOS conducted an in-depth simulation study of the future production concept with varying plant setups and production scenarios:

• One vs. two EAF setups
• New ladle furnace and/or revamping of the existing one
• Different hot metal production levels
• Varying DRI and scrap quality
• Updated process times and routes
• Changes to the product mix

Key findings

The simulation revealed that the original plant concept — one EAF with a revamped LF — would lead to approximately 16% lower productivity compared to current BOF production.

Operating costs would also be affected:

• Slower EAF tap-to-tap times and insufficient secondary metallurgy capacity would decrease average sequence length, causing a 21% increase in tundish costs
• Certain steel grades would require additional RH-degasser treatment instead of LF only, significantly increasing costs for those grades
• Hot metal buffering during EAF operation prevented increasing sequence lengths, creating another constraint

The result

FESIOS modelled, simulated, and analysed eight unique plant configurations at various operating points. The 3D visualization of the entire plant, dynamic Gantt charts, and meaningful KPIs allowed quick comprehension of this complex matter — from operators to senior management.

With these results, AMEH could strategically discuss the merits and drawbacks of each configuration, enabling informed decisions for a successful green steel transformation.