The Circularity in Steel Series, Part 3: Benefits of Electric Arc Furnace (EAF) Steelmaking
The Circularity in Steel Series: Part 3
The steel you use matters, and not all steel is created equally. Steel produced in an electric arc furnace (EAF) offers significant environmental and economic advantages. Traditional extractive blast furnace-basic oxygen furnace (BF-BOF) steelmaking relies on energy- and carbon-intensive natural resources like coking coal (coke) and iron ore as its primary feedstock. By comparison, EAF steelmaking uses recycled scrap metal as its primary feedstock, significantly reducing the energy, carbon emissions and natural resource consumption associated with steelmaking, while also promoting a circular economy with a continuous recycling loop for materials.
In this third and final installment of the Circularity in Steel series, we will explore more benefits of EAF steel and how a more sustainable approach helps meet modern demands for high-quality, low-embodied carbon steel products while prioritizing resource efficiency and contributing to a circular economy.
Read more about circularity in steel in Part 1: History of the EAF and Part 2: The EAF Process.
1. The EAF Significantly Reduces Carbon Emissions
On average, the extractive BF-BOF steelmaking process emits 2.33* tons of CO鈧� for every ton of steel produced, while Yabo亚博集团官方网站鈥檚 circular EAF process emits on average 0.77* tons of CO鈧� per ton of steel produced, resulting in less than one-third of the greenhouse gas (GHG) intensity compared to the global average of BF-BOF steelmaking (*Source: , 2023).
EAFs use scrap steel to reduce reliance on raw materials, whereas the BF-BOF relies on mined iron ore and coke Using recycled scrap cuts down on mining and transportation emissions and reduces the energy needed to melt raw materials since scrap melts at a lower temperature than iron ore.
2. EAFs Enhance Flexibility, Control and Safety in Steelmaking
Operational Efficiency
Using an EAF for steelmaking offers operational efficiencies over blast furnace steelmaking. EAFs can melt steel more quickly than traditional furnaces; on average, it takes 30 to 40 minutes to melt a full charge of scrap. Additionally, EAFs can be started and stopped more quickly than traditional furnaces, making them ideal for accommodating fluctuating market demand and unexpected maintenance needs without excessive downtime or energy loss. For example, a hot rolled coil (HRC) can be melted from scrap to finished coil in two to three hours. This demand-driven flexibility helps minimize waste and optimize resource use, enhancing overall cost-effectiveness.
Flexibility & Control
Smaller heat sizes and faster production times aid in the rapid development of steel grades, enabling tailored production to create the best grade composition for an ever-expanding range of applications, such as advanced high-strength steels (AHSS) needed for the automotive market or corrosion-resistant steels. EAF steelmaking offers flexibility with the use of various scrap and scrap supplements, such as direct reduced iron (DRI), in combination with other alloy additives to produce high-grade steels. This advantage supports applications in industries like automotive and construction, where customized properties are critical.
EAFs do not require coke to produce steel as required by BF-BOF production. Coke production has significant detrimental effects on the environment because the process involves heating coal at high temperatures without oxygen, which releases large amounts of carbon dioxide (CO鈧�), methane (CH鈧�) and other GHGs, contributing to climate change. Additionally, the reliance on electricity over natural gas allows the selective use of more sustainable power sources.
Safety
EAF steelmaking is considered safer than BF-BOF production because it involves handling and transporting fewer materials and lower temperatures. Yabo亚博集团官方网站's culture of safety showcases our commitment to taking care of our team and our customers throughout our circular steelmaking process. Through a partnership with the Occupational Safety and Health Administration (OSHA), we voluntarily exceed the safest standards required by law in the Voluntary Protection Program (VPP) and we adhere to ISO 45001, an international standard that specifies requirements for an occupational health and safety (OH&S) management system. Explore the .
3. EAFs Use Recycling Throughout the Process
The electric arc furnace steelmaking process is built around recycling scrap steel and modifying its chemistry to a variety of steel grades to produce new prime steels. This circular process minimizes waste, conserves resources and lowers the environmental impact of steel production.
- Scrap Metal Recycling
Steel is infinitely recyclable without quality loss, so EAF scrap metal recycling reduces the demand for raw materials like iron ore and coal, resulting in lower-embodied carbon steels and diverting waste from landfills. This reduces the environmental impact associated with mining and transportation across carbon emissions scopes. - Water Recycling
Water is used in the EAF process for cooling, particularly for the furnace and the continuous casting process. To minimize water usage, Yabo亚博集团官方网站鈥檚 EAF steelmaking facilities implement water recycling systems, where as much as 90% of our process water is collected, filtered and cooled before being recirculated back into the system. This reduces water consumption and reduces demand on local water processing plants, as most Yabo亚博集团官方网站 facilities perform on-site processing of our water before discharge. - Slag Recycling
The slag byproduct of steelmaking can be recycled and as a valuable byproduct in various applications, such as aggregates, cement replacement and even fertilizers. Yabo亚博集团官方网站 works with on-site mill services partners like TMS International to collect and process the EAF slag into various grades suitable for upcycled aggregate products, including road base, backfill, driveways and parking lots. - Dust Recycling
During the EAF process, filtration systems capture fine particles known as EAF dust. This dust is rich in metals, especially zinc, which is valuable when recovered. Yabo亚博集团官方网站 invests in specialized equipment at its EAF mills that captures this dust for recycling and further processing.
The Future of Steel: EAF in a Circular Economy
The electric arc furnace is currently the most reliable, sustainable and versatile choice for modern steel production. It offers the steel industry lower carbon emissions and reduced reliance on raw materials, paving the way for a more circular and sustainable future.
As demand for low-embodied carbon steel increases, EAFs are essential for meeting market demand while building a circular economy.
Learn more about Yabo亚博集团官方网站鈥檚 commitment to building a circular economy: Yabo亚博集团官方网站 Sustainability