High-temperature processes – such as those required to manufacture metal products – are very difficult to monitor, model and control.

Nucor Corp. is partnering with the University of Kentucky (UK) Research Foundation to test a carbon dioxide (CO₂) capture system at Nucor Steel Gallatin. This is one of 12 research projects being funded by a Department of Energy grant to advance point-source carbon-capture and storage technologies that can capture CO₂ emissions generated from natural gas power plants and industrial facilities that produce commodities like steel. More than 50 industry and university experts are working together to tackle the difficult challenge of applying carbon-capture and sequestration techniques to an electric-arc furnace (EAF) steelmaking process. Once this pilot is complete, Nucor and UK will have a better understanding of the costs and effectiveness of carbon-capture technology for flue gas with low CO₂ content and the feasibility of replication of this technology at other EAF steel mills.

SMS group has been chosen by Jindal Stainless Ltd. (JSL) to build a new blast furnace at its Kalinganagar unit in India. The blast furnace will have a production capacity of 2 million tons of hot metal per year. The plant will serve both existing downstream steelmaking facilities and future facilities. The blast furnace will be the first in JSL’s new stainless steel complex, which is currently based on electric-arc furnace (EAF) technology, and will be the core of JSL’s Kalinganagar plant expansion. Commissioning of the plant is expected by the end of 2023. The project is another step toward India’s goal of bringing the country’s domestic production to 300 million tons by the end of the decade.

Tenova was awarded a contract from Tosyali for the supply of an electric-arc furnace (EAF) for its plant in Bethioua, Algeria. This will be the second EAF that Tenova has supplied to this site and is a key component of Tosyali’s current expansion project. The new EAF will be designed to be almost identical to the current EAF, which was supplied in 2016. It will process 2.5 million metric tons of DRI pellets per year to produce hot-rolled coil (HRC). A charging system will allow charging and melting of more than 12 tons of HDRI (hot DRI) per minute. The composition of the DRI produced and processed at the Bethioua site is adjusted by blending iron concentrates from different sources to achieve the most profitable balance between cost of raw materials and energy.

A 500°F (260°C) top-loading, electrically heated oven is used for heat treating parts.

In a typical multi-burner furnace with numerous temperature measurement points, the change in a single burner’s firing rate can alter the thermal profile inside the furnace in a nonlinear fashion. Consequently, each independent tuning adjustment has cascading downstream effects on the rest of the system.

Sheffield Forgemasters announced a breakthrough in the industrialization of electron-beam welding (EBW) for thick-section materials. Using EBW, the company weld-joined two 200-mm-thick (8-inch-thick), 3-meter-diameter (9-foot-diameter) forged vessel sections of nuclear-grade steel. The weld, equivalent to approximately 10 meters (32 feet) in length, was completed in a single pass and in a dramatically short timeframe. The weld was completed in 140 minutes with no reportable defects shown in preliminary nondestructive testing (NDT). A weld of this kind would typically take months and include numerous stages of NDT and heat treatment.

Here is a complete list of all the feature articles that appeared in the pages of FORGE magazine in 2021. The month each article appeared in is included. All articles are hyperlinked for your convenience.

American Axle & Manufacturing (AAM) secured multiple next-generation full-size truck front and rear axle programs with global OEM customers. These contracts, including a previously announced award in early 2021, are expected to generate more than $10 billion of lifetime revenues from mid-decade to beyond 2030. 

ArcelorMittal confirmed with the government of Ontario its plan for a $1.4 billion investment in decarbonization technologies at ArcelorMittal Dofasco’s plant in Hamilton. The investment will reduce annual CO₂ emissions at the facility by approximately 3 million metric tons, which represents approximately 60% of emissions. This means the Hamilton plant will transition away from the blast furnace/basic oxygen furnace (BOF) steelmaking production route to the direct reduced iron (DRI)/electric-arc furnace (EAF) production route. The project is scheduled to be complete by 2028.